Here's how you can overcome challenges when adopting new technology in manufacturing.

When determining which operational areas would benefit most from the introduction of new technologies, it is crucial to assess return on investment, identify bottlenecks and repetitive tasks, and consider integration with existing systems. Additionally, it's important to analyze the impact on human work and the scalability of the technology. Evaluating the potential for sustainability and environmental impact is also essential to align with corporate responsibility goals.

Before the selection process starts, a Project Launch Team should be assembled with representatives from all departments / stakeholders involved. The Team should meet and agree upon what will have the most impact within the current budget and by priority related to operations. Once agreed upon, continue meeting from sourcing needs to right through until the launch within the operation. The Team should collect data to prove out the capital expense return. Brainstorm further improvements post launch and agree upon what to implement or adjust. Select the next priority within budget and repeat process. This can be carried year after after year.

Before introducing new technology prepare a Roadmap and set a clear goal and strategies. Review current process and find out the area to merge new technology. Do FMEA for SQDC and check the efficiency of the old process vs new process. Start in small project and small pilot scale and then add more technology and value. Give training and education to team or operators to adopt the technology. Continuous review the process and analysis the data frequently. Do continuous improvement.

When bringing new technology into manufacturing, it's important to make sure everyone understands why it's happening and how it helps. Train employees well so they know how to use the new tech. Try out the technology on a small scale first to see how it works and get feedback. Make sure the new technology can work smoothly with what's already in place. Plan for things that might go wrong and have a backup plan. Encourage everyone to be open to the changes and work together. Keep an eye on how well the new technology is working and make improvements when needed. Work closely with the people who made the technology to get help when it's needed. By doing these things, adopting new technology can make manufacturing better and more efficient.

Quando trazemos uma nova tecnologia para a manufatura é importante definir um time gerencial que atue em todo o processo de implantação. Avaliar quais serão os seus impactos, rever plano de controle, atualizar FMEAs, analisar questões de segurança, impactos ambientais, etc.. Fundamental comunicação clara e objetiva com todas as áreas envolvidas sobre a importância e necessidade, da implantação desta nova tecnologia. Ter um plano de transição detalhado e amplamente divulgado de todas as fases de implantação com atualizações frequentes. Estes cuidados minimizam os contratempos, motiva os envolvidos, cria uma atmosfera otimista e desafiadora que impulsiona o time a enfrentar os desafios.

There are many ways to help improve the technology in your manufacturing operation.....it is critical to start with items you know you can implement and use that as a building block to the larger scale projects. Expensive technology does not guarantee success (no matter how easy the providing company makes it sound). To me the MOST IMPORTANT aspect is to complete the project, no matter what it is. This is a positive step for your company, staff, customers and yourself.

You can overcome challenges when adopting new technology in manufacturing by fostering a culture of continuous learning, providing comprehensive training, offering support throughout the transition, and encouraging open communication among team members to address concerns and ensure a smooth integration process.

Em todas as situações é necessário realizar uma análise de necessidades e verificar o que uma mundaça pode possibilitar de benefícios dentro da produção.

Antes de mergulhar na mais recente tecnologia de fabricação, é importante avaliar completamente suas operações atuais. Identifique as áreas em que a nova tecnologia pode ter mais impacto, como automatizar tarefas repetitivas ou melhorar o controle de qualidade. Essa etapa garante que você não esteja apenas correndo atrás dos gadgets mais recentes, mas tomando decisões estratégicas alinhadas com seus objetivos de negócios e requisitos operacionais. Ao identificar suas necessidades, você pode selecionar as tecnologias que oferecerão o maior valor aos seus processos de fabricação.

To overcome challenges when adopting new technology in manufacturing, it's crucial to invest in comprehensive training programs for employees, establish clear communication channels, foster a culture of innovation and adaptability, conduct thorough risk assessments, and collaborate closely with technology vendors to address any issues promptly. Additionally, phased implementation strategies and pilot programs can help mitigate disruption while allowing for iterative improvements based on real-world feedback.

Um plano de transição bem elaborado é essencial ao integrar novas tecnologias em suas operações de fabricação. Isso deve incluir um cronograma, orçamento e a alocação de recursos, incluindo pessoal que gerenciará a transição. O treinamento para sua equipe é fundamental; garantir que eles sejam confortáveis e proficientes com os novos sistemas. Além disso, considere executar sistemas paralelos temporariamente, permitindo um fallback enquanto se ajusta à nova tecnologia. Essa abordagem em fases minimiza as interrupções e ajuda a resolver quaisquer problemas antes de uma implantação em grande escala.

