1. It’s not about who has the biggest budget. Connectivity is key.

“Efficiency today is not about isolated improvements, it’s about how everything works together,” said Alexander Zoller, President of ZOLLER Inc. “The companies making real progress are not necessarily the ones investing the most, but the ones executing with discipline, connecting tool data, preparation, and machine integration into a single, consistent process.” 

2. Smart manufacturing requires smart investments in new technology.

Although many manufacturers are determined to “make do” with their old technology, investing early and intentionally in innovative equipment can save time, improve accuracy, and drive revenue growth across the shop floor. 

Tom Basset II, President of Pro-Cam LLC, said that most shops buy equipment when something breaks. But based on his own experience, he recommends that shops do the math and make proactive, strategic upgrades that increase throughput, improve finishes, and reduce tool spending.

3. Maximize success with a shared future for smart manufacturing.

When implementing new technology, a lone decision-maker may move forward without fully appreciating how the new technology will change processes or cross-functional collaboration. But taking the decision to a larger team ensures that production environments stay tightly controlled. 

“Validate your ideas thoroughly with your team as you consider a technology investment,” said Peter Doyle, President of Hirsh Precision. “Get buy-in and clearly describe in detail what a successful future state looks like.”

4. Find automation solutions that scale up as you do. 

Automation is a key component of smart manufacturing, and its impact can be felt across the shopfloor. Whether you’re automating processes with software, gathering tool measurements with hardware, or embracing full automation with robots, automation around cutting tools can have a significant impact. Dietmar Moll, Director of Sales at ZOLLER Inc., says manufacturers should invest in expandable solutions that can meet the changing needs of their businesses.

5. Your operators may be hesitant to adopt new solutions, but their buy-in is critical.

Some employees on your shop floor may be worried that automation will replace their jobs, rather than change the way they work. 

Walt Swenton, Senior Manager of Advanced Manufacturing/Industry 4.0 at Eaton Aerospace, says manufacturers should plan for some resistance and keep the lines of communication open. This will put employees more at ease, encourage adoption, and help gather critical feedback straight from the shopfloor.

6. Data is everywhere. But not everyone knows how to use it.

Max Egan, CEO of Atlas Fibre, pointed out that every single step in your process is a data point for collection. But unless you have a system and culture to collect that data, you’re ignoring most of your output.

“The factories that are winning are able to make data-driven decisions from data that is happening right now—real-time data getting to the people that need it in order to make the decisions that realize your production capability,” said Sam Kirkpatrick, Product Manager at ANCA. 

7. In today’s challenging market, greater operational control is needed.

Jeff Cederstrom, President of ARCH Cutting Tools, noted that escalating pricing on tungsten carbide is having a downstream impact on production, margins, and competitiveness. Supply chain instability and material cost volatility require manufacturers to take an even closer look at their day-to-day operations for safety, reliability, and efficiency.

8. Smart solutions introduce greater transparency to the shopfloor.

In many shops, there is still a lack of communication between hardware, software, and operators. Moll recommends using solutions like a single database to drive information to CNC, as well as unique identifiers like QR codes to digitize and connect the tool management process.

9. Data will fuel the future. 

Emerging Industry 5.0 puts emphasis on human and AI collaboration, which requires real-time data that gets acted on as soon as it’s available.

“That’s when we have vast machine learning or AI-style technology applied to these rich, accessible datasets that have integrity. And that’s when we’re able to do these really cool things, and we’re able to almost predict the future,” said Kirkpatrick. 

For more helpful tips and useful information on smart manufacturing, visit our reports and stories section.