Understanding smart manufacturing

In the beginning, there were people. There were smart people making useful things. There were individuals and small communities with the desire to improve the quality of life for their children.

Eventually those innovations come together in such a way that brought about a defining moment in the human story, an industrial revolution. A certain group of ideas, skills and techniques, in constellation, gave us a moment that changed the direction of travel forever.

But an industrial revolution isn’t a moment in time when we can say things changed. It’s wrong to think of it as a single point.T hat’s as true for smart manufacturing, or industry 4.0, as it was for the first industrial revolution.

“Smart manufacturing is a journey and how you define it depends on where you start on that journey” Paul Rogers, President Hexagon’s Manufacturing Intelligence division for the Americas and Asia Pacific

It’s a journey along a road paved with diverse technologies, signposted with a million buzzwords and definitions. Where’s it headed? Towards a final destination that probably doesn’t even exist. Why? Because technology and innovation never stand still.

Paul Rogers tells us, smart manufacturing is not a single thing, but many things to many organisations. If he’s right, the road is as wide as it is long.

In this blog, we’ll take a closer look at smart manufacturing. We’ll look at the evolution of manufacturing processes. We’ll ask, what are the key technologies driving smart manufacturing, and ultimately why should we care? What are the benefits, the roadblocks, the challenges and finally what might the future hold?

But before all that, let’s take a step back and look at the wider picture. Smart manufacturing is a term used interchangeably with Industry 4.0, so let’s see in the context of the evolution of manufacturing processes.

Evolution of manufacturing practices

Industry 1.0

August 24, 1814, The Battle of Bladensberg, in the modern-day Washington Metropolitan area, was a key event in the smart manufacturing story.

Some 21 years had passed since the US Declaration of Independence, yet British forces continued to interfere with US trade, especially with France. There were pressgangs forcing US citizens into the British Navy, and British support for native American resistance groups.

British forces won the battle and went on to lay siege to the city of Washington. In his book “Exactly: How Precision Engineers Created the Modern World” Simon Winchester takes up the story:

“There were many reasons for the defeat… yet one, a most notorious shortcoming of the American forces was that the muskets with which the infantrymen had been equipped were notoriously unreliable… and when they failed, they were fiendishly difficult to repair.”

Perhaps the main problem with these weapons was that they broke frequently. When that happened, the whole thing had to be replaced. At that point, no one had ever made a weapon from component partsso precisely made they were interchangeable.  

This battle was one of many events we could have chosen to make the point. Cutting a long story short, the first industrial revolution saw large scale mechanisation of processes. It came with the introduction of steam power and widespread use of Iron and Coal. Finally, it introduced us to the factory system and along with it the beginnings of standardised interchangeable parts.  

Industry 2.0

Fast forward 100 years and we enter the era of mass production, mass standardisation, electrical power and the division of labour, the production line. Improved measurement technology allowed engineers to produce components with far greater accuracy and precision. Instead of master craftsmen making complete finished products, people could specialise in a particular area of production. We could build components in different parts of a factory, or even buy in objects, and know they would fit together in a consistent way.

This shift in production methods transformed industries and had a profound impact on society. For the first time, ordinary people could access goods that were previously considered luxuries. Factories became larger and more organised, often employing thousands of workers and introducing new levels of coordination and management. With so many workers, factories became central to many communities. Areas like Lancashire, and Manchester in the north of England developed deep cultural ties to certain industries and factories within them.

Industry 3.0

Beginning in the mid-20th century, we saw the introduction of computers and robotics into factories. Automation enabled machines to perform repetitive tasks with precision, accuracy, speed, and consistency, reducing the reliance on human labour.

At the heart of Industry 3.0 was the integration of digital technology into industrial processes. Manufacturers cold monitor and control production lines in a way that wasn’t possible before. Robotics began to appear on factory floors in the 1970s and took automation to new heights. Factories could produce goods faster and with fewer errors.

This era also saw the rise of lean manufacturing and techniques like just-in-time production, pioneered by companies like Toyota. Industry 3.0 also brought significant changes to the workforce. While automation reduced the need for manual labour in many areas, it created demand for skilled workers who could design, programme, and maintain the new machines. This shift led to the rise of engineering and technology-focused careers, as well as the need for ongoing training and education to keep pace with rapidly evolving technologies.