Devemos salientar que toda mudança deve ser planejada para não ocorrerem impactos negatívos durante a transição. A necessidade de uma parada de máquina pode causar impactos significativos, onde, o planejamento tem função extremamente importante durante a mundança de tecnologia.

I would make sure that a risk analysis is made before and the plan done with all the stakeholders including End-Users often forgotten unfortunately!

Before diving in, carefully assess your manufacturing needs to identify the challenges new technology can solve. This targeted approach ensures you choose the right tools. Then, develop a comprehensive transition plan that includes training for your team, data migration strategies, and clear communication to manage expectations. By planning ahead, you'll overcome adoption hurdles and unlock the full potential of new technology in your manufacturing operations!

Tvorbu plánu treba dôkladne pripraviť a preveriť s každým zainteresovaným. Je dôležité, aby každý pochopil a súhlasil s ním. Treba si vyjasniť, prečo sa robia jednotlivé kroky, kedy a čo treba spraviť, kto je zodpovedný za vykonanie. Treba definovať potrebné vstupy, ako sa budú vykonávať jednotlivé kroky a výsledok jednotlivých krokov ako sa bude vyhodnocovať. Realizovať plán bude multifunkčný tím tvorený zamestnancami závodu a externými dodávateľmi. Jednotlivých členov treba patrične pripraviť na zvládnutie svojich úloh a prideliť potrebné prostriedky a čas na realizáciu. Výmena informácii medzi členmi tímu musí byť dopredu definovaná. Do plánu treba zahrnúť aj úlohu obsluhy starého systému po jeho vyradení.

Tvorbu plánu treba dôkladne pripraviť a preveriť s každým zainteresovaným. Je dôležité, aby každý pochopil a súhlasil s ním. Treba si vyjasniť, prečo sa robia jednotlivé kroky, kedy a čo treba spraviť, kto je zodpovedný za vykonanie. Treba definovať potrebné vstupy, ako sa budú vykonávať jednotlivé kroky a výsledok jednotlivých krokov ako sa bude vyhodnocovať. Realizovať plán bude multifunkčný tím tvorený zamestnancami závodu a externými dodávateľmi. Jednotlivých členov treba patrične pripraviť na zvládnutie svojich úloh a prideliť potrebné prostriedky a čas na realizáciu. Výmena informácii medzi členmi tímu musí byť dopredu definovaná. Do plánu treba zahrnúť aj úlohu obsluhy starého systému po jeho vyradení.

É fundamental existir uma comunicação clara entre todos os envolvidos, é necessário que todos tenham conhecimento sobre a mudança, o que a nova tecnologia irá possibilitar e serem qualificados para conseguirem extrair o máximo da nova tecnologia.

O gerenciamento de mudanças é crucial na adoção de novas tecnologias. Comunique-se abertamente com sua equipe sobre as mudanças e como elas beneficiarão a empresa e seu trabalho. Incentive o feedback e aborde as preocupações prontamente para promover uma atitude positiva em relação à nova tecnologia. Ao envolver sua equipe no processo, você pode garantir uma transição mais suave e adoção mais rápida. Lembre-se, o aspecto humano da mudança tecnológica é tão importante quanto o técnico.

I agree with this point for sure! When implementing new changes, feedback and action are two of the most important factors. When your team sees you adopting an idea or portion of an idea they came up with, it shows that they are heard and valued. This will help smooth the transition with minimal effort. The most valuable observations are often made by the person routinely performing that task.

The human aspect is the most importance one as a technology without adoption is useless! To do so use the “vertical start up” strategy meaning spending time with the person concerned and ensure their needs are fulfilled and risks eradicated so when we start that is a complete success. Better spend more time beforehand than rectifying everything afterwards (pull vs push!)

Assess your manufacturing needs first: what challenges can new technology solve? Choose the right tools, then craft a transition plan. This includes training, data migration, and clear communication to manage expectations. Anticipate resistance to change. Address concerns, involve stakeholders, and emphasize the benefits (efficiency gains, cost savings). By planning and managing change effectively, you'll overcome adoption hurdles and leverage new technology for a stronger manufacturing future!

Zmena sa začne v okamžiku, keď prvá osoba pocíti potrebu zmeny súčasného stavu. Nakoľko veľký počet zmien sa zruší hneď na začiatku, preto je potrebné myšlienku zmeny najprv sformulovať, prehodnotiť, čo to prinesie a čo to bude stáť. Aby zmena bola úspešná, treba presvedčiť zainteresovaných, že prínosy prevážia nad cenou realizácie. Počas realizácie treba sledovať pripravený plán, ak sa zistia nezhody, treba na nich včas reagovať.

