Digital manufacturing uses computer-aided design and computer-aided engineering to design, analyze, and create products. It has become increasingly popular in recent years due to its cost savings, efficiency, and overall success rate. But what happens when digital manufacturing fails?

Let’s take a look at some of the most common reasons why digital manufacturing failures happen, as well as how manufacturers can avoid them in the future.

Poor Data Quality in Digital Manufacturing Failure 

One of the most common causes of digital manufacturing failure is poor data quality. This means that the data used to design and manufacture products is not accurate or up-to-date enough to yield desired results.

To prevent this from happening, manufacturers need to ensure that all data is properly collected, stored, and updated on a regular basis so that it remains relevant and accurate for use in digital manufacturing processes. 

Lack of Standardization Leads to Digital Manufacturing Failure

Another issue that can lead to digital manufacturing failures is a lack of standardization across departments or within individual teams. Without standards in place, it can be difficult for teams to collaborate effectively or utilize shared resources while minimizing risk. To avoid this problem, manufacturers should invest in creating clear guidelines for how teams should work together and what processes they should follow when utilizing digital manufacturing tools and systems.  

Poorly Defined Processes Contribute to Digital Manufacturing Fails

In addition to standardizing across departments or teams, manufacturers also need to have clearly defined processes in place for using digital manufacturing tools and systems. Without these processes established beforehand, it can be difficult for teams to know exactly what steps they need to take in order to achieve their desired outcomes with digital manufacturing technology—leading inevitably toward failure. Ensuring that everyone involved understands the necessary steps before diving into any project will help minimize miscommunication and maximize success rates with digital manufacturing projects.

What to Do When Digital Manufacturing Fails 

Digital manufacturing provides numerous benefits to manufacturers but it also comes with its own set of risks that must be managed properly in order for it to be successful. By understanding these risks and implementing the proper measures to address them, manufacturers will be better equipped to handle any potential issues that may arise from using digital manufacturing processes.

With the right approach and preparation, manufacturers will be able to enjoy the many benefits that come along with digital manufacturing while minimizing any potential problems they may encounter along the way.

At ProcessMiner, our research and development team has developed a data science solution that has helped an F500 and one of the largest plastic injection molding manufacturers to reduce scrap rates by more than 50 percent. When ProcessMiner began this journey, we knew it was going to be a game-changer in the manufacturing industry. Fast forward to a few years later, we made a significant impact in the pulp and paper and plastics industries. 

Our industry-leading autonomous control solution delivers process improvement recommendations and parameter control changes in real time to the production line. Our platform ensures high-quality output while driving reductions in scrap, defects and waste commonly encountered in complex manufacturing processes.

Below are a couple of successful examples:

  • ProcessMiner team developed a data science solution that helped an F500 plastic injection molding manufacturer to reduce scrap rates by more than 50 percent.
  • Our artificial intelligence platform achieved unprecedented autonomous chemistry control for the tissue mill. Using a closed-loop controller in conjunction with quality parameter predictions, the mill was able to control its strength chemistry autonomously to ensure optimal chemical feed and adhere to target parameters. As a result, there was a 25% reduction in wet strength chemistry, a 33% reduction in wet tensile variation, and a 98% increase in target adherence.

Digital manufacturing offers a wealth of benefits for manufacturers looking to improve their production processes—but only if done correctly! While there are many potential causes of failure when working with digital manufacturing technology, there are also strategies available for avoiding them altogether if implemented properly from the start.

By ensuring that data quality is high, standards are enforced across departments or teams, and processes are established before starting any project—manufacturers can set themselves up for success with their next digital manufacturing endeavor!