Search
Close this search box.

Factory Transformation Solutions

Digital transformation in manufacturing. Start your journey with your digital transformation project.

What is digital transformation in manufacturing?

Digital transformation in manufacturing is a revolutionary shift in the way the industry functions, emphasizing the use of digital technologies to modify and improve traditional manufacturing processes and systems. At its core, digital transformation is not just about transferring analogue documentation into computerized forms but about leveraging technology to achieve operational excellence, efficiency, and improved decision-making.

A prime example of this transformation is the ANT system, which digitizes the entire spectrum of production processes. From initially downloading data directly from machines to analyzing this data, reporting relevant information, and executing production plans with peak efficiency, digital transformation ensures a seamless flow of information and operations.

Digital Transformation in Production is gaining momentum. Source: McKinsey study based on 400 global manufacturing companies.

Which industries can benefit for factory digital transformation?

Factory digital transformation isn’t confined to just one or two industries. Its principles and technologies can be applied across various sectors, leading to enhanced efficiencies, reduced costs, and improved product qualities. Here are some industries that can significantly benefit from factory digital transformation:

Automotive

Digital technologies can optimise assembly lines, enhance design and testing processes, and enable predictive maintenance in automotive manufacturing plants. Moreover, they can facilitate the creation of connected cars and the integration of AI-driven features.

Aerospace & Defence

With the need for precision and the high cost of errors, the aerospace and defense industry can benefit from digital processes to enhance design, simulation, prototyping, and production.

Electronics & Semiconductors Indsutry

Given the rapid pace of innovation and high volume of production, digital transformation can drive efficient design, prototyping, assembly, and quality control processes in this industry.

FMCG

From farm to table, digital solutions can optimise supply chains, enhance food processing methods, and ensure stringent quality controls.

Pharma
& Biotechnology

Digital transformation can enhance drug discovery, production, and quality control processes. Traceability and compliance, crucial in this industry, can also be efficiently managed with digital solutions.

Heavy Indsutry

These industries can utilise digital transformation for better design, enhanced production methods, predictive maintenance, and improving the lifespan of machinery.

What are benefits and challenges of digital transformation in manufacturing?

  1. Operational Efficiency: Streamlined processes, automation, and real-time data analytics lead to optimized production cycles, reduced downtime, and faster time-to-market.

  2. Reduced Costs: Predictive maintenance, resource optimization, and waste reduction can significantly lower operational costs.

  3. Improved Product Quality: Enhanced monitoring and feedback mechanisms ensure higher product quality and reduced defects.

  4. Better Decision Making: With data-driven insights, manufacturers can make informed decisions rapidly, adapting to changes in market demand or supply chain disruptions.

  5. Increased Flexibility and Customization: Advanced manufacturing technologies allow for more flexible production lines, enabling customization at a scale that was previously not feasible.

  6. Enhanced Supply Chain Management: Real-time visibility into the supply chain enables better inventory management, demand forecasting, and supplier relationship management.

  7. Reduced Environmental Impact: Efficient resource utilization and waste reduction can lead to a smaller carbon footprint.

  8. Improved Safety: Advanced sensors and monitoring systems can predict and prevent accidents, enhancing workplace safety.

  9. Competitive Advantage: Early adopters of digital transformation can gain a significant edge over competitors in terms of innovation, efficiency, and customer satisfaction.

  10. Enhanced Customer Experience: Digital tools can provide better customer insights, allowing manufacturers to tailor products more closely to consumer needs and preferences.

Challenges of Digital Transformation in Manufacturing:

  1. High Initial Investment: Implementing new technologies and systems can require substantial upfront costs.

  2. Skills Gap: The workforce may lack the necessary skills to work with advanced digital tools, necessitating training and reskilling.

  3. Resistance to Change: Employees accustomed to traditional manufacturing practices might resist or be wary of digital transformation efforts.

  4. Cybersecurity Risks: As operations become more interconnected, they become more vulnerable to cyber threats, necessitating robust security measures.

  5. Integration Issues: Integrating new digital tools with legacy systems can be complex and may lead to operational disruptions.

  6. Data Overload: Managing vast amounts of data generated by digital operations can be overwhelming and may require advanced data analytics capabilities.

  7. Reliability Concerns: Over-reliance on digital systems can pose challenges if there are technical glitches or system failures.

  8. Regulatory and Compliance Issues: Digital transformation can introduce new regulatory challenges, especially in industries like pharmaceuticals or aerospace.

  9. Rapid Technological Changes: The pace at which technology evolves can make it challenging to choose the right solutions and ensure that they remain relevant for a reasonable time.

  10. Supply Chain Disruptions: Over-reliance on specific technologies or suppliers can lead to vulnerabilities in the supply chain, especially if there are global disruptions.

Digital Transformation Pays Off

Among 150 companies in a range of industries and found that revenue growth and compound annual growth rate among the leaders (the top quartile) in tech intensity were more than double that of the laggards (the bottom quartile). Source HBR May-June 2022

89% of Managers Agree That Digitising the Factory Brings Multiple Benefits to the Production

89%

Operational efficiency and better decision-making were the two most frequently cited factors.

Why digitisation of production plants fails?

The failure of digitisation of production plants can be attributed to several factors, including the lack of clear objectives, inadequate training and onboarding of personnel, and inadequate MES systems. Poorly planned and implemented MES systems can cause problems with data accuracy, data reliability, and lack of scalability. Additionally, a lack of proper change management can lead to resistance to digital transformation or multiple independent initiatives introduced by different departments. This results in a lack of integration, and system interoperability, ultimately leading to the failure of digitisation of production plants.  

