How Emerging Technologies are Making Manufacturing Processes more Efficient and Reducing Costs

July 22, 2024

Salt Lake City -- Many new advancements have been made in technology in the field of manufacturing in recent years.

Emerging technologies are making manufacturing companies’ processes more efficient and helping companies reduce costs.

“Technology enables far greater quality by providing better precision, easier and better traceability, and more real time visibility into performance monitoring,” said Vobev’s Director of IT Taylor Ward. “This means more product in spec and less rework."

We found out about the latest technologies and smart tools Vobev is currently implementing at our facilities, which is improving and enhancing our company’s processes.

According to the Forbes article “Five Predictions For Manufacturing And Logistics In 2023,” the connection of physical devices (such as sensors or actuators) through a wide variety of wireless methods, including smartphones, tablets and dashboards, are helping employees and operations teams report back data and metrics more quickly and efficiently.

IoT (Internet of Things) devices collect and analyze data to help companies improve business operations in manufacturing and logistics. This data can highlight inefficiencies, help process managers streamline distribution and improve infrastructure maintenance. This information can also help manufacturers improve worker safety and reduce waste.

According to Forbes, the total number of IoT devices is expected to more than double in the next few years. Forbes also reports that, with the increased use of smart technology on the manufacturing floor, companies are being forced to more frequently scrutinize security vulnerabilities related to the increased use of smart devices on the manufacturing floor.

Ward shared information about the devices currently being used at Vobev, and the measures the IT team is taking to improve and tighten security with the use of this technology.

Smart technology enhances and streamlines Vobev’s processes in a variety of ways, but mainly in three categories: visibility, quality and automation.

“Without visibility into what we’re doing, we can’t know how well or poorly we’re doing,” Ward explained. “Manufacturing technology gives us more visibility, and more visibility means the ability to spot problems more efficiently, to improve our processes, and to reduce costs.”

Ward said automation capability is growing rapidly at Vobev, and explained it has made an impact in the way we run our operations.

Ward says, at times, it’s about utilizing emerging technologies, and at other times, it’s about properly implementing and utilizing existing systems.

“We all enjoy being wowed by AI tools and the latest and greatest fancy tech that hits our social media reels,” Ward says. “But, often times, in manufacturing, implementing properly fitting baseline technology such as ERP and MES systems (and a robust network to secure them) provides the proper foundation for the most sustained efficiency.”

Ward said the greater presence of sensors, data, smart devices and automation on the manufacturing floor create a wide range of capabilities for manufacturers.

“Photo eyes, robotic palletizers, de-palletizers, and a whole variety of embedded sensors that both monitor and enable the production and filling of aluminum cans at the pace that we manufacture, we have SCADA (Supervisory Control and Data Acquisition) systems to monitor these which rolls up into our LMS (line monitoring systems) to give us visibility into all the data being captured from all the various sensors on our manufacturing lines,” Ward explained.

Ward also spoke about the increased risk of security breach that comes with the use of this type of smart technology on the manufacturing floor.

“Another issue manufacturers must deal with is the human element of security,” Ward explained. “This may be a lack of knowledge, failing to follow established IT policies, or it could be targeted attacks from outside [the organization] that are designed to exploit human factors, as it relates to sharing sensitive information or creating a potential breach within any of the devices utilized by Vobev.”

Ward explained that the use of smart devices on the manufacturing floor also poses a greater security breach risk.

“We must ensure that all devices are properly segmented from the network,” Ward said. “Then, we need to carefully monitor and secure any sensitive data that could travel through or leave the network.”

Ward explains his team works closely to monitor the systems, the network and infrastructure.

“Vobev utilizes a combination of robust cyber security tools that operate behind the scenes, along with training tools and policies to ensure employees are educated about how to properly use the equipment, to avoid scams and [to avoid] hacking attempts,” Ward said. “You may see a few carefully designed simulated phishing emails originating from the IT team to help keep our employees vigilant and skilled at quickly spotting different kinds of attacks common in the year 2024.”

Ward said Vobev also employs industry best practice policies for acceptable personal device use, acceptable use of company property, and policies and procedures for the correct management of passwords and automatic password resets. 

“Vobev actively utilizes several MDM strategies,” Ward said. “With the growing risk of cybercrime, things like encryption and properly utilizing existing security tools are just that much more important. If the number of devices doubles, it’s double important that we secure these devices properly and educate the users of those devices on how to avoid being compromised.”

Ward said utilizing existing and emerging technologies instead of purchasing new equipment also helps companies reduce costs.

“Utilizing newer technologies means we also do not have to spend money on multiple sources of hardware,” Ward said. “And we don’t have to manually configure devices.”

Ward concluded with a quote, which he says he feels best encapsulates technology's role in manufacturing:

“When we stand back to look at the rise and fall of great corporations over the long course of history, we find that technology is an accelerator of greatness already in place, never the principal cause of greatness or decline. Great companies first build a culture of discipline —disciplined people who engage in disciplined thought and who take disciplined action. They then use technology to enhance these pre-existing variables, never as a replacement.” – Jim Collins  Good to Great (2021)