É necessário identificar possíveis riscos e trabalhar para o menor impacto possível, existem situações para implementar testes e obter indicadores que poderam embasar uma mudança com os riscos calculados, o que irá possibilitar uma transição mais saudável.

A introdução de novas tecnologias traz riscos como falhas no sistema ou problemas de compatibilidade. Para mitigá-los, realize testes completos da nova tecnologia antes de entrar em operação. Tal deve incluir testes de esforço, análises de desempenho e assegurar a compatibilidade com os sistemas existentes. Ter um plano de contingência para possíveis contratempos ajudará a manter as operações durante desafios inesperados. A mitigação de riscos não se resume à prevenção; é também sobre estar preparado para lidar com problemas de forma eficaz quando eles surgem.

Mitigate risks by creating a pilot program to test the new technology in a controlled environment before full-scale deployment. This measured approach ensures you overcome adoption challenges and leverage new technology to future-proof your manufacturing operations!

Na zníženie riziku zlyhania nového systému je úspešný nástroj FMEA, kde odborníci a budúci užívatelia prehodnotia možné chyby a hľadajú riešenie na ich odstránenie, poprípade na zníženie ich následkov. Na určenie, ktoré parametre sú kritické pre nový systém je dobrý nástroj aj „Design of Experiments“. Pri určení hodnoty kritických parametrov je výhodné ich prepočítať, fyzicky otestovať. Teraz sú už k dispozícii rôzne počítačové systémy, ktoré dokážu spraviť analýzu, simuláciu a tak uľahčiť našu prácu, aby sme postupne znižovali riziko výskytu chýb počas realizácie. Pred uvedením do výroby nového systému, treba uskutočniť skúšobnú prevádzku a validáciu

Na zníženie riziku zlyhania nového systému je úspešný nástroj FMEA, kde odborníci a budúci užívatelia prehodnotia možné chyby a hľadajú riešenie na ich odstránenie, poprípade na zníženie ich následkov. Na určenie, ktoré parametre sú kritické pre nový systém je dobrý nástroj aj „Design of Experiments“. Pri určení hodnoty kritických parametrov je výhodné ich prepočítať, fyzicky otestovať. Teraz sú už k dispozícii rôzne počítačové systémy, ktoré dokážu spraviť analýzu, simuláciu a tak uľahčiť našu prácu, aby sme postupne znižovali riziko výskytu chýb počas realizácie. Pred uvedením do výroby nového systému, treba uskutočniť skúšobnú prevádzku a validáciu dôležitých parametrov.

Um bom sistema tecnológico pode capturar dados e transformar em informações preciosas. Esse tipo de sistema ajuda a tomar decisões assertivas. Uma delas é a otimização de processos de fabricação. Além de alcançar resultados tangíveis é um forte aliado da produtividade.

If your key processes are mapped and fully understood then possibly new technology or automation could be considered. My experience to share is be slow to change because, understanding the current with using process improvements methods by team workers is critical. Change in technology is no guarantee toward competitive product enhancement impacting the time frame set first as goal thought. A smaller scale testing method achieving key results should be required and deemed successful before any adoption.

To ensure continuous improvement after implementing new technologies, companies can adopt methodologies such as Lean Manufacturing and Six Sigma, which focus on waste reduction and defect elimination. The use of advanced technology like IoT and AI enables real-time adjustments through deep analytics. Strategies like Kaizen promote daily incremental improvements, while the PDCA cycle facilitates ongoing analysis and adjustment of processes. Visual management with dashboards also provides real-time monitoring, essential for agile responses.

A otimização de processos deve ser uma prática contínua, deve existir essa mentalidade dentro da equipe, com o compartilhamento de ideias e possíveis testes.

Uma vez que a nova tecnologia esteja em vigor, aproveite a oportunidade para otimizar seus processos de fabricação. Analisar os dados coletados pelos novos sistemas para identificar ineficiências e pontos de melhoria. A melhoria contínua deve ser um objetivo fundamental, com revisões e atualizações regulares de sua tecnologia e processos. Essa otimização contínua ajudará você a maximizar os benefícios da nova tecnologia e manter uma vantagem competitiva no setor.

Optimize workflows around the new technology to maximize its impact. By focusing on optimization, not just automation, you'll overcome adoption hurdles and unlock the full potential of new technology to transform your manufacturing!