Perhaps most importantly, the age of automation laid the groundwork for the dramatic shift towards industry 4.0, or the age of smart manufacturing.

Key Technologies Driving Smart Manufacturing

Smart manufacturing is a collection of technologies that we can deploy individually or in combination. It’s a digital tool kit, and some of the main items in that kit are Industrial Internet of Things (IIoTs), Artificial Intelligence (AI), Automation and robotics, cloud computing, here we’ll take a look at some the key ones, and their impact.

Industrial Internet of Things (IoT)

The Internet of Things (IoT) is a vital technology in smart manufacturing, allowing equipment and devices to communicate and share information. By collecting real-time data from sensors, manufacturers can monitor processes more effectively and address potential issues before they disrupt operations. This improves efficiency and helps maintain consistent product quality. IoT also supports better oversight of supply chains, ensuring traceability and compliance with regulations. By providing detailed insights into production, IoT allows manufacturers to make informed decisions and adapt to changing needs. Its adoption is reshaping the manufacturing landscape, promoting greater productivity and reliability in modern industrial practices.

Artificial Intelligence and machine learning applications

Artificial Intelligence (AI) and machine learning are transforming smart manufacturing by enabling systems to analyse data and make informed decisions. These technologies help manufacturers predict equipment failures, improve production planning, and enhance quality control by identifying patterns and anomalies. AI can also automate repetitive tasks, freeing up workers to focus on more complex activities. Machine learning algorithms continuously improve over time, allowing processes to adapt and become more efficient. By integrating AI into operations, manufacturers can achieve greater precision. They can reduce waste, and respond more effectively to changing demands, making production more reliable and resource-efficient in an increasingly competitive industry.

Automation and robotics in production

Automation and robotics play a crucial role in modern manufacturing, streamlining production processes and improving consistency. Robots are used for tasks requiring precision, such as assembly, welding, and packaging, while automated systems handle repetitive or hazardous operations, reducing risks to workers. This technology improves productivity by operating continuously and minimising errors, ensuring high-quality output. Automation also allows manufacturers to scale production efficiently and adapt to changing requirements without significant downtime. By integrating robotics into production lines, businesses can reduce costs, optimise resource use, and create safer working environments, making them better equipped to meet the demands of today’s manufacturing landscape.

Challenges, roadblocks and solutions in Smart Manufacturing

Among the key challenges are the integration of legacy systems, data security and privacy concerns, and workforce training. Addressing these issues is essential to fully realise the benefits of advanced manufacturing technologies.

Integration of legacy systems

Many manufacturers rely on legacy systems that were not designed to work with modern smart technologies. These older systems often lack the connectivity and compatibility needed for seamless integration into a smart manufacturing framework. Replacing them outright can be costly and disruptive, especially for businesses with tight margins.

To overcome this, manufacturers can adopt a phased approach, gradually upgrading systems to ensure compatibility while minimising disruption. Middleware solutions, such as industrial IoT platforms, can act as a bridge between old and new systems, enabling data sharing and communication without a complete overhaul. Additionally, working with technology providers to develop customised integration plans can help businesses modernise at a manageable pace.

Data security and privacy concerns

The increased connectivity in smart manufacturing exposes businesses to heightened cybersecurity risks. Sensitive production data, intellectual property, and customer information are all vulnerable to breaches and attacks. A single cybersecurity incident can result in financial losses, reputational damage, and operational downtime.

To address these risks, manufacturers should implement robust cybersecurity measures, including firewalls, encryption, and intrusion detection systems. Regularly updating software and firmware is critical to patch vulnerabilities. Adopting a zero-trust security model, which assumes no device or user is inherently trustworthy, can further protect critical systems. Employee training on recognising phishing attempts and maintaining good cybersecurity practices is equally important. Compliance with data protection regulations, such as the UK’s GDPR, ensures that privacy concerns are addressed while building trust with customers and partners.

Putting it all together

Smart manufacturing represents the next chapter in the evolution of industry, blending innovation, connectivity, and intelligence to create more efficient, adaptable, and sustainable production systems. While challenges like legacy systems, cybersecurity, and workforce training remain, they are not insurmountable. By embracing advanced technologies and enhancing collaboration between people, machines, and data, manufacturers can unlock new levels of productivity and resilience. Ultimately, smart manufacturing is a moving target, not a destination but an ongoing journey.