Digital Manufacturing Framework for Enhanced Efficiencies

The manufacturing sector, a major contributor to global Gross Domestic Product (GDP) and employment is facing intensified challenges due to globalisation and the rise in demand for personalised goods. Traditional methods in manufacturing often lack efficient interconnection between equipment, operations, and operators, leading to inefficiencies and communication gaps. While smart manufacturing presents potential solutions, its integration poses difficulties, especially for small and medium enterprises. Thus, there's an urgent need for a framework that seamlessly connects technology, operations, and operators in real time to enhance efficiency and meet evolving market demand. A Digital Manufacturing Framework (DMF) was developed to address manufacturing inefficiencies, combining operations, operator analytics, and real-time data processing. By integrating cyber-physical systems, the DMF utilises tools like programmable logic controllers, manufacturing execution systems, and digital twins for real-time data collection. The analytical module within the DMF detects errors and offers corrective strategies, streamlining the manufacturing process. A case study on textile industry tested the effectiveness of the framework. Initially employing analytical hierarchies and optimised manufacturing layout with cyber models and simulations resulted in a manufacturing time efficiency improvement of about 4.5% over conventional methods. Upon implementing various communication tools for interconnected operations had enabled data-driven decisions. This approach realised a 20% daily operations time reduction compared to traditional methods. Further, connecting operators in real time to manufacturing resources had observed a total reduction of operation timings and production cost of ~30%. Future research on next generation Industrial Internet of Things (IIoT) devices and bionic enhancements for workers could further help manufacturing industries to enhance efficiencies.