The future of manufacturing: Digital technology driving change 

How will manufacturing transform over in the future? There is obviously no definitive way to answer this question, as so much depends on geopolitical shifts and changing consumer demands, each pushing the way factories function in different ways. 

Thinking about the future of manufacturing, it can sometimes seem very ‘crystal ball’ and result in science fiction plotlines. But ultimately what we’re trying to do is identify emerging technologies – and more importantly how to leverage them to their fullest for greater innovation, productivity and flexibility to improve manufacturing everywhere. 

We can look at this as two individual pillars for the future: 

• Market shapers – how cultural forces transform the demand for products 

• Technology influencers – how our ability to make things changes over time 

Within these two pillars there are macro trends that are easier to predict, and follow much longer timelines. But before going ahead it’s necessary to think about the important difference between these two pillars. Most people have little or no control over the Market Shapers whereas manufacturers have complete control over the technology that goes into their factories. So, focusing on the ‘Technology influencers’ pillar, here we can spot the critical importance of factors such as sustainability, AI, connected workforce, and digital twins to more efficient and robust manufacturing operations of the future. 

Factors shaping the future of manufacturing 

To really look into the future of manufacturing it’s important to have a little understanding of the past. Historically, from Richard Arkwright and the Industrial Revolution to Henry Ford and the advent of mass production, the trailblazers of the past placed a dominant focus on standardisation and scalability. This rings true today with the rise of the giga factory. The focus with this approach is squarely on productivity, getting affordable goods out in the market to people, and of course the commercial result – profit. Factories tended to be built and equipped for one specific purpose, whether than was to spin textiles or to assemble motor vehicles. This made the factories of the past (and even today) rigid or fragile. 

If the advent of a new innovation such as plastic were to come along and weaken demand for your glass bottle or ceramics, the whole operation would fold. Built heavily upon the rigid, fragile structures of the past, today’s manufacturing landscape is similarly at risk from disruption. 

This is important to understand because the future of manufacturing is likely to be shaped by factors other than scalability. Globalisation, international trade, labour costs, shipping considerations and sustainability concerns all place an emphasis on reshoring and localised production. Other factors too, seem likely to shape a very different future. Automation. Customisation and personalisation. The drive for more flexible production methods that de-risk factories – the versatility to make everything from drones to coffee machines from the same facility. For more detail on the concept of anti-fragility in manufacturing and to define your approach, please check out this blog. 

Trends will be a primary shaper of the future of manufacturing. For more assessment on the current market trends that are likely to shape the future of manufacturing, visit: https://www.ey.com/en_pk/insights/advanced-manufacturing/how-manufacturers-can-adapt-for-success-amid-rising-geopolitical-uncertainty

Embracing sustainability in manufacturing 

In most scenarios, the sustainability of future manufacturing operations is going to become increasingly critical. By adopting more efficient processes that use less energy and produce less waste, manufacturers can significantly reduce their environmental footprint and comply with the regulatory standards that will also grow more stringent. 

Advances in technology such as robotics and automation will be an important part of reducing energy consumption and emissions during manufacturing. They will also play a key role in boosting operational efficiency and ultimately the competitiveness of businesses, which is central to the long-term viability of job-providers. Laborious, repetitive tasks that are hard to fill will be replaced by robots, leaving the more creative and operational roles to people. 

Digitalisation of manufacturing processes will also support greater sustainability by increasing the connectivity between previously disparate departments. This ensures greater visibility and efficiency at all stages. And utilising digital solutions to support reduction in physical prototyping and leveraging virtual assembly will again reduce waste through reduction of errors. Further still, leveraging digital simulations not only reduce material use through reducing iterations, manufacturers can use software to make lighter, stronger products with less material, in particular benefitting industries such as aerospace and automotive with more efficient mobility solutions. 

Manufacturing right first time, reducing rework and scrap are all areas where efficiency and sustainability exist completely in harmony. Being sustainable as a manufacturer will become a badge of honour. 

Leveraging artificial intelligence for manufacturing efficiency 

Artificial Intelligence (AI) has experienced a boom in recent years across a wide range of use cases. From marketing to software programming, businesses have been eager to explore the AI’s new capabilities. From computer-aided reasoning and learning, to decision-making and perception. 

