Smart Manufacturing

Smart Manufacturing

by Anthony Tarantino
Released May 2022
Publisher(s): Wiley
ISBN: 9781119846611

Read it now on the O’Reilly learning platform with a 10-day free trial.

O’Reilly members get unlimited access to books, live events, courses curated by job role, and more from O’Reilly and nearly 200 top publishers.

Start your free trial

Book description

Explore the dramatic changes brought on by the new manufacturing technologies of Industry 4.0

In Smart Manufacturing, The Lean Six Sigma Way, Dr. Anthony Tarantino delivers an insightful and eye-opening exploration of the ways the Fourth Industrial Revolution is dramatically changing the way we manufacture products across the world and especially how it will revitalize manufacturing in North America and Europe.

The author examines the role and impact of a variety of new Smart technologies including industrial IoT, computer vision, mobile/edge computing, 3D printing, robots, big data analytics, and the cloud. He demonstrates how to apply these new technologies to over 20 continuous improvement/Lean Six Sigma tools, greatly enhancing their effectiveness and ease of use. 

The book also discusses the role Smart technologies will play in improving:

  • Career opportunities for women in manufacturing
  • Cyber security, supply chain risk, and logistics resiliency
  • Workplace health, safety, and security
  • Life on the manufacturing floor
  • Operational efficiencies and customer satisfaction

Perfect for anyone involved in the manufacturing or distribution of products in the 21st century, Smart Manufacturing, The Lean Six Sigma Way belongs in the libraries of anyone interested in the intersection of technology, commerce, and physical manufacturing.

