Tech-Clarity’s Julie Fraser was on the analyst panel of the Manufacturing Leadership Council’s (MLC’s) 20th anniversary Rethink conference. The panel looked back 20 years and forward 20 years in the journey to digital manufacturing. Julie’s perspective is that some things that seem new are not – like AI, which she wrote a report about in about 1990. That shows how many things must be in place technologically and in our mindset and culture.
The digital transformation will also require a personal transformation. The key is to go after Smart with Heart. She also believes there is a “pot of gold” at the end of this journey. Like a leprechaun, rather than only seeing the material wealth there, we’ll want to ensure we do the manufacturing dance to celebrate.
Technology and Buzzing People
The panel – and the entire conference – touched on technology, including networking, materials handling, enterprise and plant software, AI, and Generative AI. Every presentation also emphasized innovation, processes, workforce engagement, and leadership skills. The more new technologies we employ in manufacturing, the more conversation it generates around human beings. People are, and it seems will continue to be, at the center of manufacturing – even as it is increasingly automated and autonomous.
One of the notable features of this conference was the level of engagement in the MLC community. These leaders and their teams eagerly and openly engaged with each other and with the technology and services providers. It was rare to find someone standing alone for even a short time—we were all sharing and learning with each other.
The MLC is part of the National Association of Manufacturers – NAM (NAM), but people from around the world were there, sharing their stories and competing for awards. This conference has cleverly incorporated an awards gala to ensure that leaders and their teams who are nominated come, share their stories, and learn from one another. When one company shared information, you could see groups from other companies discussing it with each other.
Manufacturer Examples
Some award nominees and speakers, like Matthew Herman of Whirlpool, are turning the corner in understanding how to gain benefits while building toward scalability and enterprise-wide rollout. This scaling seems to often involve changes to the organizational structure and staffing.
Becky Sidelinger of Flex shared the journey to extreme contract manufacturing flexibility in their production operations to match product innovation. They use digital twins of their end-to-end manufacturing lines, machine learning, and AR/VR goggles to guide work. Beyond that, she discussed effectively bringing suppliers into the sustainability frame. A key takeaway was to “be generous with your time” as a leader.
J. Kirby Best of Bespoke talked about his startup custom clothing company, Bespoke. Here, autonomous robots work with people, and real-time location tracking and AI are used to gain productivity at the point of activity. This truly innovative approach to garment manufacturing is based on “getting out of your mind how anything was done before.” The result is essentially infinite selection in zero time.
Craig Stephen Slavtcheff of Campbell’s focused on their agile approach. It is not just meeting hygiene, and not just in R&D, but a deep approach to agile in food and its supply chain. Modifying existing unit operations to live up to the design brief has been crucial. Deep change management plays into ensuring data is considered an essential part of every job.
Prasad Rajiv of forklift maker Hyster-Yale talked about making great strides toward smart and autonomous products. The ability to use 5G communications and interact effectively with WMS, MES, people, and manual operations such as picking. Bringing decisions closer to the action was part of it, zero emissions another.
Chris Platz of Woodward talked about their journey to transform supplier collaboration, even with their many small suppliers. They have built a digital twin of suppliers’ capability and capacity to show what to send where and when. In about a week, they can set up a digital twin of a supplier factory and begin working with the simulation-selected best partner on a 1:1 basis based on pre-negotiated pricing.
The next-generation leaders panel dispelled misunderstandings. Megan McCarthy of General Motors discussed two-way feedback and GM’s commitment to electric vehicles. Jonathan Miller from St. Gobain Life Sciences saw that machine connectivity foundations were a tough sell, but they delivered benefits and removed drudge work once in place. His advice was, “Make everyone comfortable failing.” Angela Accurso, MPA of MdX talked about mentorship and sponsorship, and Marlon Alberto Gonzalez Martinez of IBM pushed for “giving a voice to young people and their ideas.”
Takeaways
TakeawaysHere are some of Julie’s takeaways and highlights from the two days she attended the conference.
- Working with consultants and system integrators, manufacturers are already gaining significant benefits from AI and Generative AI. Knowledge management and retention is a good application. Yet they are not the right fit for every problem.
- Scalability continues to be daunting, and while some leaders feel they are now on a good path, this path typically involves failures and learning from shortcomings.
- Technical debt is an important issue for companies to consider regarding their legacy systems and how best to avoid it with new investments.
- IT and OT are learning to work together in the most successful companies –the results can be more autonomous operations and more effective people.
- All five generations of current workers have valuable contributions—the company culture and its leaders must encourage those ideas so all can support each other.
- New technology, processes, and thinking are improving quality, efficiency, cost, and success both inside companies and across their ecosystems.
It is truly an exciting time to be in manufacturing. The transformation is underway, and while there are some challenges, the gains are tremendous. Thank you, Manufacturing Leadership Council and David R. Brousell, for hosting us there!