ARTIFICIAL INTELLIGENCE ON

MANUFACTURING AUTOMATION
-TARUN KRISHNA C B
71762102103
 INTRODUCTION
● The development of Artificial Intelligence (AI) is one to the most important
events in recent human history.
● Artificial Intelligence (AI) is a branch of Science which deals with helping
machines find solutions to complex problems in a more human-like fashion.
● With so much data being produced daily by industrial IoT and smart
factories, artificial intelligence has several potential uses in manufacturing.
● The role of the AI in manufacturing is discussed briefly in the forthcoming
slides.
 INDUSTRIAL AI
● We define industrial AI as any application of AI relating to the physical
operations or systems of an enterprise. Industrial AI is focused on helping
an enterprise monitor, optimize or control the behavior of these operations
and systems to improve their efficiency and performance.
● For example, applications relating to the manufacture of physical products,
to supply chains and warehouses where physical items are stored and
moved, to the operation of building HVAC systems, and much more. Any
company in any industry can have opportunities to apply industrial AI.
● Industrial AI is uniquely appropriate for process plants because the huge
amount of data and quickly changing circumstances are too complex for
manual or even digital management.
DEFINING INDUSTRIAL AI
 How is Industrial AI Different?
● Industrial AI is often differentiated from other types of AI because it’s more
focused on the application of AI technologies than in the development of
human or human-like systems.
● The following properties are major factor in differentiating it from other AIs :
1 Data acquisition and storage
2 Training challenges
3 Testing costs and complexity
4 High regulatory requirements
5 High cost of failure & change
6 Large state spaces
AI USE CASES WITHIN THE INDUSTRY
 Why Industrial AI?
The specific benefits of such artificial intelligence systems in industrial environments are
many. At a high level, they include:
● Enhanced, and predictive, situational awareness. By allowing enterprises to model
complex industrial systems, industrial AI allows enterprises to increase quality, reduce
downtime, avoid stock-outs, reduce risk, and more.

● Better planning and decision-making. By helping enterprises assess the

effectiveness of different policies in dynamic, unpredictable environments,
industrial AI helps enterprises increase process efficiency, improve asset
utilization, increase yields, and optimize the design and management of
complex systems.

● Greater efficiency & productivity. Industrial AI lets enterprises enhance

the results they achieve through automation, resulting in increased production,
increased product quality, lower labor costs, reduced errors and rework, lower
material consumption and less waste.
 Industrial AI categories
A framework for thinking about different types of industrial AI scenarios is
helpful in identifying the areas of a business in which to apply it.
AI applications can be categorized,based on the degree of automation
that they seek to provide, as :
● Monitoring
● Optimization
● Control

This model applies to both digital-domain and physical-domain use cases.

 Monitoring
In industrial scenarios, there is a continual need to monitor the performance of
systems and processes to identify or predict faults or other situations likely to
produce undesirable results.
Using machine learning, models can be trained on available data to learn the
internal, opaque state of complex systems.
These models can then be queried to predict those system’s future state, given
a set of input data.
There are many examples of monitoring applications that benefit from an AI-
based approach:
● Quality control
● Fault detection & isolation
● Predictive maintenance.
● Inventory monitoring
● Supply chain risk management.
 Quality control
● A common manufacturing use case for AI is for machines to visually inspect
items on a production line.
● Using AI allows quality control to be automated, and ensures that all final
product is inspected, allowing fewer defects to reach customers compared
to traditional statistical sampling methods.
● In addition to ensuring that products are free of imperfections, AI-based
visual inspection systems can validate many product attributes including
geometry and tolerances, surface finish, product classification, packaging,
color & texture
 Fault Detection and Isolation
● In regulated manufacturing environments, ensuring process compliance can be
expensive and time consuming.
● In many such scenarios, lives are at stake—as can be the case in the food,
chemical and energy industries
● By monitoring a variety of system operational factors, AI can be used in the
detection, prediction and diagnosis of undesirable operating conditions in
industrial systems.
● By accelerating or replacing unreliable and time consuming human analysis,
automated process surveillance helps prevent or minimize system downtime
and the persistence of hazardous conditions.
 Predictive Maintenance
● Predictive maintenance is a rapidly growing subset of fault detection and
isolation, focused on predicting the failure of deployed systems before they
result in downtime.
● Aircraft engines provide an oft-cited example: GE’s GEnx engine is
embedded with 5,000 sensors producing 5-10 TB of performance, health
and efficiency data each day of flight.
● This data allows GE systems to predict failures before they happen and
proactively schedule repairs and order replacement parts.
 Inventory Monitoring
● AI powers a wide variety of inventory management and supply chain use
cases, allowing enterprises to avoid costly stock-outs.
● Hardware retailer Lowe’s is currently testing the LoweBot, an autonomous
mobile robot operating in stores in the San Francisco Bay Area.
● In addition to its customer service tasks, the LoweBot uses an on-board
computer vision system to detect misplaced and out-of-stock inventory on
store shelves.
● Similar systems are being deployed in warehouses, with several startups
experimenting with drone-based approaches.
 Supply Chain Risk Management
● Effective management of a complex, global supply chain demands the
ability to identify and mitigate potential disruptions before they cause delays
or shortages.
● AI can be used to predict supply disturbances before they happen,
providing early warning for enterprise supply chains based on potential
disruptors sourced from global news, event and weather feeds.
tyjj

