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September 21, 2021

Challenges in Sustainable Battery Manufacturing and How Makoro can help in Improving Operations

Three Human Factors Critical to Industry 4.0 initiatives

To assist the rapidly increasing e-mobility sector, as well as the energy transition, climate change, and sustainability, all of these initiatives require novel solutions. Additionally, alternative propulsion concepts must be developed to considerably cut CO2 emissions. 

That is why advancements in battery manufacture are becoming increasingly important. 

However, which batteries and production techniques are capable of meeting escalating demand and stringent specifications? How can manufacturers maximize the sustainability, efficiency, and quality of their plants while automating their processes? New comprehensive automation concepts, such as those based on artificial intelligence and robotics, are critical. Additionally, these notions should consider market requirements, as well as the demands of policymakers and the battery industry. Thus, what are the current trends and future approaches in battery manufacturing that will enable European companies to seize the lead in energy storage for electric vehicles?

Battery makers must excel in terms of quality, increased efficiency, and resource optimization in order to compete better. As the field of e-mobility advances, more advanced battery technologies are being developed. It ensures the vehicles’ durability, safety, and operation. Lithium-ion pouch batteries suit a number of critical current industrial and automobile manufacturing needs. However, pouch cell manufacturing is more complex and time-consuming than cylindrical battery manufacturing. This, in turn, puts unique demands on manufacturing processes. Manufacturers are looking to artificial intelligence to assist with their manufacturing processes. For instance, AI can assist in optimizing machine efficiency and ensuring defect-free output.

Combining artificial intelligence, sensing, control, and robotics delivers higher quality.

While battery producers must react to the market’s ongoing evolution, they demand production processes that can be altered more quickly and flexibly than ever before to suit changing requirements. Combining artificial intelligence, sensing, control, safety, and robotics into a single automation platform enables manufacturers to meet customer criteria for product quality and predictive maintenance while also reaching critical sustainability goals. 

Additionally, assistance with integrated battery cell inspection solutions, as well as solutions for electrode and battery module manufacture, can assist in streamlining the testing and providing end-to-end traceability throughout the battery cell’s life.

The technology ensures sustainability.

Battery manufacturers and suppliers require a dependable partner that can give theAsset Performance Managementm powerful technology and relevant advice from a single source in order to be inventive, adaptable, and future-oriented. A holistic, artificial intelligence-based solution can assist industries in reducing waste. When used in conjunction with an intelligent warehouse system and mobile robotics, firms can significantly increase process efficiency and productivity. 

Simultaneously, battery cell quality – including capacity and battery life – should be covered sustainably by a manufacturing and lifecycle control solution that is backed up by an in-line inspection system. This solution must take into account all stages, from manufacture to usage and recycling. By applying these technologies, businesses take a critical step toward the future of sustainable industrial and battery production.

Recommendations based on data maximize utilization of production resources.

 Today’s batteries as well as their production generate massive amounts of data. Makoro™ provides a range of device and enterprise system connectivity protocol options, and a recommendation system powered by digital performance twin, enabling manufacturers to translate the data generated by the manufacturing processes into a wealth of real-time recommendations. Leveraging these recommendations in battery production helps manufacturers improve their productS and production systems efficiently. They are able to create new business opportunities based on recommendations based on aggregated, correlated, and analyzed operational data.

As a result, battery manufacturers achieve::

  1. Improved productivity of existing plants
  2. Reduced inventory and throughput time
  3. Maximum utilization of production resources

Research indicates that proactive asset recommendations result in an 11% – 13% reduction in raw material usage and a potential savings of up to 15% – 18% in energy utilization.

August 9, 2021

Digital-Twin-Powered Recommendations Deliver Operational Savings & Efficiency

 

 

Recommendations from Makoro™ deliver improved asset and process performance consistently. But instead of looking at data and making decisions yourself, the system provides a simple prescription of actions to be taken based on deep analytics. This improves consistency in decision-making and ensures compliance.

Decision-making is transparent as all actions on recommendations are tracked by the system and learned from to make future recommendations better.

Makoro™ connects to any source of data, including data from log files, and excel spreadsheets, and the data that has been sitting on your flash drives.

Makoro™ offers simple SaaS pricing (per asset per month per user) for customers – asset, equipment, and process manufacturers, owners, and operators.

Makoro™ operates frictionlessly across Edge, Private, Public, and Hybrid Clouds, and Customer Data Centers, so it leverages customer’s infrastructure to the maximum.

Makoro™ now offers 4 capability levels – starting with Starter, through Intermediate, Advanced, and Pro, so customers can onboard and scale with ease depending on their requirements.

The 10-Day Challenge program is the right point to start and mitigate your risks in Makoro™ adoption.

Makoro™ leverages #AppliedArtificialIntelligence and #NaturalLanguageRecommendations powered by #DigitalTwin in solving transformative problems in the manufacturing supply chain.

