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Using AI to enable scalable, autonomous operations

By Troy Mahr, director – Kalypso. Kalypso – acquired by Rockwell Automation in 2020 – is a diverse team of consultants, innovators, strategists, data scientists and technologists. What we consistently hear from industry leaders is the need for real-time visibility across their global operations, which is key to ensuring their operations stay agile and scalable. However, achieving this isn’t possible without removing laggy manual data collection through the deployment of connected assets and contextualised data. By eliminating data silos and unlocking industrial data and artificial intelligence (AI) capabilities, companies can enable autonomous decision-making that optimises costs, efficiency, and production resilience. This moves their organisation closer to achieving autonomous operations. Autonomous operations are the manifestation of “self-governing” systems at every step of the manufacturing process. These systems derive their autonomy from data-led decision-making models that enable them to reliably adapt their behaviour in response to dynamic environments during operation without any manual intervention. Achieving autonomy across an enterprise requires capabilities that span the full intelligence spectrum, from observation and inference to decision-making and action. These capabilities are relevant across all operational areas, including product design, manufacturing, supply chain, distribution, direct-to-customer channels, and demand forecasting. Manufacturing operations, in particular, have seen progress through Model Predictive Control (MPC), which continuously analyses real-time and forecasted data to optimise process control within defined constraints. While MPC is a strong example within manufacturing, broader autonomy demands extending similar intelligent systems across the enterprise. This journey is captured in the industrial AI maturity pyramid, which outlines a progression from basic data integration and visualisation to predictive analytics, prescriptive decision-making, and ultimately, autonomous operations. As organisations climb this pyramid, they adopt machine learning, real-time automation, and self-learning systems. Each stage requires not just technological upgrades but also cultural and structural transformation. Asset Monitoring: Find Downtime Root Causes Looking at […]

Piecing together the puzzle of future solar cell materials

Formamidinium lead iodide is considered one of the best-performing materials in the halide perovskite group, since it has promising properties for future solar cell technologies. New findings from Chalmers can now shed light on its structure; this is crucial if we are to engineer and control the material. Global electricity use is increasing rapidly and must be addressed sustainably. Developing new materials could give us much more efficient solar cell materials than at present; materials so thin and flexible that they could encase anything from mobile phones or entire buildings. Using computer simulation and machine learning, researchers at Chalmers University of Technology in Sweden have now taken an important step towards understanding and handling halide perovskites, among the most promising but notoriously enigmatic materials. Electricity use is constantly increasing globally and, according to the International Energy Agency, its proportion of the world’s total energy consumption is expected to exceed 50 per cent in 25 years, compared to the current 20 per cent. “To meet the demand, there is a significant and growing need for new, environmentally friendly and efficient energy conversion methods, such as more efficient solar cells. Our findings are essential to engineer and control one of the most promising solar cell materials for optimal utilisation. It’s very exciting that we now have simulation methods that can answer questions that were unresolved just a few years ago,” says Julia Wiktor, the study’s principal investigator and an associate professor at Chalmers. Promising materials for efficient solar cells Materials lying within a group called halide perovskites are considered the most promising for producing cost-effective, flexible and lightweight solar cells and optoelectronic devices such as LED bulbs, as they absorb and emit light extremely efficiently. However, perovskite materials can degrade quickly and knowing how best to utilise them requires a deeper understanding of […]

AI meets rugged reliability

Getac Technology Corporation (Getac), a leading provider of rugged computing and mobile video solutions and a manufacturer with advanced in-house capabilities, has announced the launch of two highly versatile new field devices: the F120, the world’s first fully rugged Copilot+ PC in a tablet form factor; and the V120, an AI-ready fully rugged laptop designed to deliver a premium computing experience in challenging work environments. Both new devices are the result of extensive real-world research and customer dialogue, building on Getac’s best-selling F110 and V110 models to deliver two brand new devices that harness the power of AI to unlock new levels of productivity in the field. Shared upgrades include larger 12.2-inch displays with a new narrow-bezel design, slimmer and lighter builds, Wi-Fi 7, Bluetooth 5.4, two Thunderbolt™ 4 ports, hot-swappable batteries, TPM 2.0, and robust MIL-STD-810H/IP66 certifications, a generational leap in performance and reliability for field professionals. F120 fully rugged tablet: the world’s first fully rugged tablet as a Copilot+ PC Copilot+ PCs are the fastest, most intelligent Windows devices currently available, with powerful processors and access to highly advanced AI models that can fundamentally transform workflows and operations in the field. To qualify as a Copilot+ PC, a device must include a neural processor unit (NPU) capable of 40+ trillion operations per second (TOPS), have a minimum of 16GB of RAM and 256GB of SSD storage, and support at least one form of biometric security authentication. Getac’s new F120 meets all these criteria. By bringing powerful edge AI into a fully rugged form factor, it transforms how field professionals work in challenging environments. Powered by the latest Intel® Core™ Ultra 200V Series Processor and groundbreaking Intel® AI Boost NPU with up to 48 TOPS, it accelerates AI-driven tasks like diagnostics, image processing, and real-time analytics, enabling users to tackle challenges faster and more effectively. […]