Table of contents

  1. Cover
  2. Title Page
  3. Copyright
  4. Dedication
  5. Foreword
  6. Acknowledgments
  7. About the Author
  8. About the Contributors
  9. Introduction
  10. CHAPTER 1: Introduction to Industry 4.0 and Smart Manufacturing
    1. Introduction
    2. The First Industrial Revolution
    3. The Second Industrial Revolution
    4. The Third Industrial Revolution
    5. The Fourth Industrial Revolution
    6. The Major Components of Smart Manufacturing
    7. Summary: The Advantages of Smart Manufacturing
    8. Sample Questions
    9. Notes
  11. CHAPTER 2: Lean Six Sigma in the Age of Smart Manufacturing
    1. Introduction
    2. The History of Lean – American Assembly Lines
    3. The History of Lean – Toyota Embraces Deming and Piggly Wiggly
    4. The Toyota Production System: The Birthplace of Lean
    5. Lean Empowers Employees, Treating Them with Respect
    6. Resilient Supply Chain Management: How Toyota Fared During the COVID-19 Pandemic
    7. The History of Six Sigma: Bill Smith and Jack Welch
    8. Six Sigma's DMAIC Framework to Fix an Existing Process
    9. The DMAIC Framework Using Smart Technologies
    10. Six Sigma's DMADV Framework to Design a New Process
    11. The Statistics Behind Six Sigma
    12. Six Sigma Professionals in the Age of Smart Manufacturing
    13. Six Sigma Project Charters and SMART Goals
    14. Lean and Six Sigma Uses of the Scientific Method
    15. Summary: Six Sigma's Marriage to Lean
    16. Sample Questions
    17. Notes
  12. CHAPTER 3: Continuous Improvement Tools for Smart Manufacturing
    1. Introduction
    2. Voice of the Customer in the Age of Smart Manufacturing
    3. Voice of the Customer Using Net Promoter Score
    4. Voice of the Customer Using the Delphi Technique
    5. Voice of the Customer Using the Kano Model
    6. Affinity Diagrams to Organize Many Ideas into Common Themes
    7. Critical to Quality to Convert the VOC to Measurable Objectives
    8. Types of Data
    9. Benchmarking
    10. Process Maps
    11. Types of Process Maps
    12. SIPOC
    13. Process Maps with Decision Points
    14. Process Maps with Swim Lanes
    15. Limited Data Collection and the Hawthorne Effect Impacting Process Mapping
    16. Value Stream Maps to Eliminate Waste
    17. Value-Added Activity versus Non-Value-Added Activity
    18. Root Cause Analysis Using a Fishbone Diagram and Risk Matrix
    19. Root Cause Analysis Using the Five Whys
    20. Changes Coming to Root Cause Analysis with Smart Technologies
    21. Pareto Chart
    22. Kanban Pull System
    23. Poka-Yoke to Error-Proof Processes and Products
    24. Five S
    25. Heijunka
    26. Plan-Do-Check-Act
    27. Kaizen
    28. Setup Time Reduction Using Single Minute Exchange of Dies
    29. Gage Repeatability and Reproducibility (Gage R&R)
    30. Failure Modes and Effects Analysis (FMEA) to Solve Complex Problems
    31. Pugh Matrix to Design New Processes and Products
    32. Quality Function Deployment (House of Quality)
    33. Summary
    34. Sample Questions
    35. Notes
  13. CHAPTER 4: Improving Supply Chain Resiliency Using Smart Technologies
    1. Introduction
    2. Supply Chain Resilience
    3. Supply Chain Risk Heat Maps
    4. Supply Chain Mapping at a Macro and Micro Level
    5. Preferred Supplier Programs
    6. Bill of Material Risk Grading Tools
    7. Environmental Risk Solutions
    8. The Global Driver Shortage and Poor Utilization
    9. Vehicle Monitoring Tools
    10. Computer Vision Systems Using Smart Cameras
    11. Autonomous Trucks
    12. Supply Chain Resilency in a Post-COVID World
    13. Criticism and Defense of Lean Inventory Management
    14. Good Sourcing Strategies
    15. Supply Chain Stress Testing
    16. Summary
    17. Sample Questions
    18. Notes
  14. CHAPTER 5: Improving Cybersecurity Using Smart Technology
    1. Introduction
    2. Trends Increasing the Risk of Manufacturing and Supply Chain Cyberattacks
    3. So Why Is Manufacturing and the Supply Chain an Attractive Target?
    4. Primary Motives Behind Manufacturing and Supply Chain Attacks
    5. Methods Used to Breach Target Systems
    6. What Are the Potential Costs of a Cyberattack?
    7. Protecting Against Cyberattacks
    8. Summary
    9. Sample Questions
    10. Notes
  15. CHAPTER 6: Improving Logistics Using Smart Technology
    1. Introduction: Why Logistics?
    2. Megatrends in Logistics That Impact Brands/Manufacturers
    3. The Different Expectation of Your Customer-by-Customer Type
    4. The Cost of Not Paying Attention to Logistics
    5. The Benefits of Making Logistics a Strategic Competency
    6. Steps to Make Logistics Your Competitive Advantage
    7. Why Technology Is So Important to Logistics
    8. Area 1: Insight/Planning/Monitoring
    9. Area 2: Task Execution
    10. Area 3: Exchanges and Collaborations
    11. Area 4: Safety, Security, and Compliance
    12. Summary
    13. Sample Questions
    14. Notes
  16. CHAPTER 7: Big Data for Small, Midsize, and Large Operations
    1. Introduction
    2. Structured Data and Relational Databases
    3. Unstructured Data
    4. Why Manufacturing Needs Big Data Analytics
    5. The Four Levels of Data Analytics
    6. Descriptive Analytics – What Happened?
    7. Diagnostic Analytics – Why Did It Happen?
    8. Predictive Analytics – What May Have Happened?
    9. Prescriptive Analytics – What Is the Best Next Step?
    10. Future of Big Data Analytics
    11. Data Science Tools
    12. Data Analytics Pipeline
    13. The Benefits of Big Data for SMEs
