Sandvik Coromant: Automating Manufacturing Successfully

06: Design

Computer-aided design (CAD) is a standard among manufacturers for conceptualising and creating 3D product design drafts. It can be used with generative design, which creates design variations within set parameters, to optimise design and eliminate functional challenges. 

Once designed, simulation and validation tools can be used to determine quality, feasibility and durability. Like VR and AR prototyping, it situates the design in a simulated real-world environment to evaluate scale, user interaction and overall aesthetics. 

Where relevant to the design, tools are used to simulate environments and situations – involving thermal dynamics, aerodynamic simulations and stress – that would be dangerous and costly to create in real life. This allows manufacturers to rigorously test a design’s safety and effectiveness without any real-world risks and costs.

05: Process Planning

Digital twins, or virtual recreations of real-world objects, can be utilised in process planning. They help manufacturers predict disruptions and visualise solutions as they have the power to simulate the entire manufacturing process. Processes can be optimised through AI, helping manufacturers allocate resources and maintain their systems. They can also be simulated to evaluate project costs before they’re enacted by machines in real life.

Internet of Things (IoT) integration also allows data to be collected in real-time from the factory floor, giving manufacturers the data they need to make improvements to products, waste management and machine performance. 

04: Operations planning

CAD software can be used to convert drawings and models to machine-ready instructions, known as NC code. This allows manufacturers to enhance the efficiency of their machines, reduce waste and seamlessly transition from design to production. 

There are also production scheduling systems which use algorithms to optimise job sequencing and capacity planning tools, which help manufacturers avoid overproduction or underutilisation. Both these automation tools reduce idle time. 

Demand forecasting gives manufacturers the data to make informed production decisions, using AI and past data to predict future demand. Resource allocation systems create superior uses of materials and manpower by analysing the real-time needs and data of manufacturers.

03: Production logistics

RFID and barcode systems can be used to track products during the production process and across the supply chain, reducing errors and processing time. Supply chain management software allows for data-focused integration of distributors, suppliers and manufacturers, allowing companies a top-down perspective during decision-making. 

Automation means accessing inventory management systems that track, manage and predict inventory levels through software and sensors. Through better management, manufacturers can optimise their storage space, minimising excesses and reducing stockouts. Robotic systems like Automated Guided Vehicles (AGVs) can also be used to transport materials around the factory, reducing labour costs and handling errors. 

02: Machining

Robotics takes the risk and unreliability out of dangerous and precise aspects of the manufacturing process. They can be utilised for 24/7 assembly, welding and loading and unloading vehicles, maintaining high levels of productivity. There’s also CNC machining which uses computerised controls to manipulate machine tools, resulting in a more precise ability to produce and repeat complex patterns. Automation also provides adaptive control systems which can adjust operations in real-time as they monitor machining conditions, improving surface finish and extending the life of tools.

01: Verification

By using automated feedback systems, manufacturers can integrate verification results back into their systems for continuous learning and improvement, resulting in enhanced future operations. 3D scanning and Coordinate Measure Machines (CMM) measure the geometric characteristics of an object, allowing for the detection of anomalies. There are also automated sensors and software which can be utilised to reduce wastage and monitor product quality during production. These tools result in reduced human error, assured product quality and quicker inspection times.