By: Kathryn Gerardino-Elagio
As the 2024 State of Smart Manufacturing Report reveals a significant shift towards increased automation, Tarkieltaub discusses the driving forces behind this movement, including the quest for higher efficiency, productivity gains, and solutions to labor shortages. His expert perspective sheds light on how these trends are shaping the future of manufacturing in one of the world's most dynamic regions.
IMNA: What trends or drivers are propelling the 48% increase in automation investment by APAC manufacturers, as noted in the 2024 State of Smart Manufacturing Report?
The 2024 State of Smart Manufacturing Report reveals that nearly half of APAC manufacturers are boosting automation investments. This trend is driven by the need for cost efficiency, productivity gains, and addressing labour shortages. Automation enhances production cycles, reduces operational costs, and decreases errors. An IDC report predicts that 60% of APAC manufacturers will use automation to improve operational roles, leading to a 50% increase in worker efficiency. Additionally, the ageing workforce is accelerating automation adoption to maintain or improve productivity levels amidst labour challenges.
IMNA: What critical factors are driving 69% of APAC manufacturers to adopt smart manufacturing in the next 6 to 11 months?
Rapid adoption is driven by accessible advanced technologies like AI and IoT, as highlighted at Rockwell Automation's ROKLive event in Kuala Lumpur. Sustainability is another key factor, with 91% of APAC manufacturers having ESG policies, aiming to improve efficiency and competitiveness. Cybersecurity is also critical, with 35% of companies citing it as a major challenge and it being a top skill sought in 2024 and a leading use case for AI/ML over the next three years.
IMNA: How is smart manufacturing enhancing product quality for the 43% of APAC manufacturers aiming for this outcome?
Quality remains a top priority for manufacturers, with 43% of APAC respondents aiming to improve it through smart manufacturing technology adoption. This desire is followed by reducing costs and enhancing overall equipment efficiency. Smart manufacturing achieves this through real-time monitoring, advanced automation, AI-driven process optimisation, and integrated quality management systems, ensuring consistent and reliable products and enhancing competitiveness in the dynamic market.
IMNA: What technologies are being implemented by the 36% of APAC manufacturers to track and quantify sustainable practices, and how do they contribute to sustainability goals?
APAC manufacturers are embracing various technologies to track and quantify sustainable practices. They utilise IoT devices and sensors for real-time monitoring of energy usage, emissions, and waste, enabling optimisation of operations and reduction of resource consumption and emissions. AI and Machine Learning analyse data to enhance efficiency, predict maintenance needs, and optimise supply chains, thereby minimising downtime and environmental impact. Energy Management Systems oversee energy usage, pinpointing areas for improvement and ensuring energy-efficient operations. Data analytics tools offer insights into production processes, aiding in identifying inefficiencies and implementing sustainability measures. Automation reduces human error, enhances precision, and promotes energy efficiency in manufacturing, resulting in reduced waste and resource consumption.
As an example, the largest pet food manufacturer company in Australia found that with the rapid growth of the production and the business, standardisation of data became vital to ensure ongoing process improvements. With the IoT feature developed as the basis for FactoryTalk® InnovationSuite, they have managed to collect, visualise and analyse data easily through a standardised data platform, easing the business to better contextualise the overall consumption of energy, therefore aiding them in achieving their sustainability goals.
IMNA: How is Rockwell Automation addressing cybersecurity concerns in smart manufacturing for APAC manufacturers, where it's cited as the top external challenge by 35%?
Rockwell Automation addresses cybersecurity concerns in smart manufacturing by providing a robust OT cybersecurity capability. This includes a blend of specialised in-house cyber expertise and strategic partnerships tailored to customer needs. Solutions encompass firewalls, intrusion detection/prevention systems, secure remote access, and data encryption to safeguard manufacturing systems. Additionally, Rockwell Automation offers training and awareness programs to instil cybersecurity best practices and foster a security-conscious culture within manufacturing organisations. Through these strategies, Rockwell Automation aids APAC manufacturers and global clients in mitigating cybersecurity risks and safeguarding their smart manufacturing operations.
IMNA: What are the main benefits APAC manufacturers gain from implementing smart manufacturing solutions? Can you share some case studies or examples?
APAC manufacturers benefit significantly from smart manufacturing solutions, seeing increased efficiency, improved quality, cost savings, and enhanced flexibility. Automation and robotics boost production speed and accuracy, while predictive maintenance and real-time monitoring reduce downtime and maintain consistent product quality. For instance, a leading Chinese polymer manufacturer successfully integrated Rockwell Automation's FactoryTalk® Analytics™ Pavilion8® software to stabilise production, reduce quality fluctuations, and increase yield. This advanced process control system minimised labour intensity and material consumption, showcasing the transformative impact of smart manufacturing in the petrochemical industry.
IMNA: What are the key gaps or challenges that businesses must tackle to fully harness the potential of smart manufacturing in the APAC region, despite its benefits?
Rockwell Automation’s State of Smart Manufacturing Report identifies significant barriers for APAC manufacturers in adopting smart manufacturing, including employee resistance to technology, skill gaps, and infrastructure readiness. To overcome these challenges, empowering employees with digital skills through training and upskilling is essential. AI and ML tools facilitate experiential learning, while AI-powered systems optimise manufacturing processes in real-time for enhanced efficiency and quality. Machine learning algorithms analyse sensor data to detect defects, ensuring consistent product quality and waste reduction.
IMNA: What are the primary barriers to adopting smart manufacturing in the APAC region, and how can they be addressed?
The main barriers to smart manufacturing adoption in the APAC region include high costs, skill gaps, cybersecurity concerns, and infrastructure limitations. Overcoming these barriers necessitates technological advancements and strategic interventions. Addressing skill gaps requires investments in training and education, with collaboration between organisations, governments, and educational institutions. Effective change management strategies are essential to foster continuous learning and innovation. For instance, Rockwell Automation signed an MOU with the USAID HEPI project in Indonesia to develop advanced automation teaching labs at universities, preparing students for careers in manufacturing. Rockwell Automation also supports manufacturers through programs like ROKLive and PartnerNetwork, offering education and tailored solutions to kickstart and sustain their digitalisation journey.
IMNA: What emerging technologies will be crucial for smart manufacturing evolution in the APAC region?
The Asia-Pacific Smart Manufacturing Market is projected to grow significantly, from USD 54 billion in 2024 to an estimated US$80.38 billion by 2029, with a CAGR of 8.28%. Emerging technologies such as blockchain, Industrial IoT, AI, and 5G connectivity are driving this transformation, enhancing efficiency and sustainability as we transition from Industry 4.0 to Industry 5.0.
IMNA: What strategies or programs does Rockwell Automation offer to assist APAC manufacturers in addressing smart manufacturing challenges like cybersecurity and sustainability?
At Rockwell, we host ROKLive, a regional event series offering insights into our latest solutions, including AI, AR, and robotics, and showcasing successful technology implementations. The recent Southeast Asian event in Kuala Lumpur focused on aiding businesses in adopting smart technologies, with another planned in Surabaya, Indonesia. Our PartnerNetwork program connects customers with leading companies to design, build, and maintain automation solutions, streamlining supply chains and maximising investment value.
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