#MakoroAI #CodeDataIO #PredictiveRecommendations #10DO, #DataIsNotEnough, #AssetPerformanceRecommendations #ContinuousIntelligence #Industry40 #SimplifiedROI #BusinessAgility #OperationsAgility

July 1, 2021

Pharma 4.0 – Road to the Smart factory

Pharma 4.0 - Road to the Smart factory

Smart factory development is a top priority for manufacturers across all industries and sectors. It is a component of a business’s digital transformation, and it is critical to maintaining competitiveness while also meeting the demands of consumers and end-users, as well as B2B customers and regulators.

This is all part of Industry 4.0, the umbrella term for the revolution currently sweeping the manufacturing sector.

As with previous industrial revolutions, Industry 4.0 will evolve over many years and decades as new technologies and processes are developed, and as businesses, regulators, and consumers grow.

What are the critical smart factory developments worth examining today if you work in the pharmaceutical or medical technology industries?

Why is Industry 4.0 even more critical to the pharmaceutical manufacturing industry?

  1. Increased Productivity — Automating processes enables them to be completed more quickly and accurately. Reduce downtime through automation and the use of sensors and predictive systems that enable equipment to function autonomously.
  2. Improving the supply chain’s efficiency through integration –  They are making it feasible to transition from batch to continuous manufacturing, a production approach that results in much less downtime and increased efficiency.
  3. Increased Quality – Increased automation and continual monitoring of your manufacturing plant will result in fewer mistakes and higher-quality final products.
  4. Risk ReductionThis follows naturally from the preceding two arguments – increased manufacturing precision reduces the danger of substandard items reaching end customers.
  5. Facilitates Regulatory Compliance –  Compliance with existing and upcoming laws in the E.U. and other parts of the globe is made more accessible via the use of Industry 4.0 technology. To comply with the Falsified Medicines Directive, new track and trace systems and serialization solutions are presently being deployed.
  6. Improved Business Oversight  – Industry 4.0 technologies enable real-time reporting, increased data collection, improved data analysis, and improved data presentation in usable formats.
  7. Development Of New Business Prospects –  Industry 4.0 will also open up new commercial prospects for pharmaceutical businesses. For instance, Industry 4.0 technologies enable seamless and highly efficient end-to-end supply chain integration. This increases productivity, which helps your business immediately. A more connected and efficient supply chain, on the other hand, is also more scalable, opening up new potential for your organization. Covid-19, a quick-win situation.
  8. Increased Profitability – When all of the aforementioned are combined, the outcome is improved corporate profitability. Additionally, your firm will be more competitive and better able to address future difficulties and opportunities. Covid-19 has accelerated the advancement of biotechnology problems.

The pharmaceutical industry has only recently begun to adopt Industry 4.0 technologies, despite the fact that it has been using batch manufacturing for more than 50 years. However, the traditional batch process technique has been demonstrated to be lengthy: after each stage in the process, production is generally halted to allow for quality assurance testing of the material. Each break lengthens the lead time and increases the likelihood of defects and errors (FDA, 2016).

This encouragement comes at a critical time – we are entering an era of precision (personalized) medicine, “where medicines must be produced with unique characteristics and made available to people in need more rapidly.” (U.S. Food and Drug Administration, 2016).

To create customized medications, pharmaceutical companies no longer need to produce large batches but rather tiny ones tailored to a limited group of individuals who require a certain treatment in a specific dosage. Batch production is not the answer to these demands, but continuous manufacturing that is connected, smart, adaptable, and accurate.

Continuous manufacturing is used in the pharmaceutical business to move substances nonstop inside the same facility, eliminating wait times between process steps; the materials are fed via an assembly line of integrated components. Manufacturing that is continuous “saves time, decreases the risk of human mistakes, and enables a more agile response to market changes. It can operate for an extended length of time, potentially reducing the probability of medication shortages.” (U.S. Food and Drug Administration, 2017).

Pharma Opportunities 4.0

  • Gains in economic terms, such as greater revenues as a result of reduced transaction costs
  • Increased reliability and consistency in production and output, as well as higher-quality products
  • Energy-efficient and ecologically friendly manufacturing systems
  • Utilization of human and material resources effectively.
  • Changes in work structure, with a greater emphasis on remote, flexible, and on-demand labor

Pharma 4.0’s Obstacles

  • Gaps in infrastructure
  • Policies and regulations that are out of date and do not take into account 4.0 Industry
  • Ownership and security of data
  • Transparency, confidentiality, and ethics
  • Changes in the fundamental characteristics of innovation processes and their implications for competition and entry barriers

Take away points

We may now re-evaluate our industry’s accomplishments while simultaneously re-strategizing our future strategy toward offering high-quality therapy at scale and bringing fresh hope to humanity.

By strategically integrating the production process, we as an industry will be able to stay ahead of the problems and expectations on which the rest of the world is so reliant.

Predictive analytics enables you to foresee issues, minimize risks, capitalize on opportunities, and ensure that resources are directed appropriately.

Predictive analytics is already being used by pharmaceutical and medical device makers in the field of equipment maintenance. It is possible to forecast the effect of a variable on a piece of equipment, a production line, or a process using technology such as digital twins.