Australia’s competitiveness hits 13-year high

Australia rose to 13th from 19th place out of 67 nations for competitiveness, according to the Swiss-based IMD World Competitiveness Yearbook 2024. It was Australia’s highest ranking in 13 years. The improved ranking is the result of Australia’s stronger business and government investment, population growth and budget positions. Australia’s stable economy, transparent regulations and global business ties provide a secure and thriving environment for investors. Singapore, Switzerland and Denmark were ranked the world’s top three most competitive economies respectively. While the United States was ranked 12th (down three places), the United Kingdom, France and Japan were outside the top 20. The World Competitiveness Ranking measures economies, regions and sub-regions based on how they optimise their individual competencies to achieve long-term value for their people. The ranking examines economic performance, business efficiency, government efficiency and infrastructure. Top 10 for economic performance Australia’s overall economic performance improved from 10th to 7th. Australia’s competitiveness in international investment was ranked in the global top five. The high ranking reflected the country’s strong performance in both inbound and outbound investment. Strong international trade, high commodity prices and a comparatively healthy local economy have also helped drive this rebound in Australia’s competitiveness. Australia was ranked highly for: government efficiency (13th in the world) infrastructure (18th in the world) business efficiency (22nd in the world). Read more about Australia’s competitiveness profile [PDF, 440KB] in the IMD’s World Competitiveness Yearbook 2024. A top investment destination Australia has long been a top destination for investment, thanks to a resilient economy, a skilled workforce, and stable and transparent regulatory frameworks. Strong business ties with Asian markets make Australia a natural springboard into the fast-growing region. In green energy and critical minerals, Australia is a global leader – and intends to capitalise on its natural advantages to become a renewable energy superpower. […]

A global treaty to limit plastic pollution is within reach

Winnie Courtene-Jones, Lecturer in Marine Pollution, Bangor University. Representatives from 175 countries will gather in Geneva, Switzerland, in August for the final round of negotiations on a legally binding UN treaty to end plastic pollution. Non-governmental organisations, academics and industry lobbyists will also be in the room. They will all be hoping to influence what could be the world’s first truly global agreement on plastics. The summit, known as “INC-5.2”, follows a failed attempt to reach agreement in Busan, South Korea, late last year. That meeting ended without resolving important issues, despite hopes that it would conclude the treaty process. Now, it’s crunch time in Geneva. Either countries bridge their political divides, or risk the whole process falling apart. I’ve been researching the effects of plastic for more than a decade and have been involved in the UN treaty process since 2022. I’ve attended several of the negotiations and will be in Geneva next month. The science is clear: we need ambitious action which tackles every stage of the plastics lifecycle, from production through to disposal. But the question is, will countries deliver? In 2022, the UN Environment Assembly agreed to develop a legally binding treaty to end plastic pollution. Since then, progress has been slow. Negotiations have repeatedly stalled over issues such as whether the treaty should limit plastic production or regulate chemicals, how to define terms, and how to fund implementation. Environment activists calling for a strong global plastics treaty in Busan, South Korea, December 2025. Associated Press/Alamy Industry lobbying has also played a powerful role throughout. At the last round of talks, lobbyists for the petrochemical and plastics industries made up the single largest delegation. They outnumbered representatives from the EU, all of Latin America, the Pacific islands, independent scientists and Indigenous communities. This imbalance threatens to weaken the science-based action that is urgently […]

SMB manufacturers are cutting costs without cutting corners

Andrew Mamonitis, Vice President – APAC, Manufacturing Division, ECI Solutions In today’s volatile business landscape, small and mid-sized manufacturers (SMBs) are navigating a minefield of cost pressures. Inflation may be easing, however supply chains remain erratic, and the modern workforce demands greater flexibility. Many SMBs, desperate to stay afloat, are tempted by aggressive cost-cutting. Yet experts warn blunt force cuts can do more harm than good. For many SMBs, the question isn’t whether to modernise operations – but how fast. Leading SMBs are adopting modern precision strategies – leveraging real-time data, automation, and smarter planning tools – to trim waste without jeopardising growth. Eight key strategies they are embracing are: Making data-driven decisions: Modern enterprise resource planning (ERP) systems have transformed how SMBs uncover inefficiencies. With integrated analytics, businesses can now detect underperforming products, costly customers, and process bottlenecks that erode profits. Consider the case of a building supply firm. By analysing inventory data, they discovered specialty mouldings (long considered essential), were costly and slow-moving. By shifting these to a special-order model and doubling down on core items, they cut inventory costs while improving customer satisfaction. Inventory as a Strategic Asset: Many manufacturers still treat inventory as a necessary evil, overstocking to avoid shortages or running lean to conserve cash. But modern inventory management systems offer a better path. With AI-powered forecasting and unified inventory views, companies can optimise stock across multiple locations. One distributor, plagued by stockouts in one warehouse and excess in another, solved the issue by synchronising inventory across five sites. The result was lower overall stock levels and higher availability. Production planning that plays in harmony: Inefficient production planning is among the costliest problems for SMBs. A reactive approach (scrambling to meet yesterday’s demand) leads to overtime, delays, and wasted resources. A homebuilder suffering from poor […]