These typically-human qualities can be supercharged with powerful computer systems. And the potential of this is staggering. Manufacturers, of course, are starting to see the benefits now and the future will see this current potential fully realised. 

Predictive maintenance, accelerating software simulations, and optimised machine programming are all areas where AI can deliver real progress. And this is only the beginning. Beyond reducing downtime and speeding up processes, the future of manufacturing will see enhanced worker safety and a more integrated and efficient supply chain. Not to mention higher quality output. 

Many of these benefits can be viewed more simply as better, faster decision-making. This is ultimately the true power of AI. And there is no better example of this in action than in additive manufacturing (AM). 

By incorporation AI algorithms into the additive design process, manufacturers can optimise designs for 3D printing. This is achieved by analysing and improving complex geometries, reducing material usage, and ensuring structural integrity depending on the guidelines given for it to work with. Generative design uses AI to explore a vast array of design possibilities to then select the most efficient one, significantly accelerating the overall process. 

While not a new technology, there is still hope that in the coming years, technology will continue to support AM’s transition into a fully viable industrial manufacturing method for a broad range of industries. 

Enhancing workforce skills for future manufacturing 

As mentioned previously, the workforce will see significant changes for the better in many areas of manufacturing with advances in technology. 

For example, in areas such as training, which to some extent has relied on tribal knowledge, we can share and record skills and expertise with greater digitalisation and smarter systems. 

This is particularly important while many manufacturers are facing major challenges recruiting staff as skilled labour reaches retirement age. This is about automating processes and ensuring hardware and software can be used more efficiently by non-experts. That’s especially important as more positions become non-specialist in the future. User interfaces need to be clear, interactive and intuitive, reflecting the way younger people are used to working with devices. 

The manufacturing workforce of the future will also be more connected and collaborative. That will help instil continuous learning and improvement into their domains. It will also promote agility within an organisation. This need for adaptability is key while trends suggest that market demands will continue to change rapidly. 

Digital Twins: Continuing to transform manufacturing 

Digital twins are almost the figurehead of digital transformation. They represent – at the most fundamental level – the future of industry and the way we can manipulate data. But we are still on a journey towards digital twins fully transforming manufacturing workflows as more and more operations discover their power through leveraging virtual replicas of physical parts, processes and systems. 

Manufacturing processes have the potential to benefit immensely from digital twins. Their capabilities allow manufacturers to control and optimise machine operations with precision, reducing the likelihood of costly errors. 

Digital twins are particularly beneficial in areas such as supply chain efficiency, asset management, and energy optimisation. These applications, although sometimes narrow in scope, have the power to deliver substantial value by improving overall operational efficiencies. As digital twins become more embedded within manufacturing processes over the coming years, we expect the sector to increasingly embrace this technology, driven by the need for flexible production lines and higher quality standards. 

In product development, digital twins also have a huge value. They ensure stakeholders across all departments can visualise iterations on a single source of truth. This empowers real-time collaboration, streamlining the process and increasing time-to-market. 

As manufacturing progresses, digital twins’ role will expand, offering unprecedented opportunities for innovation and growth. 

A connected future, quality-focused and predictive 

So, are we any closer to identifying how manufacturing will transform over the next 5 years or the next decade? One thing does seem inevitable. Digitalisation will continue to have a profound impact on manufacturing, driving a transition towards more connected, quality-focused, and predictive operations. As manufacturers integrate advanced technologies like AI, digital twins, and automation into their processes, they will embed new levels of efficiency and innovation. 

The future of manufacturing will also be characterised by a more sustainable approach, both strategically and technologically. Manufacturers will continue to reduce their environmental impact while maintaining competitiveness. With sustainable practices and digital solutions, manufacturers can create more resilient and agile operations. They can then respond to changing market demands and regulatory pressures while also having greater visibility and control. 

It is crucial to remember that the workforce will play the most important role in this transformation. As technology plays a bigger role the industry, there will be a growing emphasis on upskilling and reskilling employees. We must learn to work alongside and manage advanced systems, such as AI and robots. This will enhance productivity and ensure creativity and problem-solving remain at the forefront of manufacturing innovation. 

Ultimately, the future of manufacturing promises to be dynamic. Technology and human ingenuity will converge to create smarter, more efficient, and sustainable production processes.