Why Software Upgrades Are as Critical as Equipment Investment in Manufacturing

Why Software Upgrades Are as Critical as Equipment Investment in Manufacturing

Behind every robot and automation in a production environment is manufacturing software, and high-functioning, upgraded systems have become as pivotal as any equipment investment. The next generation of industry is focused on accenting the value of intangible resources that amplify the usefulness of traditional production components.

Competitive manufacturing strategies realize key advantages of the automation software sooner in their process discoveries.

Enhanced Data and Analytics for Process Optimization

Holistic corporate software solutions range from enterprise-level planning, manufacturing execution systems (MESs) and building management systems. Each option provides a broad-scope visualization of the facility’s structural health and resource utilization. This software is primed for gathering and clarifying large amounts of data, syncing to make an accurate picture of current operations.

Reviewing these data sources would require countless hours of manual labor, underscoring the value of holistic software applications for companies. Software can automate data review processes, allowing the workforce to generate faster insights about how to optimize operations further.

For example, a review could reveal prominent sources of quality-control errors, such as debris buildup on robotic cameras or label sensor miscalibrations. The data verifies these are the most significant priorities, making the software responsible for continually justifying an equipment investment.

Improved Supply Chain Visibility and Management

Manufacturers and their many partners use a medley of hardware resources — sometimes with minimal overlap and interoperability. Manufacturing software could streamline equipment information, eliminating siloes and improving transparency between collaborators. Consistent and accurate visibility over machinery data points is crucial for ensuring all stakeholders maintain an understanding of corporate goals, maintenance needs and the state of every return on investment.

Global supply chains continue to grow in complexity, with copious disruptions causing delays and miscommunications. Everything from raw-material shortages to trade tensions can strain manufacturing leaders, and software could help soften those challenges.

Advanced solutions include software platforms powered by blockchain that automatically track every smart contract and transaction in an encrypted space. Every point of contact on a product’s journey can see where and who is in control of the process at all times, because the data is immutable. This oversight improves risk management and protects the equipment by helping operators anticipate their future needs.

Manufacturing Automation Software for Increased Efficiency and Quality

If manufacturing software is programmed to control a conveyor belt or an autonomous guided vehicle, every machine should operate optimally if the parameters are regularly reviewed. The programs can even adjust performance metrics if they begin to deviate. This constant adjustment allows the equipment to achieve higher throughput and higher quality more often.

Additionally, if the software commands a tool to adjust its performance to its ideal state, then it preserves components to extend its lifespan.

Robotic process automation is one of the most prominent examples of this use case. It can control countless essential, administrative functions that help everyone, including procurement with automated ordering and accounting with repeat invoicing.

While this may not relate to machinery, as RPA mostly operates in digital spaces, the time savings allow operators to focus on more thorough, value-added equipment enhancements and monitoring. One case study highlighted a company employing RPA, and it handled 55,000 invoices and 650,000 transactions in a year, reducing data entry and verification by 90%.

Advanced Material Handling With Intelligent Software

The up-front costs of an equipment investment are typically the most significant hurdle. Implementation is difficult to justify. However, combining software with three new fiber lasers could lead to a 19.6% boost in material savings, with a 50% higher feed rate. Combined, these benefits demonstrate how software makes equipment more precise and adept at handling and preserving materials.

Additionally, warehouse management systems can provide a more comprehensive image of a facility’s material-handling habits and trends. It could reveal that conveyors and mobile robots are using inefficient pathing to carry materials from one location to another. Insights like this could help machinery by encouraging zoning, routing adjustments or batching.

Optimized Inventory Control Software for Reduced Costs

Balancing stock numbers is a constant battle for manufacturers and warehouses. There must be sufficient safety inventory to ensure product and parts are available in case of an emergency or an increase in demand. However, excessive amounts lead to higher costs, stressed machinery and burdened racks. Inventory control software, combined with data forecasting, that connects to equipment can track fulfilled orders and quantities.

These can be more accurate than manual counting and data entry, allowing financial teams to better estimate carrying costs and prevent stockouts. Inventory mismanagement and distortion already cost companies around 20% more, which includes extra storage expenses. More precise monitoring, especially when augmented by artificial intelligence, can identify savings opportunities to help machinery and shelves remain stable under pressure.

Cybersecurity and Data Integrity

IT teams and cybersecurity analysts are already in short supply, and workforce shortages are exacerbating an already intimidating rise in critical infrastructure attacks. Automated software can improve the cybersecurity posture of an entire facility and better protect equipment connected to the internet. Because these resources generate a lot of revenue and have a significant impact on society, manufacturers are high-value targets for cybercriminals.

Software can alert analysts to suspicious activity and dubious access attempts, and issue security patches. These solutions complement staff efforts, providing greater coverage than before. Added defenses are essential for protecting equipment investments, as machinery can be a vulnerable device in a breach.

The most intense attacks could render expensive equipment useless. Combine this loss with the high cost of recovering from a cyber threat, and purchasing software as another security blanket makes sense.

Enabling Agility and Future-Proofing

Facilities have to scale in multiple ways. They need to accommodate AI, increase throughput, embrace customization and create higher-quality products while considering cost. These are only a few concerns stakeholders need to consider in the coming quarters, and software could ease some of the burdens associated with creative ideation and solution development.

For example, companies with an implemented MES can more easily install new equipment that seamlessly interconnects with other hardware and software assets. Enterprises without this visibility may need to replace equipment to make it compatible, disrupting workflows and requiring more workforce upskilling to adapt to new processes.

Designing manufacturing workflows around a single resource makes it easier to develop agile processes and select the optimal machinery.

How Manufacturing Software Became the Powerhouse of Production

Facilities are stretching software to its limits, finding direct and indirect ways to empower machinery. Willingness to experiment and innovate is leading to greater productivity, better communications and improved equipment durability.

The most competitive organizations are deploying software to future-proof their machinery and enable it to scale with the changing demands of clients and customers.

Lou Farrell

Lou, a Senior Editor at Revolutionized, has specialized in covering Technology, Manufacturing, and Transportation topics for several years. He loves to write, and enjoys being able to share his knowledge with others however he can.