AI’s Outcomes Rely On Its Rollout
If done right, AI will revolutionize everything from safety and quality to efficiency and maintenance
TAKEAWAYS:
● AI represents a unique opportunity to improve the efficiency of production, especially when it comes to preventative maintenance.
● Integrating AI into production can increase cyber risk by creating new potential access points for bad actors.
● More extensive training is required for AI to accomplish complex tasks, while repetitive tasks require less training.
For centuries, manufacturers have faced the challenge of addressing safety hazards in factories while boosting efficiency and controlling costs. Now, many manufacturers are learning that artificial intelligence (AI) can help them make new strides when addressing protracted worker safety and efficiency challenges. Consequently, it is no surprise that 36% of manufacturers say they will pursue Industry 4.0 investments according to the 2023 BDO Manufacturing CFO Outlook Survey. As more manufacturers explore AI’s future and how it can help them improve safety and efficiency, it is critical that they set themselves up for success by securing employee buy-in and preparing factory infrastructure to take full advantage of AI-based systems.
Today, much of the public has become aware of generative AI, such as OpenAI’s ChatGPT, with its ability to quickly answer complex problems with written prompts. Generative AI is exciting to the general public, but many plant managers are passionate about AI systems that are specifically designed to operate in a manufacturing setting. Rather than only using written prompts, AI systems used by manufacturers leverage inputs from computer vision, lasers, and other sensors to predict when a safety issue may occur, which robot caused a manufacturing defect, and how machines should be calibrated to minimize downtime.
Leveraging Technology to Combat Safety Hazards
Despite decades of regulations and improved protocols, safety issues persist in modern manufacturing. Updated safety codes and maintenance plans cannot always prevent worker injuries that result from negligence or unpredictable hazards in a manufacturing facility. While strong employee training programs remain one of the best ways manufacturers can improve safety in settings from chemical plants to automobile factories, even the most dedicated employees are not constantly vigilant to workplace dangers. This is why many manufacturers are investing in AI-powered safety systems, which can predict when and where a safety violation could happen, allowing plant managers, and sometimes the AI itself, to remedy the situation before it becomes irreparable.
However, to work successfully with AI, workers need to be trained to interact with these new systems. The latest advancements in augmented reality (AR) and virtual reality (VR) technologies enable companies to make training programs for employees who interact with AI-powered safety systems even more effective, further empowering workers to keep themselves safe. AR or VR simulations can give employees a sense of what it is like to work with potentially dangerous machinery in preparation for operating the real equipment. Workers can also practice carrying out the necessary safety procedures before entering a secure area or shutting down a robot in need of repairs on the factory line. These AR- or VR-enabled training exercises can reduce the likelihood of mistakes, which could result in worker injury or damage to machinery.
While AR and VR training can help workers keep themselves safe, these simulations can also teach factory employees about AI systems designed to improve safety. Many workers have never interacted with AI systems tasked with actively reinforcing safety guidelines before and may be inclined to ignore or distrust safety alerts that do not come from a person. AR and VR training can incorporate scenarios where a machine breaks down, or a co-worker fails to follow safety protocols to teach employees about which hazards an AI safety system can detect and how they should respond.
