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Emerging Technologies for High Quality Manufacturing (Technical Insights)

  • April 2013
  • 87 pages
  • Frost & Sullivan
Report ID: 2043429

Summary

Table of Contents

Advanced Technologies for Reduced Defects in Manufacturing

The research service focuses on the various emerging technologies that are enabling reduction in defects of the manufactured products. This reduction in defects translates to a decrease in waste and hence the manufacturing costs. This service is most suited for executives in manufacturing industries who are looking to have insights into the latest technologies for defect identification and quality management.
Frost & Sullivan has identified 4 main technology areas, which we think are the enabling technologies for attaining high quality in manufacturing. They are as follows:
•Lasers
•Machine Vision
•Software
•Smart Packaging

The research service provides insights into different emerging technologies for high quality manufacturing across diverse industries. This research service covers
- Technology overview; Key benefits or strengths of emerging technologies for high quality manufacturing
- Capability and value chain of emerging technologies for high quality manufacturing
- Market impact of key innovations
- Key technology and business drivers
- Key challenges for emerging technologies for high quality manufacturing
- Technology adoption cycle and demand side analysis of companies in the emerging technologies for high quality manufacturing
- Opportunity evaluation and roadmapping for emerging technologies for high quality manufacturing
- Technology roadmap
- A brief snapshot of the key patents in this space

Research Methodology

Step 1: To provide a thorough analysis of each topic, Technical Insights’ analysts perform a review of patents to become familiar with the major developers and commercial participants and their processes.
Step 2: Building on the patent search, the analysts review abstracts to identify key scientific and technical papers that provide insights into key industry participants and the technical processes, on which they work.
Step 3: The analysts then create a detailed questionnaire with content created to address the research objectives of the study, which functions as a guide during the interview process. While the analysts use structured questionnaires to guarantee coverage of all the desired issues, they also conduct interviews in a conversational style. This approach results in a more thorough exchange of views with the respondents, and offers greater insight into the relevant issues than more structured interviews may provide.
Step 4: The analysts conduct primary research with key industry participants and technology developers to obtain the required content. Interviews are completed with sources located throughout the world, in universities, national laboratories, governmental and regulatory bodies, trade associations, and end-user companies, among other key organizations. Our analysts contact the major commercial participants to find out about the advantages and disadvantages of processes and the drivers and challenges behind technologies and applications. Our analysts talk to the principal developers, researchers, engineers, business developers, analysts, strategic planners, and marketing experts, among other professionals.
Step 5: The project management and research team reviews and analyzes the research data that are gathered and adds its recommendations to the draft of the final study. Having conducted both published studies and custom proprietary research covering many types of new and emerging technology activities as well as worldwide industry analysis, the management and research team adds its perspective and experience to provide an accurate, timely analysis. The analysts then prepare written final research services for each project and sometimes present key findings in analyst briefings to clients.

Key Findings

Machine Vision
•The market for industrial machine vision is continuously growing due to the significant pressure on producers to create the high-quality, non-defective goods. According to a Frost & Sullivan study, Analysis of the Global Industrial Machine Vision Market (published February 2013), the market for industrial machine vision inspection systems generated the revenue of $xxbillion in 2011.
•The higher proliferation of smart cameras is expected to happen due to the increasing number of commercially available smart cameras combined with their increasing image processing and analysis capabilities.
•On the other hand, in order to ensure the high quality of manufacturing, technological innovations are necessary. Hence, emerging technologies such as 3D machine vision or hyperspectral imaging emerge in the industrial applications. Hyperspectral imaging is the technology used for imaging and analysis of large numbers of very narrow, contiguously spaced spectral bands over a continuous spectral range. Hyperspectral imaging will find diverse emerging industrial applications such as monitoring of films and patches, inspection of single or multilayer webs, blend monitoring, inspection of chemical non-uniformity in pharmaceutical tablets, in-process color monitoring and thin films monitoring.
•Some of the emerging applications for the smart cameras include automated control systems and video surveillance

Lasers
•Lasers are a key enabling technology in automation and manufacturing.
•One issue that can somewhat hinder the further proliferation of lasers in the industrial applications is the price of this technology. Moreover, the high R&D costs and other market barriers lead to situation in which the market is dominated by key huge participants such as Trumpf, Coherent, Rofin and Cymer. Innovative technologies such as ultrafast lasers are extremely expensive.
•Still, the prognosis is very optimistic and lasers are deployed in diverse industrial scenarios in various industries ranging from automotive to jewellery.
•Fiber lasers are finding key opportunities in industrial welding and cutting applications and have strong growth potential going forward. Significant developments occur in terms of output power that can be achieved with the use of various types of lasers, and capabilities of lasers to enter

Smart Packaging
•Packages with the ability to detect changes occurring in the environment and respond by changing its properties or by producing a signal are referred to as active or intelligent packaging. These are sometimes referred to as smart packaging. Another innovation in smart packaging which can be competing with smart electronics as an alternate enabling technology is polymer additives.
•Key purposes served by smart packaging will include contamination detection, leak assessment, expiration detection, consumption compliance etc.
•Major beneficiaries of such packaging will be the food and beverage, pharmaceutical and electronics industry.
•Smart Packaging is currently facing some resistance from traditional packaging manufacturers due to the lack of understanding of the enabling technologies involved. However, with appropriate partnerships, this barriers will slowly be removed in the future.

Software
•Enterprise software and machine specific software (such as those used for machine vision and metrology) are becoming a part of the quality control processes in major industries such as automobile, aerospace, food and beverages and pharmaceutical.
•Major software enterprises such as SAP, Sage, Microsoft and Plex have developed different modules such as ERP, MES and SPC which can be used for root cause analysis and defect reduction.
•Hardware specific software such as machine vision and metrology software are now sufficiently advanced to be adopted in the manufacturing industries, and are already being used in industries such as automobile ,consumer electronics manufacturing and cement manufacturing. Machine vision software specifically gave made great strides, becoming more efficient in the edge identifications and reducing the dependence on ambient lighting conditions. Some major participants have also emerged in the metrology software market, such as Hexagon Metrology and Nikon Metrology. The market for machine vision software developers is mostly fragmented.
•A challenge associated with such software is the lack of standardization in the protocols used by different systems in manufacturing facilities. Some key advances made in software for high quality manufacturing are 3D vision inspections, alignment methods and better tool building using real time feedback for accurate actions of the metrology system. In enterprise software, key advances have included offering of some enterprise software in the form of a “Software as a Service”, integration of supply chain management software modules and implementation of pricing optimization modules in the recent past.

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