About Makoro™:

Makoro™ leverages #AppliedArtificialIntelligence and #NaturalLanguageRecommendations powered by #DigitalTwin in solving transformative problems in the manufacturing supply chain. 

If you are still leading with reports and dashboards, you are falling behind. You are leaving money at the table. When you can shave off minutes and hours you spend making the right decisions on your assets.  

Asset performance recommendations from Makoro™ deliver improved asset and process performance consistently through recommendations. These recommendations are backed by data and can be traced to the sources of data. 

Makoro™ recommendations deliver direct operations savings and indirect compliance savings.

 

May 24, 2021

Three Human Factors Critical to Industry 4.0 initiatives

Three Human Factors Critical to Industry 4.0 initiatives

Manufacturers worldwide are under pressure to modernize their factory workforces, but 57 percent of manufacturing leaders report that their company lacks the trained staff necessary to support digitization plans, according to a Gartner, Inc. survey.

The survey found that manufacturers are currently experiencing a challenging phase in their digitization journey towards more intelligent manufacturing.

Connected factory workers rely on a variety of digital resources and data management strategies to enhance and incorporate their experiences with their physical and virtual environments, increasing decision precision, spreading information, and reducing uncertainty.

1. Change Management is the Most Difficult Task

Complexity in the organization, integration, and process reengineering are the most common barriers to implementing smart manufacturing initiatives. When taken together, these issues represent the most significant change management roadblocks.

83 percent of respondents believe that their leadership recognizes and supports the need for smart manufacturing investment. It does not, however, reflect whether the majority of leaders grasp the scale of change ahead of them – both in terms of technology and talent.

2. Intelligent Manufacturing Needs Technology 

Businesses are beginning to recognize the importance and potential of smart manufacturing. However, implementing new innovations alone is insufficient. The most critical action is for businesses to recognize that this is about more than digitization, as it entails coordinating activities for capability growth, capability enablement, and human empowerment.

3. Human capital needed for Smart manufacturing

Factory staff must adapt in lockstep with technology and be prepared for future changes. In the long run, it is critical to embed a data-driven culture in manufacturing operations through governance and training – without choking employee innovation and imagination.

Makoro™’s Dynamic Learning technologies help retain tribal knowledge. This assists in onboarding new employees and provides them with the augmentation necessary to make them better at their jobs immediately,

Sign up for our 10-day challenge and see the performance.

April 27, 2021

Moving towards Smarter Manufacturing

Moving Towards Smart Manufacturing

The term “Industry 4.0” is often used interchangeably with “Smart Manufacturing.” Despite widespread public confusion and initial business reservations about Industry 4.0, the benefits appear to be very promising. It is expected that over the next five years, an AI system will be able to run computers autonomously.

Additionally, AI benefits businesses by improving operating efficiency. It can further shorten time to market and reduce factory safety incidents. By connecting business data end-to-end, from supply chains to manufacturing, delivery, and use, AI will alert employees to both possible challenges and opportunities.

The first step in Implementing Smart Manufacturing in real scenarios is to collect data from a variety of structured and unstructured sources. It could be from IoT and IIoT systems, HMIs, PLCs, ERP, and CRM systems, as well as manual data records. Integrating data on raw materials, processing, manufacturing, shipping, distribution, and transportation all the way down to the customer level adds increasing value across the entire manufacturing supply chain.

But data collection and aggregation is the first step. The real value is realized by what businesses do with the data. Some go down the path of data visualization to understand data better. But advanced AI systems like #MakoroAI aggregate, correlate, and analyze this data in order to make recommendations that directly impact business outcomes and drive workforce adoption.

Makoro™’s always-on, secure and scalable asset performance solution.  It is powered by #AppliedArtificialIntelligence and #PredictiveRecommendations gives you the edge in the fast paced #Industry40. Thereby reducing the downtime and maintenance costs.

Sign up for the Makoro™ 10-Day Outcome Challenge and see the results yourself.

April 19, 2021

Makoro™ AI Predictive Asset Management

Makoro™ uses applied artificial intelligence to solve transformational problems in manufacturing supply chain

Makoro™ uses applied artificial intelligence to solve transformational problems in the manufacturing supply chain.

Makoro™ AI differentiates itself in Enterprise Asset Management and Asset Performance Management spaces through its AI-powered predictive asset performance management for asset manufacturers, owners, and operators. Makoro™ AI lets you connect to all operations and IT data sources and transforms data to recommendations in minutes – recommendations that power higher asset uptime, lower maintenance costs, and higher workforce engagement.

Makoro™ illustrates the power of #ArtificialIntelligence applied to solve the deep-domain problems of the manufacturing supply chain.

#MakoroAI #CodeDataIO #PredictiveRecommendations #NaturalLanguageRecommendations #PredictiveAssetManagement #ContinuousIntelligence

April 16, 2021

The story of Makoro™ AI

The Story of Makoro™ AI