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One of the foundational aspects of Industry 4.0 protocols is the creation of electronic “digital twin” models of product data and production processes. This includes an exact replica of all machine tools, including complex work envelopes showing the particular spindles, fixtures, and cutting tools.

The bane of modern engineering is complexity. One promise of artificial intelligence and machine learning is helping engineers to use complex tools and harness vast data sets effectively.

Simulation in manufacturing is becoming much more pervasive. Advanced visualizations are used everywhere, from machining on shop-floor CNCs to offline CAD/CAM programming of NC equipment.

If you’re feeling a bit overwhelmed by the prospect of Industry 4.0, and perhaps a bit sheepish about your lack of progress, you’ve got good company.

Finland-based global welding automation manufacturer Pemamek Oy named Michael Bell director of sales for its North American subsidiary Pemamek LLC. Pemamek provides welding automation technology and integrated manufacturing solutions to a wide range of industries including shipbuilding, heavy fabrication, oil and gas, wind energy, and boiler manufacturing.

As additive manufacturing (AM) moves from prototypes to mass production, manufacturers are setting their sights on the holy grails—the products and processes that will be game-changers. Many game-changers are already in play.

As with any digital transformation process, the devil is in the details, and there are many potential pitfalls that can derail projects.

Road to maturity involves safeguarding supply chains, treating security with the same urgency as safety, for starters.

There is no shortage of competition in a global market. As a manufacturer trying to get ahead of the pack, automation can help with problems like a limited skilled labor force, quality control issues and suboptimal throughput. But the high initial cost and extended implementation time can be deterrents.

Manufacturers are facing shrinking product lifecycles with frequently changing customer demands. As a result, they need agile production and flexible factory layouts that can easily be modified whenever needed.