Applications of cloud platforms include remote monitoring of production processes. (Image source: Canva)

Global technology intelligence firm ABI Research has completed its 2024 Manufacturers’ Technology Adoption & Attitudes Survey, gathering insights from 461 manufacturing decision-makers across the United States, Malaysia, and Germany. The survey reveals key trends and attitudes surrounding the technological landscape in the manufacturing sector.

A significant finding is the widespread belief among respondents that cloud platforms are essential for real-time collaboration with suppliers, distributors, and partners. According to the survey, 76% of respondents have already implemented cloud-based solutions to enhance data accessibility and improve supply chain efficiency.

Additional applications of cloud platforms include remote monitoring of production processes and the efficient management and analysis of production data.

New insights

These insights highlight the growing role of cloud technology in modern manufacturing, as companies increasingly rely on digital solutions to streamline operations and boost efficiency.

“Manufacturers are leveraging cloud platforms, especially hybrid cloud solutions, to help increase production output and efficiency. Manufacturers are leveraging cloud-based supply chain applications to track inventory, shipments, and production status, to improve supply chain visibility and transparency. However, some fundamental challenges remain, such as the integration of legacy infrastructure and data security concerns, that continue to hinder the widespread adoption of cloud solutions in the manufacturing industry,” saidYih-Khai Wong, principal analyst with ABI Research.

Manufacturers are accelerating their digital transformation efforts, driven by the increasing demand for Artificial Intelligence (AI) and Machine Learning (ML) solutions, the expansion of smart IoT devices, and the surge in data generation across both on-premises infrastructure and public cloud platforms.

However, many manufacturers operate within heterogeneous technology environments, where various platforms and solutions are used throughout the manufacturing process. This complexity and the lack of unified technology standards often hinder real-time collaboration. A cloud-based enterprise data fabric architecture offers a solution by breaking down data silos and integrating data from multiple sources, enabling seamless real-time collaboration across the business.

“Cloud platforms provide flexibility and scalability for manufacturers to scale up or down, based on production and business needs. This will be crucial in ensuring a robust enterprise data fabric architecture, which allows manufacturers to foster real-time collaboration, enhancing the capability for remote monitoring and analysing production data more efficiently, ultimately increasing production innovation,” concluded Wong.

This improvement was achieved using a reliable and precise deep learning machine vision solution. (Image source: Zebra technologies)

Zebra Technologies, a provider of digital solutions that enable businesses to intelligently connect data, assets, and people, announced that TAS, a global supplier to automotive OEMs, has enhanced the production quality of electric vehicle battery caps.

This improvement was achieved using a reliable and precise deep learning machine vision solution powered by Zebra’s Aurora Vision Studio software, ensuring greater accuracy and security in the manufacturing process.

To ensure precise finishing for each battery cap, TAS employs a meticulous process where robotic systems handle the metal sheets through various inspection stages. A highly sophisticated camera system is utilised to detect potential defects that could affect quality.

Custom-built operations

This custom-built camera system, designed by ID Engineering, a Zebra Registered Industrial Automation System Integrator specialising in machine vision, can identify even the smallest surface imperfections, ensuring the caps' safety and performance.

The adaptability of Aurora Vision Studio enhances the system's reliability, allowing TAS to continuously improve safety and precision by addressing coating irregularities, surface scratches, and laser marking issues.

Setting itself apart from other solutions, the Aurora Vision Studio system integrates deep learning tools that drive continuous improvement throughout the manufacturing process. The system is trained using a comprehensive dataset of images, enabling it to recognise and classify specific defect types. These image datasets are annotated and fed into the system, which can be retrained to identify new inspection criteria or fine-tuned for existing defects. This allows the image processing solution to evolve and improve continuously, leveraging deep learning technology.

A key advantage of this deep learning capability is its flexibility, ensuring reliable inspection even when industrial conditions change—a significant benefit over traditional image processing tools, which may not adapt well to evolving production environments. The system’s flowchart-based image processing solution uses a no-code approach, enabling fast and convenient training, ensuring that TAS maintains consistent product quality while adapting to production changes.

“The successful integration of surface treatment technology and a custom-built quality control system with deep learning represents a significant advancement in quality control and our continuous commitment to innovation,” said Temel Tas, managing director, TAS. “With Zebra Technologies’ machine vision system, we can meet the high-quality standards of the automotive industry, and we are already planning to implement this technology in future projects.”

“The main advantage of Zebra’s Aurora Vision Studio is its speed in development and execution time when analysing many and sometimes large image files simultaneously, which is much faster than other technologies we tested,” said Michael Sartor, machine vision department head, ID Engineering. “The scalable Zebra system is easy to use and it’s no-code solution enables fast development. Beyond the technology, we appreciate the valuable support from Zebra.”

