Possible Scenarios of Change in Manufacturing Processes

Over recent years, the manufacturing industry has been undergoing a profound transformation characterized by the increasing use of digital technologies in production processes alongside new production paradigms. This deep-seated change is giving rise to a new production model known as Advanced Manufacturing. Let's delve into various aspects with an eye on future applications.

Production Process Technology in Manufacturing from Today to the Next 15 Years

On a global scale, over the next 10-15 years, manufacturing processes are expected to evolve towards more decentralized models, focusing increasingly on the use of highly flexible machinery.

Reduction of Machinery in Companies

Consequently, a reduction in the number of required machines is anticipated, alongside greater flexibility in production processes. This aim is expected to be achieved within 15-20 years, reducing the number of machines currently fulfilling specific roles across various stages of the production chain.

Decline in Large-Scale Production

As anticipated, a gradual decline in large-scale mass production is foreseen, with the introduction of reduced production batches and greater specificity in finished products (e.g., high customization in color varieties and dimensions) to meet market demands.

Labor Reduction Thanks to CAD, CAM, and CAE Design

There is an expected reduction in generalist labor due to process automation and subsequent specialization of the workforce. This trend will lead to increased demand for professionals with advanced technical skills capable of operating Advanced Manufacturing machinery, such as CAD and CAM drawings.

Regarding CAD, a PC is used to transform an idea into a project to ascertain its feasibility. CAM production, on the other hand, involves the consideration of the project and its material realization through machine tools. It is noteworthy that CAD is increasingly intertwined with CAM due to ongoing advancements towards principles of advanced manufacturing, particularly in 3D design.

Similarly, in the realm of design for additive manufacturing, CAD represents a largely outdated methodology superseded by Computer-Aided Engineering (CAE). CAE involves applying computer-assisted mathematical analysis and simulation techniques to product development. This approach combines traditional CAD techniques with specialized disciplines such as Finite Element Analysis (FEA), Computational Fluid Dynamics (CFD), multiphysics, and engineering calculation. The primary goal of CAE is to create products or individual parts validated for specific operational conditions, optimized with a focus on weight and robustness variables.

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Move towards a Decentralized Model

There will be an increasingly pronounced shift towards a decentralized model, possibly in an "as-a-service" logic. This entails an increased outsourcing of production and the development of such models to reduce investment costs and the necessity of creating a traditional production chain, especially for SMEs. A large-scale reorganization by major manufacturers is expected through models enabling centralized control of operations and decentralization of production processes at regional levels. Moreover, an evolution towards "Dark Factory" models in production facilities is anticipated.

More Advanced Scenarios: The Dark Factory Model

The Dark Factory model represents an evolution of the concept of the intelligent or "Smart Factory." This model aims to create a highly automated and digitized production environment. Unlike the Smart Factory, however, the Dark Factory model is characterized by the absence of human operators within the production facility, relying instead on advanced technologies based on robotic systems, artificial intelligence, automation, and IoT.

In this type of production facility, the entire production process is managed entirely automatically, without the need for manual intervention. This approach offers numerous advantages, including increased efficiency, reduced operational costs, greater flexibility, and the ability to operate in hazardous environments.

In summary, the Dark Factory represents an evolution of the smart factory concept, aiming to create highly automated and digitized production facilities to maximize benefits.