Cognitive Manufacturing: Advantages and Disadvantages

This page explores the advantages and disadvantages of Cognitive Manufacturing, along with a basic introduction to the concept. It outlines the benefits and drawbacks of implementing cognitive manufacturing processes.

Introduction

Recent advancements in big data, Artificial Intelligence (AI), the Internet of Things (IoT), and advanced analytics have significantly boosted manufacturing processes. IoT, in particular, has seen widespread adoption across various industries, leading to a massive increase in data volume. Traditional computing techniques often struggle to process and analyze such vast quantities of data effectively. To address this challenge, cognitive manufacturing processes are being increasingly adopted.

What is Cognitive Manufacturing?

Cognitive manufacturing refers to a system that leverages cognitive computing, the Industrial Internet of Things (IIoT), and advanced analytics to optimize manufacturing processes. This infrastructure utilizes data gathered from equipment and processes to generate actionable insights across the entire value chain.

Common applications of cognitive manufacturing include managing and optimizing compressors, boilers, furnaces, and rotating equipment, where failures are frequently encountered.

Image Courtesy : IBM

One prominent example of cognitive manufacturing is IBM Watson IoT, as illustrated in the figure. It facilitates the transformation of manufacturing processes in three key areas:

• Intelligent asset & equipment management
• Cognitive processes & operations
• Smarter resource & optimization

For more detailed information, please visit ibm.com.

Benefits or Advantages of Cognitive Manufacturing

The following are the key benefits and advantages of implementing cognitive manufacturing:

• Increased Efficiency: Cognitive manufacturing significantly enhances the efficiency of manufacturing processes. This leads to improved flexibility, reliability, yield, and overall availability of manufacturing operations.
• Fast Assembly Line Setup & Monitoring: It enables rapid assembly line setup and provides continuous execution monitoring of manufacturing processes.
• Higher Accuracy and Business Continuity: Cognitive systems offer high accuracy rates (around 95%), ensuring business continuity and resulting in significant savings in maintenance costs.
• Enhanced Safety: It promotes greater safety by minimizing the likelihood of major safety-related accidents.
• Reduced Calibration & Testing Time: The total time required for calibration and testing of critical equipment is substantially reduced.
• Reduced Downtime & Defect Rates: Unplanned downtime and defect rates are significantly minimized.

Drawbacks or Disadvantages of Cognitive Manufacturing

While offering numerous advantages, cognitive manufacturing also has certain drawbacks:

• Vulnerability to Breaches: Due to the handling of large volumes of data, these systems are susceptible to security breaches.
• Longer Development Efforts: The inherent complexity of the technologies involved necessitates longer development cycles.
• Need for Skilled Engineers: The development and maintenance of these systems require skilled software and hardware engineers, which can increase costs for the company.
• Extensive Training Required: Users of these systems require meticulous and comprehensive training.