MES acts as the core of plant digitalisation progress, because clearly indicated OEE losses in the process, defining where should we focus our attention.

microstops

Which system should I choose to start my factory digital transformation?

Starting a factory digital transformation is a significant decision that requires careful consideration of various systems and solutions. The right choice depends on your specific needs, existing infrastructure, budget, and long-term goals. Here are some systems and platforms commonly used to kickstart digital transformation in manufacturing:

  1. Enterprise Resource Planning (ERP) Systems: ERPs integrate various business processes into a single unified system. Popular solutions include SAP, Oracle, and Microsoft Dynamics. They can help streamline processes, enhance visibility, and improve decision-making across the enterprise.

  2. Manufacturing Execution Systems (MES): These systems focus on tracking and documenting the transformation of raw materials to finished goods. MES solutions like ANT Solutions can improve production output, quality, and consistency.

Product Catalogue

  • Get a complete catalogue of ANT Solutions products
  • Read how ANT Solutions can help your company to grow
  • Share the catalogue with your colleagues and co-workers 

What supplies should I secure to start my factory digital transformation?

Depending on the scale of the project and the type of solutions being implemented, the digitalisation project may require mobilizing human resources with a variety of profiles, including technical and quality specialists, technologists and managers. Additionally, the digitalization team may require project management specialists to ensure that human resources are used effectively and the project is kept under control. 

human resources table

In order to get a fast quote ANT Team needs to know:

• What system from our portfolio suits you the most? 

• Briefly describe your production process, include production input and output. 

• Number of lines and machines (workstations). 

• What systems would you like to integrate with? 

• Describe IT hardware available in the plant.

• What system architecture? On-premise or Cloud.

• How many facilities your company plans to digitalise?

Sign up to our newsletter

How to start your production digitalisation?
The roadmap.

If your factory is a greenfield project try to follow up these steps to ensure that your factory will benefit from the digitalisation project. Start small and scale fast as your expertise and requirements grow.­

1.

Create a wired network through your factory or look for a complete solution provider like ANT that will do it for you. 

2.

Connect all machines and start collecting data. Calculate your OEE from day one.

3.

Use production software to analyse data and count OEE

  • Identify gaps and shortcomings to increase your OEE
  • Make your production more efficient
  • Understand what the production progress is

4.

Grow your manufacturing systems and add an additional module to build up a fully functional MES – Integrate with existing ERP to get streamlined data flow across the entire facility. 

MES with Material validation + Traceability + Quality inspections

5.

Use Advanced Planning and Scheduling System to produce on time in the spirit of lean manufacturing. 

6.

Expand your system with advanced maintenance management (CMMS) software. 

7.

Link your Warehouse with WMS to fully manage your stockpiles and deliveries. 

Notify logistics to deliver materials on time right to the shopfloor. 

8.

Fully digitalise your production with a Paperless module and workflow builder.

9.

Combine your production with energy usage and use the EMS system to analyse production cost in relation to consumed energy and other utilities to save resources. 

Project timeline

Be sure everything is on time thanks to proven implementation methods!

What should be taken into account when looking for a partner for factory digital transformation?

Understand Your Needs:

  • Identify specific business needs and challenges.
  • Evaluate the scale and complexity of your operations.

Features and Functionality:

  • List down the features and functionalities essential for your operations.
  • Ensure that the software can be customised to fit your specific needs.

Budget:


  • Consider the initial implementation and ongoing maintenance costs.
  • Evaluate the return on investment.

Vendor Reputation:


  • Research the vendor’s reputation and track record.
  • Consider testimonials and reviews from other users.

Security and Support:

  • Ensure that the software adheres to industry-standard security protocols.
  • Confirm that the vendor offers reliable support and maintenance services.

Ensuring Long-term Resilience and Competitiveness: Why to choose ANT as your solution provider?

Leading machine connectivity solutions

Independent software provider

Agility, flexibility & modifications

Quick implementation

Various products in a single scalable platform. Integration with all existing systems

Business know-how and technical knowledge

Start your digital transformation project

Contact with our Expert

industrial software expert

Łukasz Iskra

Industrial Software Expert

LinkedIn

Why to get a demo?

  • 60-minute online meeting with a dedicated specialist presenting a top system from an industry similar to yours
  • Live modeling of your production process
  • budget quotation after the meeting

Get more insights

Hey there, seems like you are interested in software for production...

Sign up to a newsletter and get a catalogue to share with coworkers

Sign up to our Newsletter and Download Sample Project Plan

Attention: Please provide your Work Email, emails from popular domains like (gmail, yahoo etc.) will be automatically filtered and won’t receive the Sample Project Plan

See a MES demo and get pilot in 3 weeks

industrial software expert

Łukasz Iskra

Industrial Software Expert

LinkedIn

[email protected]

Why to get a demo?

  • 60-minute online meeting with a dedicated specialist presenting a top system from an industry similar to yours
  • Live modeling of your production process
  • budget quotation after the meeting

Leave your email or phone number

We Will Contact You Immidietly​

Get more insights about MES with our case study

Download for free

Welcome back!

See MES ROI

Download Return of Investment (ROI) Document in Molding Injection Machine Industry

This website uses cookies to improve its performance and your experience. Check our privacy policy