Nové systémy je výhodné navrhnúť tak, aby vykonali samostatne zber kľúčových parametrov, napr. počet vyrobených kusov, úroveň kvality, výrobný čas, hodnota kritických parametrov. Štatistickými nástrojmi je možné údaje analyzovať, zistiť slabý bod systému. So zlepšením slabého bodu, je možné zvýšiť efektivitu celého systému. Pravidelným vyhodnocovaním údajov je možné predpovedať zlyhanie systému a včas prijať nápravné opatrenie.

Nové systémy je výhodné navrhnúť tak, aby vykonali samostatne zber kľúčových parametrov, napr. počet vyrobených kusov, úroveň kvality, výrobný čas, hodnota kritických parametrov. Štatistickými nástrojmi je možné údaje analyzovať, zistiť slabý bod systému. So zlepšením slabého bodu, je možné zvýšiť efektivitu celého systému. Pravidelným vyhodnocovaním údajov je možné predpovedať zlyhanie systému a včas prijať nápravné opatrenie.

Finalmente, promover uma cultura de inovação é vital para o sucesso a longo prazo de suas operações de fabricação. Incentive sua equipe a pensar criativamente sobre como aproveitar as novas tecnologias para novos avanços. Ao promover uma mentalidade que acolhe a mudança e a inovação, você estará mais bem posicionado para se adaptar aos futuros desenvolvimentos tecnológicos e ficar à frente no setor de manufatura. Essa abordagem proativa à inovação pode ser a diferença entre liderar o mercado e ficar para trás.

Počas používania nového systému sa odhalia uzly, ktoré za daných okolností, už náročne sa zlepšujú a tak vzniká priestor na ďalšie zmeny. Požiadavky trhu tak isto motivujú na zmeny. Na nekončiaci zlepšovací proces treba byť vždy pripravený. Pozorným počúvaním užívateľov, údržbárov a odborníkov je možné získať nápady pre ďalší rozvoj. Treba im dávať priestor na realizáciu. Vývoj vedy a techniky napreduje, nové možnosti sa objavujú. Zamestnancom treba umožniť, aby sa s nimi oboznámili, dať im možnosť, aby prišli s nápadom, ako ich aplikovať pre súčasné a budúce systémy. Pritom netreba zabudnúť ani na jednoduché riešenia, ktoré malou zmenou dokážu dosiahnuť veľký úspech.

I believe involving the team with tech change starts with the Need for change assessment, then carries on through every step including ding Continuous Improvement. Involving the team is more than sharing information, it is listening to ideas as a valuable perspective to improve or adjust the change at each step, optimizing an opportunity or even avoiding an unforeseen disaster in a timely, respectful manner. Often change is handled expeditiously missing this optimization and team-building opportunity. Being respectful doesn’t mean compromising the result. It can be the difference between failure and success.

Research & Test: Don't jump in blind! Research new tech and pilot test it to ensure it aligns with your needs. Embrace Experts: Partner with tech vendors for implementation and training. Upskill Your Team: Invest in training to empower employees to leverage the new tech effectively. Focus on ROI: Clearly demonstrate the cost-saving or efficiency gains the new tech will bring. By taking a thoughtful, data-driven approach, you can turn tech adoption into a manufacturing win!

Before implementing it in Commercial Scale, do it in the lab scale , scale it in pilot scale and collect the data, Design the entire process as per pilot data. Select the right supplier have a detailed with the data and finalize URS. Proceed design as per URS. Qualify the Equipments by DQ,IQ,OQ and PQ. Then do the Process validation and finalize operating parameters, quality parameters and inprocess checks with the validation data.with this data prepare risk matrix with the corrective measures, In each process steps ,the entire CFT have to involve and train which is to ensure New technology implemented effectively.

Remember most of people do not like change and will be reluctant ! So start with the support of Change Agents in the project (not only process or tech engineers) to ensure they will make sure everyone is on board !

Keď som nastúpil k poslednému zamestnávateľovi, s kolegom sme dostali úlohu od manažmentu na výrobu nového produktu vyvinúť flexibilnú výrobnú linku, ktorú za krátky čas vieme prispôsobiť na nové podmienky, keď sa zmení produkt alebo sa zmení požiadavka na kapacitu, požiadavky na tréning operátorov a údržby bol minimálne, pritom sklad náhradných dielov nemuseli výrazne prehodnotiť. Rozhodli sme sa pre linku, ktorá sa bude skladať zo samostatne fungujúcich pracovných staníc, kde rozpracovaný produkt automaticky sa presúva medzi stanicami. Pri tvorbe staníc sme použili maximálne možné totožné prvky aj pre manuálne ovládanú stanicu, aj pre automatickú bez potreby obsluhy.