“This solution is a good example of how deep learning algorithms can be used to help ensure better quality in industrial production,” said Donato Montanari, vice president and general manager, Machine Vision, Zebra Technologies. “Aurora Vision Studio and its deep learning add-on provide the foundation on which even huge amounts of data can be processed and utilised. This is an important contribution to the manufacturing technology of the future.”

The survey revealed that many companies are currently evaluating XR suppliers. (Image source: Canva)

According to a recent State of Technology in Manufacturing survey by global technology intelligence firm ABI Research, Extended Reality (XR) technologies, such as smart glasses and VR headsets, are at a similar stage of development as digital twins, machine vision, and Artificial Intelligence (AI)-enhanced devices among industrial and manufacturing operators.

Of the over 460 respondents from various roles in discrete and process manufacturing, 68% indicated some level of XR consideration, while 32% were at different stages of actual implementation.

“The value of XR to organizations has been known for years, especially in areas like training, remote workforce enablement, and collaboration. However, the barriers to that value have also been well-known and remain. Device cost, integration concerns, and confusion around offerings are most common,” says Eric Abbruzzese, research director with ABI Research.

The survey revealed that many companies are currently evaluating XR suppliers, with 30% already at some stage of deployment, ranging from creating implementation programs (10%) to having completed XR integration across all relevant areas (2%). This pattern mirrors other digital transformation technologies, particularly during the evaluation stages. However, XR is more frequently considered for adoption over the next 12-24 months rather than being actively implemented in Proofs of Concept (PoC) or undergoing supplier evaluation compared to other technologies.

Challenges

Improving equipment performance and quality levels was another key priority for respondents. While XR is still in the early stages of adoption, it has demonstrated benefits in areas such as remote maintenance, interactive training, and knowledge capture and sharing. Nevertheless, significant barriers around people and processes remain. The survey identified a lack of time for planning and a general lack of expertise in XR as key obstacles, alongside difficulties in articulating needs from solutions and a lack of clear Return on Investment (ROI). These issues are further complicated by fragmented platform offerings and a rapidly changing XR landscape.

“The XR market has seen plenty of ups and downs over the past decade, which has hindered trust and understanding in the market despite proven value. A lack of clarity among available platforms and paths to market hold back potential adoption. However, the growth of related digital transformation technologies, especially digital twins and machine vision, is a boon for XR and vice versa. Over time, a more holistic view of visual workforce enablement will take hold, rather than a focus on individual technologies, and XR will be an increasing portion of that offering,” concludes Abbruzzese.

These insights come from ABI Research’s Industrial and Manufacturing Survey 1H 2024: Extended Reality (XR) report, which is part of the company’s Extended Reality (XR) Technologies research service, including research, data, and ABI Insights.

The new hub at SPARK was officially inaugurated by Emerson’s leadership team. (Image source: Emerson)

Emerson has inaugurated a new manufacturing and innovation hub at King Salman Energy Park (SPARK) as part of its expansion in the Middle East

The 140,000-square-foot facility consolidates automation technologies such as control systems, valves, and industrial lighting under one roof.

"This new facility reinforces Emerson’s position as a key player in the industrial sector in the Kingdom and contributes to Saudi Arabia’s long-term Vision 2030 of strengthening local talent, boosting supply chain localisation and advancing sustainable growth," said Mathias Schinzel, president of Emerson Middle East and Africa.

As part of its net-zero emission goals, the facility incorporates energy-efficient technologies, including rooftop solar power, compressed air optimisation, and lighting system optimisation.

Mishal I. AlZughaibi, SPARK president and CEO, added, “We are proud to collaborate with Emerson to support their new cutting-edge manufacturing hub at SPARK. With the establishment of these facilities, we are closer than ever to achieving our localisation goals. Having Emerson on board strengthens our vision, and we are confident that together, we will continue to advance Saudi Arabia’s industrial journey.”

Emerson has been expanding its presence in Saudi Arabia, having first opened a valves manufacturing facility in Jubail in 2011, followed by additional sites in Dammam and Dhahran Techno Valley.

The new hub at SPARK was officially inaugurated by Emerson’s leadership team, including president and CEO Lal Karsanbhai, alongside key figures from the Ministry of Energy, MISA, SABIC, SWCC, and Ma'aden.

"As part of Emerson's contribution to the 'Made in KSA' initiative, Emerson’s facility will serve domestic and regional markets with advanced technologies designed to meet the evolving needs of various industries, further solidifying Saudi Arabia's position as a leader in localised manufacturing and innovation," said Hussein Zein, vice-president of Emerson in Saudi Arabia and Bahrain.

The facility aims to reduce reliance on imported goods and strengthen local supply chains, aligning with Saudi Vision 2030’s goals of building self-sufficient industries to support the country’s economic growth.