INNOVATIVE BUSINESS IDEA

Manufacturing Industry

SUBJECT: INNOVATION AND ENTREPRENEURSHIP

Submitted By:
Swagatika Mohanty
SAP no.: 80203180142
Roll (C063)

Neha Gupta
SAP no.: 80203180142
Roll (C036)

SVKM’s NMIMS
Deemed to be UNIVERSITY

Bengaluru Campus
 Introduction
Innovation in manufacturing sector is defined as any change in the business, which generates
monetary benefits directly or indirectly. Innovation is a requisite for growth in any business. In
manufacturing context, innovation can be said as something that is newly introduced at any level of
value addition entailed in the production process and the change is successfully commercialised.
Innovation is measured with respect to performance and growth, led by upgradation in efficiency,
productivity, quality, competitive positioning and/or market share of the company. It can be broadly
classified into the following four categories, depending on the area of business where a change has
been introduced.

Innovation in manufacturing activities can be broadly classified under the below four categories.

 Innovation in Sourcing that is done by change in raw material or supplier or the influence of
supplier in the manufacturing supply chain. A unit can be said to have innovated with the
sourcing of raw materials, when any change in the raw materials or suppliers, and change in
the degree of involvement of suppliers in the supply chain leads to quantitative benefits
directly or indirectly.
 Innovation in Manufacturing Process is modification at any level of production. The aim of
such innovation can be to reduce the turnaround time, enhance the product quality, trim
the cost of production, achieve the flexibility of customising the product as per customer
demands as well as reap other benefits that result into better product competitiveness.
 Management Innovation covers introduction of a new method of carrying out business.
 Innovation through technology involves change in the manufacturing process through
adopting a different technology usually away from the conventional method. Such
innovations typically take time to gain acceptance and become commercially successful; as
the long-term advantages offered by the technology are not immediately evident to
consumers. Hence, companies that innovate in these areas need to have a long-term view

Two Innovations in the Manufacturing Industry:

The Audi Smart Factory: The Model Factory of the Future

Audi, the German automaker, is preparing for the future with its Smart Factory. It is now vital to
optimize the production line considering the increased complexity of automobiles. In this factory of
the future, big data – the creation and intelligent connection of large volumes of data – will facilitate
data driven and thus highly flexible and highly efficient manufacturing. In this factory the parts will
be manufactured using 3D printing and transported by drones. Audi is already making excellent
progress with its drones which are currently able to transport steering wheels. Furthermore,
the piloted cars will drive themselves off the manufacturing line when completed. This is a method
of production in which Audi might no longer build its cars on an assembly line but according to a
radically new, disruptive concept called modular assembly. The modular assembly method is
thought to improve productivity by approximately 20 percent compared to the current assembly
line. The system allows the projection of virtual 3D components onto the car. In Audi’s tooling
division, a 3D printer produces complex metal parts, and intelligent tools are able to exactly
distribute the high-pressure forces to stamp sheet‑metal parts that are accurate to one hundredth of
a millimetre. And in the assembly process, a robot works with the employees on the production line
without a protective fence, passing them components at exactly the right speed and in an
ergonomically pleasant position.
Processes within a smart factory

 Manufacturing operations
o Additive manufacturing to produce rapid prototypes or low-volume spare parts
o Advanced planning and scheduling using real-time production and inventory
data to minimize waste and cycle time
o Cognitive bots and autonomous robots to effectively execute routine
processes at minimal cost with high accuracy
o Digital twin to digitize an operation and move beyond automation and
integration to predictive analyses
 Warehouse operations
o Augmented reality to assist personnel with pick-and-place tasks
o Autonomous robots to execute warehouse operations
 Inventory tracking
o Sensors to track real-time movements and locations of raw materials, work-
InProgress and finished goods, and high-value tooling
o Analytics to optimize inventory on hand and automatically signal for
replenishment
 Quality
o In-line quality testing using optical-based analytics
o Real-time equipment monitoring to predict potential quality issues
 Maintenance
o Augmented reality to assist maintenance personnel in maintaining and
repairing equipment
o Sensors on equipment to drive predictive and cognitive maintenance analytics
 Environmental, health, and safety
o Sensors to geofence dangerous equipment from operating in close proximity
to personnel
o Sensors on personnel to monitor environmental conditions, lack of movement,
or other potential threats
How it adds Value:

 Self-correction is what distinguishes the smart factory from traditional automation,

which can yield greater overall asset efficiency, one of the most salient benefits of a
smart factory. Asset efficiency should translate into lower asset downtime, optimized
capacity, and reduced changeover time, among other potential benefits.
 The self-optimization that is characteristic of the smart factory can predict and detect
quality defect trends sooner and can help to identify discrete human, machine, or
environmental causes of poor quality. This could lower scrap rates and lead times,
and increase fill rates and yield.
 Optimized processes traditionally lead to more cost-efficient processes—those with
more predictable inventory requirements, more effective hiring and staffing decisions,
as well as reduced process and operations variability. A better-quality process could
also mean an integrated view of the supply network with rapid, no-latency responses
to sourcing needs—thus lowering costs further.
 The smart factory can also impart real benefits around labour wellness and
environmental sustainability. The types of operational efficiencies that a smart factory
can provide may result in a smaller environmental footprint than a conventional
manufacturing process, with greater environmental sustainability overall.
  Greater process autonomy may provide for less potential for human error, including
industrial accidents that cause injury. The smart factory’s relative self-sufficiency will
likely replace certain roles that require repetitive and fatiguing activities. However, the
role of the human worker in a smart factory can lead to greater job satisfaction and a
reduction in turnover.
Recycling Robots: Reducing Waste the Smart Way:

Apple came up with Daisy, a recycling robot that can strip apart iPhones and allow the materials to
be reused. It's highly likely that other smart device manufacturers will follow suit with similar robots
in future. The benefits of a device like Daisy are twofold. For starters, it allows customers to safely
dispose of their discarded smart devices. Secondly, it reduces the resources spent on sourcing the
materials for new devices, as the materials can be taken from older models and reused.