QUALITY CONTROL PREDICTIVE MAINTENANCE FAULT DETECTION AND

ISOLATION

INVENTORY MONITORING SUPPLY CHAIN RISK

MANAGEMENT
 Optimization
AI-based planning and decision support systems go a step beyond monitoring and
allow users to determine a path, or plan, for getting to a desired system state in a
way that optimizes a target set of business metrics.
In classical academic artificial intelligence circles, “planning” refers to a specific
category of problem, often formulated with unrealistic constraints, such as offline
agents operating in static, deterministic environments.
Optimization activities that can benefit from the application of ML & AI include:
● Process planning
● Scheduling
● Yield management
● Anticipatory logistics & supply chain management
● Product design
● Facilities location
 Process Planning
● Many industrial scenarios involve complex sequences of work whose
ordering can significantly impact factors such as cost, time, quality, labor
input, materials input, tool life and waste.
● A simple and well-studied example is the sequence of operations required
to create a machined part or die using Computer Numeric Control (CNC)
machines.
● A given part is made up of a sequence of operations such as cuts. Each cut
is made using a specific tool,of which there are many, but only a few can be
loaded on the machine at the same time.
● A variety of different optimization problems arise from this scenario,
including set-up planning, operation selection and sequencing, machine
and tool selection, and tool path sequencing.
● Each of these has been solved with a variety of machine learning
techniques including genetic algorithms and neural networks.
 Scheduling
● The job shop scheduling problem, a specific type of process planning problem, models
the allocation of jobs of varying processing times to a set of machines with varying
processing power.Job shop scheduling provides a well-studied, if idealized, model for
many common industrial scenarios.
● Many different types of problems can be modeled using the general job shop
scheduling approach and AI, including the famous “traveling salesperson problem,”
which seeks to optimize the routing of a salesperson traveling to a list of cities given the
distances between each city pair.
● These problems have been historically solved using operations research methods such
as combinatorial optimization, but lend themselves to learning approaches that can
more easily adapt to changes in their environment.
 Yield Management
● In manufacturing, the yield of a given processes can mean the difference between
profitable and unprofitable products.
● For example, in semiconductor manufacturing, in the face of increasingly complex
manufacturing processes, with many hundreds of process parameters coming into
play in the production of a single wafer, traditional techniques for estimating and
optimizing yields have become untenable.
● Machine learning allows manufacturers to fully utilize available data to continually
improve process quality and increase yields.
 Anticipatory Logistics and Supply Chain Management
● Supply chain management is traditionally a two-step process. First statistical tools
are used to produce a demand forecast.
● The forecast is then used as input to an optimization process that evaluates the cost
of stock-outs against the delivery times, holding costs and other factors associated
with the supply chain.
● Using machine learning, it is now possible to implement a single-step process that
learns the relationship between all available input data, including traditional supply
chain data such as inventory levels, product orders, and competitive data, as well as
external data like weather, social media signals and more, to produce better
operational performance.
 Product Design

