Taking a step into the world of the smart factory is a daunting prospect for manufacturers and for a host of reasons. Many organisations lack (or believe they lack) the required technical skills.
Similarly there are issues around data and the integration of differing systems and costs are perceived to be high or require considerable Cap-Ex outlay in relation to business size.
And, of course, there’s the perennial argument that a smart approach just won’t align with the company culture and that it will upset the employee applecart.
But sticking with current operational methods simply won’t cut it forever, not least because the core of any ‘traditional’ factory is good, knowledgeable people, and they are increasingly hard to find. So, before the competition catches you up or overtakes you forever, here’s why it’s time to move beyond traditional methods and stop relying on memory to run your factory:
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Memory and knowledge aren’t scalable – data is
Traditionally, factories relied on “memory” – the knowledge of supervisors, operators and technicians who knew what to do and when. But as businesses grow, that approach quickly hits its limits. People leave, processes change, and consistency suffers.
You’ll know when you’re in that situation when the only person capable of dealing with a core, but ‘temperamental’ part of your production process goes on holiday… and all you can do is hope nothing goes wrong for two weeks.
Smart systems don’t go on holiday, they don’t leave for another job and they don’t forget – they learn, scale, and improve. And all that information stays right where your business needs it.
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AI can see (and predict) more than any human
Artificial Intelligence (AI) doesn’t just analyse data, it interprets it and can recommend or even take action. Whether it’s predicting maintenance needs or adjusting production schedules, AI can process more information, from more sources, in less time than any human team ever could. Think of it as replacing gut-feel with data-backed decisions.
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Machine learning keeps getting smarter
AI isn’t static. Through machine learning, it continuously adapts and refines its decision-making. That means your factory operations become more accurate and efficient over time by default. Looking for improvements is baked into the day-to-day operations and continuous smart improvement is a reality.
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Real-time data beats rear-view guesswork
Not so very long ago, a control room needed walls of dials and warning lights to monitor equipment, with skilled and knowledgeable people to interpret them and know how to react. Now, the same production floor machinery can deliver live data streams directly into intelligent dashboard systems that can analyse, flag, and act immediately based on all the data interactions that have gone before. This shift from manual monitoring to real-time AI insights is revolutionising industrial operations.
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No factory is an island
It’s easy to think of the factory as a self-contained unit, chugging along, churning out goods for the warehouse shelves. But that’s no longer viable. Customer insight permeates every facet of manufacturing, whether that’s sales volumes determining production levels, quality issues or speed of delivery, what the customer wants drives shop-floor decision making,
Your ERP system is the bridge between the shop-floor and the outside world, holding all your transactional data, delivery dates, and sales information. For a truly smart factory, ERP must work hand-in-hand with your AI tools and automation hardware to make customer-centric decisions.
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Modern manufacturers need more than memory
Today’s leaders can no longer bank on experience or instinct. The days of relying on someone saying “the last time this machine made that crunching noise…” are over. They need data, the means to interpret data and then to be able to act.
Technology provides the insights needed to act decisively, at scale, and with consistency. As the saying goes, “A short pencil is better than a long memory.” In our world, systems are the new pencil.
Final thought: a powerful trio
But here’s the really interesting bit. It’s hard to pull this off this without your employees, their knowledge and memory.
Sure, the tools exist both in terms of software (think AI and ERP) and automation hardware (from precision robotics through to an automated conveyor), but to piece this all together means using the memory and knowledge you’ve already got. Technology alone is not enough.
The triumvirate of today’s modern smart factory is real-time, interpretable data to drive decisions, automated and monitored hardware plus the knowledge and memory to use those tools to shape your production environment.
In a fast-changing manufacturing landscape, depending on any one element alone isn‘t enough. By embracing automation, AI, machine learning and integrated ERP systems and leveraging the experience you have, you’re setting your factory up not just to survive – but to thrive.
To find out more about how SysPro ERP can help you better manage your data and gain insights into your business, visit: syspro.com.
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