Tag Archives: Advanced Manufacturing Techniques


Thanks to cloud and edge computing, SaaS — software as a service — has become a highly transformative technology in both manufacturing and the supply chain. It makes software systems and various technologies accessible to a wide range of operations, big or small. That’s because the system itself is hosted remotely, so the central technologies don’t have to be on the premises or within a facility. SaaS tools are fully built cloud applications.

Picture the type of software that governs a sophisticated manufacturing system. The servers that host that software, and where most of the data is contained, are located off-property away from the manufacturer’s facility. At any time, it can communicate with the connected equipment, and users can access the entire system remotely as well.

However, it’s maintained, serviced, and even secured by a remote provider. The only thing the manufacturer has to worry about is whether or not the connected equipment is running optimally. They don’t have to manage an on-site data center, update servers and software configurations, or even troubleshoot major problems — that’s all done by the SaaS provider.

SaaS is innovative, but how does that system affect the manufacturing industry as a whole? What are the benefits of SaaS when deployed within a smart factory or Industry 4.0 environment?

1. Reduced Costs

Manufacturing software comes in many forms. There are tools to aid in engineering and design, sales or marketing, measure production quality, organize finances, and much more. Each one of those applications requires a steady stream of data and a team to manage both the software and its backend.

Just imagine how much processing power is necessary to handle all of those systems, let alone the physical storage needed to contain the resulting data to keep it all running. The best solution even today is to build a data center, whether on-site or remote. They are very costly to manage and maintain.

SaaS solutions eliminate those costs and requirements because the bulk of the system is hosted elsewhere, on the provider’s servers. There’s no equipment to install and no software to update or manage. It’s all done off-site. That also reduces the need for a large IT or software development team on the manufacturing side.

The kickback is much lower operating costs for manufacturers, despite all the benefits realized from the applications.

2. Better Security

When you need a process completed, but you don’t have the proper knowledge, the common practice is to call in a specialist. That is precisely what SaaS providers are, and it means they have access to highly specific resources and tools that no manufacturer realistically does. That translates to a better solution overall, especially when it comes to digital and data security.

Because their entire business is securing and maintaining their data centers, to provide software to clients, they have much more sophisticated and capable solutions in place. That filters down to the manufacturers subscribing to SaaS services, who realize better data security and smarter digital protections.

3. Unparalleled Flexibility

Manufacturers maintaining software and technology solutions in-house have to scale up when the operation grows, which can be devastating depending on how the market shifts and demand fluctuates. Spending hundreds of thousands to upgrade equipment only to experience a downturn in the market can ruin any business.

SaaS providers handle scaling and delivery. They can add new terminals and new users, and install or activate servers to accommodate their clients. This is not only done seamlessly, but it will also happen near-instantly. Customers can even try before they buy, trialing the services and solutions before deploying them within their facilities. If the software doesn’t work out or add value, it can be canceled at any time with a minimal impact on the greater operation.

Woman on computer using SaaS in manufacturing

SaaS solutions can be accessed anywhere at any time allowing for more flexible operations.

4. Enhanced Interoperability

Typically, two pieces of distinct software cannot communicate with each other and the data they utilize isn’t guaranteed to be interchangeable. In manufacturing, this happens a lot with ERP and CMMS solutions. It complicates manufacturer-vendor relationships, especially when the default systems offer no interoperability.

Because SaaS solutions are hosted in the cloud, the systems accommodate interconnection between many different tools and platforms. CMMS, ERP, CRM, and project management tools can all communicate and share data, and the SaaS platform ensures it’s compatible and readable between those solutions.

5. Truly Agile Operations

If you look at what SaaS solutions provide manufacturers from a top-down perspective, it affords many operational efficiencies and creates new opportunities, without increasing the responsibilities the manufacturer is forced to take on. They have everything to gain and almost nothing to lose. Faster and more agile operations are implemented as a result, thanks to a system that’s always on, always ready to scale, and constantly being adapted to the needs of the manufacturer.

6. A Mobile Workforce

Because of the way SaaS solutions are maintained and delivered, they open up a whole new level of accessibility and mobility for manufacturing teams. Everyone from the decision-makers and supervisors to equipment operators gain access to on-demand and mobile-friendly solutions that can be accessed anywhere, at any time.

