Inside the Smart Factory - Part 2

Andrea Gillhuber,

Artificial intelligence in the smart factory

Digitalization is the dominant topic in the manufacturing industry. At the same time, there is a great deal of uncertainty due to different definitions of terms and unclear demarcations. The article series "Inside the Smart Factory" clarifies misunderstandings and obstacles on the way to the digital factory. In the second episode: Why the thinking machine is an illusion.

Insights into the Smart Factory. © Shutterstock / julia.m

When the German government presented the first details of its AI strategy in mid-November, Peter Altmeier felt compelled to create a new term to describe the impact of the technology: Artificial intelligence is "not just any innovation", but "basic innovation that will change and improve our economy and our lives as a whole", said the Federal Minister of Economics. The artificial intelligence megatrend has also long since arrived in industry. And here too, the expectations are enormous. Bold forecasts are talking about additional growth of up to 10 billion euros per year and an increase in productivity of a third - the term basic innovation seems almost an understatement.

The term artificial intelligence is actually over 60 years old. There are various reasons why it is experiencing a renaissance right now: On the one hand, the massive increase in available computing power means that the necessary parallel data processing is becoming faster and cheaper, while at the same time the available storage space is also increasing massively thanks to largely freely scalable cloud computing. On the other hand, it has become much easier to collect machine data in the factory thanks to the inexpensive equipment of machinery with sensors. And finally, providers such as Siemens, IBM and GE now provide platforms with which AI applications can be integrated extremely easily thanks to the Open API interface. In short: AI has become suitable for the factory and is increasingly finding its way into the smart factory in one form or another.

Advertisement

Machine learning, AI and neural networks

At the same time, however, the approaches that often operate under the AI label are so broad and not very clear-cut that the aspirations and reality of industrial AI applications are often far apart. In order to clear up any misunderstandings, a distinction should therefore first be made between some central approaches:

Weak AI vs. strong AI: A key misconception about AI systems is that they have the same intellectual abilities as humans, such as the ability to think logically, make decisions even in the face of uncertainty or plan and learn. However, such a so-called "strong AI" is still only a vague vision whose practical implementation is not yet in sight. Today's AI applications can all be classified as "weak AI". They are geared towards the fulfillment of a clearly defined task and rely on learned methods without varying the approach to problems or gaining a deeper understanding of the problem solution. Typical fields of application include text, image or speech recognition, automated translations or expert systems that provide recommendations for action based on knowledge databases.

Machine learning: The terms AI, machine learning and deep learning are often mistakenly equated in everyday life. However, machine learning and deep learning are each only sub-areas of artificial intelligence or of each other. While AI as a generic term describes all methods and approaches for replicating human intelligence, machine learning refers to a collection of mathematical methods of pattern recognition that enable a system to independently generate knowledge from experience.

Deep learning: Deep learning, in turn, is a sub-area of machine learning using neural networks. They function along the lines of the human brain with several layers between the input and output of information. The advantage of artificial neural networks is the gradual abstraction of correlations in the intermediate layers. Instead of a deterministic algorithm, deep learning therefore relies on statistical data analysis and thus enables self-learning and self-optimizing systems. Almost all current AI applications use the methods of deep learning or neural networks.

In summary, today's AI applications can be described as self-learning methods of statistical data analysis that are able to recognize patterns within large amounts of data and derive recommendations for action.

More than just predictive maintenance

Machine learning refers to a collection of mathematical methods for pattern recognition. © Shutterstock / Sammby

There are various fields of application for this form of data analysis in industry today. The best-known example of applications that use AI approaches is in the context of condition monitoring or predictive maintenance. Here, the systems are trained to recognize certain wear patterns or value deviations that indicate the failure of a machine, for example, even before this has actually occurred. The area of maintenance and repair also includes a large number of AI-based image data processing programs that are used to compare fault patterns with fault databases and thus support remote maintenance.

Another example of the use of artificial intelligence in the production process is provided by Kamax Tools & Equipment. The manufacturer of machine tools for screw production uses an ontology-based knowledge database for variant management. The data and rules behind the components of the different variants are stored in this database. The entire knowledge of designers and machine operators is thus stored in algorithms, so to speak. This enables the user to freely configure a component and have it manufactured without having to individually calculate or enter the underlying specifications.

The majority of these systems come from large software manufacturers such as IBM, Microsoft or Nvidia. However, there are also an increasing number of smaller providers who are developing weak intelligence to solve specific problems or tasks.

The crux of data consistency

Large providers of AI software solutions in particular repeatedly give the impression that AI applications can be easily integrated into existing production environments at any time, while neglecting the infrastructural requirements needed to implement such a solution. This is because the success of AI applications stands and falls with the quantity and quality of the data available.

Depending on the complexity of the application, the amount of data required can be very high. The rule of thumb is that 10 data points are required for each parameter that can be adjusted in the model. In a deeper neural network, there are around 100,000 adjustable parameters, i.e. 1 million data points, and these cannot be extracted from every system. Above all, however, companies must be able to provide the data from the production process in the first place.

Implementation of AI in operational practice

As the necessary expertise is often not yet available in companies and plug-and-play does not usually work with AI, it is advisable to bring professional support on board. Through the targeted selection of suitable use cases in combination with a proven approach, a good cost-benefit ratio can be achieved even in a seemingly complex environment. In many cases, even experienced experts are surprised by the insights that can be gained from a well-designed AI.

In the current debate, however, AI is all too often reduced to the issue of job killer versus panacea. Both perspectives suggest an overestimation of the technology that does not correspond to the actual state of the art. A dose of pragmatism in dealing with artificial intelligence is therefore highly recommended. Above all, this means understanding artificial intelligence as a powerful tool that opens up new opportunities to increase effectiveness and efficiency. It is crucial to recognize the potential fields of application and then tackle them consistently.

Prof. Dr.-Ing. Werner Bick, Chief Representative of ROI Management Consulting AG and Professor at OTH Regensburg / ag

  • Xing Icon
  • LinkedIn Icon
Advertisement
Advertisement

You might also be interested in

Advertisement
Advertisement
Advertisement
Advertisement
Advertisement
Advertisement
Advertisement

IIoT networking

How production can benefit from AI

Together with AI technology, IIoT networking makes it possible to better control machine parameters and optimize quality with predictive quality. Downtimes and set-up times can also be further minimized. Cloud platforms also make these technologies...

read more...
Subscribe to our newsletter
Advertisement
Back to home