    14. Big Data Tools for SMEs
    15. Problems SMEs Face in Adopting Big Data Analytics
    16. Best Practices in Data Analytics for SMEs
    17. Summary
    18. Sample Questions
    19. Notes
  17. CHAPTER 8: Industrial Internet of Things (IIoT) Sensors
    1. Introduction
    2. PLCs
    3. Carnegie Mellon
    4. Consumer-Oriented IoT
    5. Webcams
    6. IIoT -Enabling Technologies
    7. IIoT Platform Building Blocks
    8. IIoT Sensors
    9. Application Areas for IIoT
    10. Industries Where IIoT Can and Does Play a Role
    11. Future Trends in IIoT
    12. Summary
    13. Sample Questions
    14. Notes
  18. CHAPTER 9: Artificial Intelligence, Machine Learning, and Computer Vision
    1. Introduction
    2. History of AI and Computer Vision
    3. Understanding Machine Learning and Computer Vision
    4. Issues with Artificial Intelligence
    5. Conclusion
    6. Sample Questions
    7. Notes
  19. CHAPTER 10: Networking for Mobile Edge Computing
    1. Introduction
    2. Brief History of Networking
    3. Basic Networking Concepts, Architecture, and Capabilities
    4. Subnets
    5. Basic Wi-Fi Concepts, Architecture, and Capabilities
    6. Mobile Cell Phone Concepts, Architecture, and Capabilities
    7. IT and Telecommunications Networking Convergence
    8. Summary
    9. Sample Questions
    10. References
    11. Popular Acronyms Used in Networking and Mobile Computing
    12. Notes
  20. CHAPTER 11: Edge Computing
    1. Introduction: What Is Edge Computing?
    2. Benefits of Edge Computing
    3. Top Use Cases for the Edge in Smart Manufacturing
    4. The Data Challenge
    5. Deployment Challenges
    6. Solving Deployment Challenges with an Edge Computing Platform
    7. The Edge Computing Platform Landscape
    8. Edge-to-Cloud Computing
    9. How a Successful Edge Computing Rollout Works
    10. Summary
    11. Sample Questions
    12. Notes
  21. CHAPTER 12: 3D Printing and Additive Manufacturing
    1. Introduction
    2. History
    3. Additive Manufacturing Process
    4. Applications
    5. Summary
    6. Sample Questions
    7. References
  22. CHAPTER 13: Robotics
    1. Introduction
    2. Industrial Robots
    3. Manipulator
    4. Actuators
    5. Controllers
    6. End Effectors
    7. Types of Robots
    8. Robotics Timeline: 1961 to 2011
    9. Collaborative Robots
    10. The Outlook
    11. Sample Questions
    12. Bibliography
    13. Notes
  23. CHAPTER 14: Improving Life on the Factory Floor with Smart Technology
    1. Introduction
    2. Life on the Factory Floor from 1700 to Today
    3. The Smart Manufacturing Factory Floor
    4. How AI Is Powering Smart Manufacturing
    5. Smart Manufacturing Is Optimizing Factory Processes
    6. Hurdles Faced in Implementing Smart Technologies
    7. Three Essential Job Types in Smart Manufacturing
    8. Three Types of Tools Needed in Smart Manufacturing
    9. Smart Manufacturing Design Choices
    10. Summary
    11. Sample Questions
    12. Notes
  24. CHAPTER 15: Growing the Roles for Women in Smart Manufacturing
    1. Introduction
    2. Women as Innovators
    3. Women Hold the Answers (Skills Where Women Excel)
    4. Women's Inspiration
    5. Companies Working to Overcome Barriers to Women's Entry
    6. Programs to Develop STEM Skills for Women
    7. Growing the Role of Women in Smart Manufacturing
    8. Maria Villamil's Story
    9. Deborah Walkup's Story
    10. Summary
    11. Sample Questions
    12. Notes
  25. CASE STUDIES
    1. CASE STUDY 1: Automating Visual Inspection Using Computer Vision
      1. Introduction
      2. Conclusion
      3. Notes
    2. CASE STUDY 2: Bar Coding, the Most Ubiquitous and Most Critical IIoT Technology
      1. Introduction
      2. Barcode Technology
      3. Mobile Barcodes: Radio-Frequency Identification (RFID)
      4. Summary
      5. Notes
    3. CASE STUDY 3: Improving Safety with Computer Vision
      1. Introduction
      2. The Deep Learning Revolution
      3. Examples of Computer Vision's Role in Improving Safety
      4. Conclusion
      5. Notes
    4. CASE STUDY 4: COVID-19 Accelerates the Adoption of 3D Printing
      1. Introduction
      2. 3D Printing During the COVID-19 Pandemic
      3. 3D Printing in a Post-COVID-19 World
      4. Summary
      5. Notes
    5. CASE STUDY 5: How Mobile Apps Benefit Small to Midsize Enterprises
      1. Introduction
      2. Mobile Apps for All SMEs
      3. Mobile Apps for Manufacturing and Distribution
      4. Summary
      5. Notes
    6. CASE STUDY 6: Using Factory-Floor Touch Screens to Improve Operations
      1. Introduction
      2. Problem Definition
      3. Solution Description
      4. Solution Choices
      5. Adjacent Applications
      6. The Future and Conclusions
    7. CASE STUDY 7: Edge Computing to Improve Operations
      1. Edge Computing Deployment Use Case: Food and Beverage
      2. Edge Computing Deployment Use Case: Automotive
    8. CASE STUDY 8: Five Highly Dangerous Jobs That Robots Can Do Safely
      1. Notes
  26. Answers to Sample Questions
    1. Chapter 1
    2. Chapter 2
    3. Chapter 3
    4. Chapter 4
    5. Chapter 5
    6. Chapter 6
    7. Chapter 7
    8. Chapter 8
    9. Chapter 9
    10. Chapter 10
    11. Chapter 11
    12. Chapter 12
    13. Chapter 13
    14. Chapter 14
    15. Chapter 15
  27. Links to Continuous Improvement Templates
  28. Index
  29. End User License Agreement

Product information

  • Title: Smart Manufacturing
  • Author(s): Anthony Tarantino
  • Release date: May 2022
  • Publisher(s): Wiley
  • ISBN: 9781119846611