Additional features include mobile and real-time notifications, instant communication even between departments, remote access to mission-critical applications, and much more. Besides, security is managed on the backend, server-side, so users can move from terminal to terminal, or device to device, without compromising the system.

The caveat is that they need to follow proper security protocols, which means no password sharing or reuse, and precise authentication or verification systems.

An Ever-Evolving Industry Requires Adaptable Solutions

SaaS solutions are changing the manufacturing and production industries, but it’s not the only technology making a dent in normal operations. The entire field is undergoing a revolution, moving ever closer to Industry 4.0. The concept will see a marriage of advanced manufacturing techniques and smart, contextually-driven platforms to achieve seamless intercommunication, efficiency, and operability.

Software as a service plays a role in that movement, as manufacturers look to offset some of the requirements of the digital transformation. SaaS allows manufacturers to keep up with ever-evolving industries and markets. It reduces operational costs, speeds up output and processes, enhances security, improves software compatibility, and helps facilitate truly agile operations. What more could you ask for?

This article is written by Devin Partida. Devin is a tech writer with an interest in the IIoT and manufacturing. She is also the Editor-in-Chief of ReHack.com.

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The U.S. economy is experiencing a period of job growth. The unemployment rate is at a low last seen more than 50 years ago, according to government data, and millions of jobs have been created since 2016, approximately 2.6 million of which were added to payrolls in 2018 alone.

Manufacturing has helped lead the way, with the industry contributing $2.2 trillion to the nation’s gross domestic product in 2016 and over 85% of small-business manufacturers confident that the good times will continue for the foreseeable future, according to the National Association of Manufacturers’ most recently updated outlook survey. Were America’s manufacturing sector its own country, it would be in the world’s top 10 economies, ahead of Spain, Brazil, and Canada, based on estimates from the Manufacturing Institute.

Largely fueling these improvements is the rise of modern manufacturing. Technology is in a constant state of enhancement and advancement. In order to drive process improvements on the shop floor, manufacturers — and companies that use the products made by them — are successfully adopting, installing, and allocating innovative technologies through the advent of modern machine manufacturing techniques, which in turn optimizes the supply chain.

What makes manufacturing techniques advanced?

From machine learning and artificial intelligence to nanotechnology and 3D printing, advanced manufacturing techniques and capabilities usually have a few characteristics in common: They’re founded in state-of-the-art functionalities, improve upon processes that already exist and serve as a workaround to existing workflow problems — without creating new complications.

For example, plastics are a major environmental hazard due largely to their ubiquity. In fact, food packaging manufacturers account for 40% of these materials. Recognizing the potential and existing problems emerging for plant life and the natural habitat, 75% of consumers want businesses to adopt sustainability initiatives.

Numerous small-business owners, franchises and multinational corporations have partnered with chemical manufacturing companies to make sustainability a reality through cleaner development of industrial plastics. In fact, dozens of chemical firms are working collaboratively to leverage process improvements to reduce output of new plastics, reuse what’s already been produced and re-engineer packaging so that it breaks down more quickly and naturally. Advancements and investments in cutting-edge manufacturing technology and adaptability have helped to make this possible.

Here are a few other technologies that stand to further transform modern manufacturing techniques:

1. Augmented reality

Augmented reality melds the real world with the imaginary by superimposing images, sounds, or places so they can be more authentically experienced. As noted by the Huffington Post, it has many applications in the manufacturing sphere, including data retrieval, real-time monitoring, communicating safety warnings, and enhancing the effectiveness of training methods.

2. Enhanced industrial sensors

From optical rotary encoders to inductive proximity sensors, industrial sensors are advancing in their capabilities and practical uses, with more businesses taking advantage of them. Prices are expected to decline for these tools over the course of 2019, which may encourage more manufacturers to invest if they haven’t already, according to ZDNet.

3. Collaborative robotics

Collaborative robots, or cobots, represent the fastest-growing category in industrial automation. This technology pairs robots with humans so they work in a more cohesive manner, as opposed to one replacing the other. Initially only utilized by large corporations, cobots are increasingly affordable and adoptable, which is why their valuation is expected to top $4.3 billion come 2023, according to a report from Markets and Markets.

Modernization is a must in the manufacturing space and at USC Consulting Group, we have the industry expertise to recognize and recommend the cutting-edge manufacturing tools and techniques that can help you achieve supply chain optimization. We have helped companies achieve operational excellence for more than 50 years — if you have a business problem, contact us to help solve it.


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