AI, particularly in the form of machine learning, is increasingly being adopted within production environments. Its most important benefit can be summarised in one word: predictability. AI's ability to analyse vast datasets and forecast unforeseen events and malfunctions can significantly enhance predictive maintenance regimes and Overall Equipment Effectiveness (OEE), leading to increased efficiency, reduced costs, and improved product quality.
The predominant application of AI today is in object recognition, which has become a staple in many industrial processes for automated defect detection and inventory management. However, we are already witnessing a shift towards more advanced applications for AI technology, such as predictive maintenance, energy efficiency and quality monitoring. By making the unknown known, AI empowers maintenance departments to plan better, ensuring timely interventions, ordering of parts, and coordination of personnel to minimise downtime and boost productivity.
At Festo, we are focused on ensuring that manufacturing companies of all sizes can benefit from innovative technologies like AI. This entails enabling original equipment manufacturers to set up new business models immediately without the need for years of development work.
The integration of AI is not limited to new devices and controllers; there are also viable retrofit options for enhancing existing systems. Many of our AI applications are designed to be compatible with current production lines. This sometimes requires the addition of sensors, but often AI-enabled devices are capable of functioning in a retrofit mode. This is particularly true for predictive maintenance applications, which rely on digital monitoring of devices to be effective.
For example, a very basic building block can be achieved on a totally ‘dumb’ component with the use of a QR code, enabling the electronic label to be scanned and automatically linked to a structured database containing a Digital Twin of the actual component. Components with Digital Twins are the smart building blocks for smarter machines.
The interaction between humans and AI systems - the human-machine interface - is a critical aspect of technology adoption. Users need to see AI technology as a tool that complements human expertise, not as a replacement. User interaction is typically achieved via a dashboard that presents critical datasets in an easy-to-access format. For instance, in predictive maintenance applications, users are guided through the process of mapping the PLC I/O to monitor specific drives. While the AI provides valuable insights, human technical skills are still required to perform on-site adjustments and repairs to maintain production continuity.
As AI becomes more embedded in factory floor products, its applications will extend beyond maintenance to enhance total production performance. The recommendations and insights provided by AI can significantly improve decision-making processes and optimise production outcomes. The technology is already available to support more widespread AI adoption. For example, the Festo Automation Experience (Festo AX) includes comprehensive software solutions for production lines as well as standalone applications designed for specific tasks. It can be applied to improve productivity, reduce energy costs, prevent quality losses, optimise shop floors, and facilitate the creation of new business models through data analysis and understanding.
Of course, the evolution of AI is not solely a technological journey; it is equally an organisational one. Operations and IT departments must collaborate closely to harness the full potential of AI. Individuals must familiarise themselves with AI technologies and experience their benefits firsthand to appreciate the value they can add to their machines and factories. Moving towards a fully AI-enabled business model doesn’t just require new skills, it requires a different mindset - but it is an essential shift if businesses are to remain competitive.
AI is set to revolutionise machine control systems, offering unprecedented levels of efficiency, predictability, and optimisation. The technology is already available to help manufacturers produce smarter and more effectively, making the most of the human knowledge and skills available in the workforce. At Festo, we are committed to pioneering further technical advancements and supporting our clients in navigating the exciting possibilities that AI brings.