● As digital and physical products grow in complexity, AI can be applied to accelerate the
design process and facilitate product engineering and manufacture.
● With generative design, designers can specify a product by its constraints, and allow a
machine learning algorithm to produce design alternatives that optimize qualities such as
weight or performance.
● Airbus and Autodesk have used this process to create an airplane cabin partition whose
design mimics cellular and skeletal structure and is 45% lighter and stronger than current
designs.
● Machine learning can also be used to supplement the intuition of product designers to
ensure that designed products are actually manufacturable,and can be used in conjunction
with product testing data to identify product deficiencies and suggest alternative designs.
 Facilities Location
● Machine learning systems can be used to direct the placement of a wide
variety of physical facilities within an environment.
● At the microscopic level, this includes the placement of circuits and
components within a semiconductor such as an FPGA.
● It also includes the placement of roads and power substations within
residential areas, the location of conference rooms and other facilities
within an office building,and the positioning of wireless and other sensors
within a factory.
PR

PROCESS PLANNING SCHEDULING YIELD MANAGEMENT

ANTICIPATORY LOGISTICS PRODUCT DESIGN

 Control
Control systems ultimately form the heart of any modern industrial operation,
and are required by organizations that seek to reap the full benefits of
automation.
Within the realm of control, there are many examples of applications that
benefit from artificial intelligence and machine learning. These include:
● Robotics
● Autonomous vehicles
● Factory automation
● HVAC automation
 Robotics
● Robots are used in a wide variety of industrial scenarios, for diverse applications such
as pick and place, sorting, assembly, painting, welding, storage and retrieval, Machine
tending, in which robots load or operate other machines such as CNC, is another
popular application.
● Traditionally, robots are explicitly programmed by directing them to move through series
of points in two-or three dimensional space and perform specific actions at these points.
● Newer approaches, such as collaborative robots (“co-robots”), simplify programming by
allowing these points to be captured by physically positioning the robot.
● The problem with both approaches is that, independent of how the points are captured,
the robot is intolerant to changes in the environment or variations in the position of the
items it is manipulating.
● AI, coupled with computer vision technologies, allows robots to avoid potential
interference by humans or other robots and to accommodate randomly positioned or
mispositioned items without operator intervention.
 Autonomous Vehicles
● Autonomous mobile robots are deployed in large number in warehouses
and factories, to support material transport and pick-and-pack applications.
● In addition, autonomous robots and flying drones are being put into service
to support inventory management applications in warehouses.
● Artificial intelligence coupled with computer vision techniques allows
autonomous robots to complete these tasks more effectively, to better
understand, map and navigate their environments, and to be used more
safely around humans.
 Factory Automation
Industry 4.0, smart factories, and lights-out manufacturing all refer to a vision of the plant
or warehouse that is data-driven, intelligent and highly automated.

This vision relies heavily on robots and autonomous vehicles to move materials and
assemble goods, on AI-based computer vision to detect faults and defects, and on smart
systems to coordinate and optimize the flow of work around the factory.
 HVAC automation
● In addition to being costly to operate, HVAC systems are often poorly behaved,
noisy, and unpredictable under real-world circumstances.
● This is especially true as equipment ages and older equipment is replaced,
sometimes with units that are mismatched or out of spec with the original
system design.
● In these situations, control strategies derived by HVAC engineers assuming
ideal conditions fail to operate in an optimal manner.
● Machine learning can help building owners maximize comfort, reduce energy
costs, eliminate system faults, and extend the life of HVAC equipment.
● Google has successfully used an AI system based on neural networks to
control about 120 data center variables, such as fans, cooling systems, and
windows, resulting in a 40% cut in electricity used for cooling and a 15%
reduction in overall data center power consumption.
 Industrial AI Requirements
Effective industrial AI offerings must help enterprises overcome the challenges and
impediments previously discussed. To do so, offerings must exhibit a variety of
attributes, such as:

Trainability on limited examples

Simulation-based training

Explainability

Provable safety

Ability to leverage subject matter expertise

Ease and speed of use

Deployment flexibility
 Conclusion: Building the Future with AI
Industrial AI lets enterprises better monitor, optimize, and control their physical
operations and systems. Doing so leads to greater visibility and situational
awareness, improved planning and decision-making, and increased efficiency
and productivity.
The implications for companies are significant: AI’s rapidly growing capability
and maturity, combined with the high levels of automation found in modern
industrial environments, has created a window of opportunity for forward-
looking companies to leap ahead of the competition.
Now is the time for those that hope to take advantage of this opportunity to
begin the process of building competency in industrial AI.