MARCH 20229MANUFACTURING TECHNOLOGY INSIGHTScharacteristics that must simultaneously match up to 500 final quality parameters. Our goal here is to implement an automatic calculation of an individual quality index for each product in each process step based on all relevant product-related data with AI. For us, it is the key player in detecting anomalies in this complex environment.It should be noted that not all anomalies are defects, but all anomalies are an indication that something unusual is happening. AI allows us to identify and analyse these correlations.In addition to installing a suitable infrastructure for data collection and processing, the challenge is to constantly learn and recognise patterns from the ever-changing data in order to ultimately react in real-time. With the implementation of conditional anomaly detection, we expect up to a 30 percent reduction in scrap and rework while reducing raw material consumption and time to market.PREDICTIVE MAINTENANCEPredictive maintenance is the in-depth analysis of machine data to predict future machine deterioration and/or failure to avoid unexpected shutdowns. In the past, we have focused on predictive maintenance projects mainly on the most important bottleneck machines. But to generate a universal predictive maintenance algorithm and make valid predictions, you need data from a large set of identical machines. You will never be successful with a small number of machines to create algorithms for the entire population. As our data experts always say: big data only works with big data.So, the first step is to consolidate the immense volumes of data in the cloud, where the current operating states can be determined and visualised in order to detect and communicate unplanned downtimes.In a second step, we are working on the development of neural networks to determine the "state of health" of the machines from this data. That means the machine or the robot is working flawlessly or is a breakdown to be expected soon.Our experts and data specialists are working hard to make our production systems smarter. Because ultimately, these process optimisations always go hand in hand with yield increases.But it also requires a precise evaluation of where and in which processes the use of AI adds value. In the end, AI is not about machines learning on their own and replacing people. The cooperation of humans and machine is the decisive factor for success. To condense the flood of data in production, to work out trends, and to make the right decisions based on the given data describes for me the future of manufacturing. If you really want to gain significant benefits with AI, the organisation must develop into a learning organisation. That means machines learn from people, learn from machines, and machines support people to make the right decisions. Dr Hans-Jurgen Braun
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