Flex is the manufacturing partner of choice that helps a diverse customer base design and build products that can improve the world. Through the collective strength of a global workforce across 30 countries and responsible, sustainable operations, Flex delivers technology innovation, supply chain and manufacturing solutions to diverse industries and end markets. Senior Vice President of Operations, Jean-Francois Zoeller is responsible for Flex operations in EMEA and Flex Automotive operations globally.
What’s driving automation in manufacturing?
During the pandemic, automation and robotics proved to be invaluable when rapidly scaling production of urgently needed products in response to the crisis; from face masks to much-needed ventilators.
It also facilitated ‘social distancing’ between employees on the factory floor. However, the benefits of using advanced technologies are far more wide-ranging and can offer a significant competitive advantage over more traditional methods of production.
A knowledge of smart technologies can optimise production by improving quality and delivering it consistently, while also lowering cost and reducing downtime.
Industry 4.0 is also about digitisation. What’s the payback?
Advanced analytics powered by artificial intelligence and machine learning technologies can help find the root cause of production bottlenecks, identify faulty components or placement, and even predict and prevent machine failure before it happens.
This substantially helps in reducing downtime and quality costs, essential in exacting industries like automotive.
Digitising the factory through a combination of sensors, edge computing and cloud solutions yields massive amounts of data. To maximise business value from digitisation efforts, it is important to establish best practices for gathering, managing and analysing data, then making it available to those who need it, when they need it, so they can make informed decisions quickly.
How does Flex use simulation?
Simulation is an advanced technology that is changing the entire approach to designing, planning, testing and optimising production lines. Strong collaboration with customers allows us to use data from a variety of sources to explore production options without affecting time, resources or capital in the real world.
We use advanced simulation to optimise every aspect of our industrial engineering line design; from how and where materials are placed, through to the circuit board production on the SMT lines, to the final product assembly lines.
Our experienced simulation engineers enable planning discussions with customers for new lines that can use best practices learned from extensive experience with hundreds of projects, or quickly design a new line and then benchmark it against existing line designs to find the best solution.
Simulation, therefore, is helping us build the future of digital manufacturing through a constant focus on integrating new technologies into production lines to accelerate consistent high quality output and more efficient production. The result is lower overall production costs by saving time and avoiding rework.
How big a role does Augmented and Virtual Reality technology play?
Simulation technology is best visualised through Virtual Reality (VR), where customers can get a truly immersive experience of their new production environment. This is a very practical application for VR that enhances the customer experience and facilitates a better planning discussion. Customers also find it quite cool.
Augmented Reality (AR), where the real world is overlaid with computer-generated content, proved to be an important communication tool during the pandemic, when travel was severely restricted.
Where maintenance needed to be performed on a machine for example, we used AR technology to collaborate with remote engineers rather than having to bring them on-site.
In addition to remote assistance or service and repair applications, using AR you can support training, logistics and order fulfilment, business development and multiple forms of communication and collaboration with colleagues, customers, and suppliers around the world.
What are the benefits of additive manufacturing?
During the design and development phase of a new product, rapid prototyping allows teams to test innovations and materials, prepare for scaled manufacturing and stay on track with time-to-market targets.
Additive manufacturing significantly speeds up this process by allowing teams to quickly prototype tools, fixtures and spare parts.
A full suite of in-house industrial additive manufacturing services can streamline prototyping and product customisation while reducing time and effort. Through state-of-the-art software, hardware and materials, it can help customers stay nimble while developing new products.
What should an organisation look for in its next manufacturing partner?
There are many considerations when choosing a manufacturing partner depending on your industry, the markets you serve and the volume or complexity of your product. We work with both highly regulated industries and sectors who need high volume global production.
Generally however, your manufacturing partner should be able to help you through the entire process, from design to delivery.
The design stage is important to decide on materials, suppliers, environmental or circular considerations, prototype production using rapid additive manufacturing, product testing and certification.
A capability in simulation avoids costly trial and error in developing an effective and optimised industrial engineering solution.
A strong design for automation capability is important so that the manufacturer is able to develop their own automation solution for you, or partner to find the right solution for your product.
By using advanced technologies like simulation, predictive technologies and advanced screening, issues in design and production flow can be caught and resolved before they become problems, and you more quickly achieve high yields and high quality as well as value for money.
Flex has invested in a focused portfolio of advanced manufacturing capabilities and technologies to lead Industry 4.0 and has two World Economic Forum Industry 4.0 Lighthouse Factories to date. It is therefore important that customers can trust their manufacturing partner to help them achieve new levels of efficiency, quality and sustainability as they deliver their next innovation to the world.