Daisy can disassemble 200 iPhones per hour or around one every 18 seconds. The teardown robot
targets components constructed from high-value materials such as the logic board, receiver, the
iPhone's taptic engine, speakers, the enclosure, and rear camera. And Daisy can recover about 1kg of
gold, 7.5kg of silver, and nearly two tons of aluminium from every 100,000 iPhones.

Apple handles disassembly and then sends the components to recyclers to recover materials.
Following extraction, Apple says the materials will be sent to secondary markets to minimize
demand for mined resources. Daisy is also designed to target components with rare-earth elements
such as neodymium, praseodymium, and dysprosium found in magnets, the haptics engine, and
speakers. Other materials extracted included tungsten, copper, palladium, tin, cobalt, and tantalum.

How it works:

 Step 1: In the first stop, Daisy jams a set of prongs into the crease between the
phone's screen and body, separating them.
 Step 2: In the next section, the iPhone loses its battery and screws.
 Step 3: The toughest part is to remove a battery glued onto the phone's body. So
Daisy blasts the glue with freezing air and knocks it with enough force. Then the
battery just falls out.
 Step 4: Then the screws that hold the logic board are punched out.
 Step 5: Daisy identifies which phone it's looking at and the angle at which it's sitting
to make sure it's accurate.
 Step 6: At the last stage, Daisy removes the cameras, haptics, speakers and other
bits. Then Daisy's left with an aluminium shell, which can be carted off to be recycled.
Fundamentally, the squad's robot arm has soft grippers ad the robot can take objects from a
conveyor belt and identify what they are made from, by touch. The Tactile sensors on the
robot are the main feature. The sensorized gripper is fully electrical driven. It can detect the
difference between paper, metal and plastic.
How it adds Value:

 In a traditional e-recycling machine, which smashes electronics in an effort to expose

valuable materials and collect them, unfortunately, these materials often get co-
mingled and become impure in the process. Soft Robotic use avoids this wastage
due to impurity.
 Although environmental and sustainability concerns have made it crucial to scale up
recycling operations, object sorting remains a critical bottleneck for recycling
scalability. Many large recycling centers already use magnets to pull out reusable
 metals, and air filters to separate paper from heavier plastics. Even so, most sorting
is still manual. It's dirty and dangerous work. Soft robotic grippers are a natural
solution for automated recycling.
 Not only that but most facilities still employ large amounts of manual labour to grasp
and sort objects that escape automation. This can lead to unsafe working conditions,
especially in facilities where normal waste is mixed with recyclables. Recycling
automatically could alleviate such a labour-intensive process.
 The gripper components are a pair of cylinders and high deformation capacitive
pressure and strain sensors Rather than relying on vision, it tells a metal object from
one that looks like metal by sensing its conductivity. This classifier works over a
variety of objects including those that would fool a purely vision-based system.

Manufacturing Sector with AI as a fuel:

The rapid evolution of artificial intelligence (AI) is coming at an ideal time for the sector. It
has the potential to help industry players operate at unprecedented speed and scale, as well
as facilitate the reduction in costs and transform customer experiences for the better.
The technology in reality, a collection of different technologies like machine and deep
learning, analytics, computer vision, all working and evolving together, enables machines to
simulate human intelligence. It lets them sense the world around them, comprehend it, and
then act accordingly, all without much human intervention.
By replacing labour activities with faster and more accurate intelligent automation,
augmenting workers as they perform higher-value tasks, and making capital stock more
productive, AI will undoubtedly bring new growth to the industry. And that’s before the spill-
over and network effects are even accounted for.
Two Upcoming Innovations in manufacturing industry are:
DIGITAL TWINS
General Electric is building an army of AI-enabled digital twins in order to make significant
operational savings. The digital twins are digital replicas of the company’s physical assets,
each capable of showing the real-time status of its physical twin based on data collected
from sensors in the equipment. By integrating an AI-powered virtual assistant, employees
can interact with the digital twin in a completely natural way, as if they were talking to a
colleague. So, questions like “Which parts of this machine are the most damaged?” will be
answered, in voice or by text, with an answer like “the turbine sub-system might fail if not
reviewed”. This will effect in a huge potential cost saving, not just in integrating technology,
but also in streamlining the training given to employees.
A GLOBAL NETWORK OF AI-ENABLED ROBOTS
KUKA, a European manufacturer of industrial robots, has partnered with Huawei, the China-
based communications company, to develop a global network of AI-powered manufacturing
robots. The proposed smart manufacturing platform is built on the Industrial Internet of
Things and will connect robots in numerous factories around the world and then embed
integrated AI and deep learning into the network. The collaboration will explore the use of
imitative deep learning in advanced manufacturing environments. The two companies will
also work together in fields like cloud computing, big data, and mobile technology to help
their customers embrace smart manufacturing.