Smarter growth, lower risk: Rethinking how new factories are built

A tailored, thoughtful combination of cutting-edge technologies, stronger contracting skills, and deep supply chain capabilities can get a new factory up and running—without costly delays. Today’s environment is giving manufacturers even more reasons to reassess their footprint strategies. For some, localisation of production may now seem increasingly attractive—particularly amid rising volatility in tariff and trade policy, evolving incentives for manufacturers Manufacturers know that building new factories—and doing so quickly—can be incredibly complex. It is possible for the chief manufacturing officer to have never overseen the expansion of an existing factory—let alone the development of an entirely new “greenfield” site. The construction industry’s capacity for new factory construction is also constrained, especially by the demand for skilled workers. The sheer scale of the capacity gap is daunting even before confronting the very real risks that major projects face, from spiralling labour costs to vulnerable supply chains. There’s no single technology or template that manufacturers can deploy in response. Instead, to close the gap, manufacturing leaders need an integrated approach to factory building, one that encompasses thoughtful factory design, a reassessment of the supply chain, and effective construction management. A blueprint for revamping factory floor design The first step is undertaking a meticulous factory design process that seeks to ensure consistent flow of production, with adequate redundancy in capital assets Heightened competition for capital under current market conditions means it’s more critical than ever for manufacturers to deliver major capital projects on time and on budget. Higher labour costs in a new location require a company to rethink the entire value chain for the new plant—and with it, core production processes. Executives need to recognise that a greenfield development offers a unique chance to invest in Industry 4.0 technologies, maximising ROI and minimising production disruption Industry 4.0 user cases can show high potential for […]

Countries successfully growing their manufacturing – and what they are doing right

From Brazil to Singapore, here’s how six countries are rethinking manufacturing. From the climate crisis and geopolitical headwinds to next-generation technologies, a series of complex challenges are rewriting the rulebook for global value chains. Against this backdrop, what are manufacturers and supply chain companies doing to ensure their operations are fit for future success? Most successful firms are moving away from making location decisions based on cost alone to a more complex process that considers factors including performance, resilience and sustainability. Countries that want to remain competitive and position themselves as manufacturing hubs must embrace this shift. By adopting innovative policies across key country-level readiness drivers, nations can boost their appeal for foreign investment, potentially increasing GDP and their share of global value chains, the report suggests. Here are some examples of those archetypes and how they are growing their manufacturing. Brazil While Brazil’s GDP per capita and manufacturing’s share of GDP are below average, the country is making efforts to boost manufacturing’s economic role. The service sector now has a larger share of the GDP than the manufacturing sector. Brazil is the world’s leading source of coffee and a major producer of sugar, soy, and beef. It also exports significant amounts of steel, automobiles, and electronics. For decades, Brazil has been actively promoting manufacturing to diversify its production and reduce its reliance on agricultural exports. In early 2024, the country launched a new policy plan to drive this effort – called Nova Indústria Brasil. This policy defined strategic areas for investment to stimulate technological development and increase the competitiveness of the Brazilian industry. Key initiatives under this plan include measures to digitally transform industrial companies and invigorate the country’s semiconductor industry. India Like Brazil, India is in the adapter quadrant of the country archetypes. It also boasts a sizeable service sector, which […]

BW Converting launches e-learning platform for enhanced customer training

New online training solution complements on-site training, offers flexible learning options and helps customers manage workforce challenges BW Converting has launched an e-learning platform aimed at transforming customer training across its entire brand portfolio. Designed to provide flexibility and support operational efficiency, this online resource allows customers to access detailed machine overview courses, enhancing on-site training and enabling easier adaptation to workforce changes. The platform spans all BW Converting brands, including Paper Converting Machine Company (PCMC), Hudson-Sharp, Winkler + Dünnebier (W+D), Baldwin Technology Company, STAX Technologies and Northern Engraving and Machine. Initially focusing on popular equipment from BW Converting’s PCMC tissue and print offerings and their Hudson-Sharp brand bag converting portfolio, the platform will expand to encompass the full range of brands and products in the near future. This launch marks a significant investment in helping BW Converting customers achieve greater productivity and operational efficiency. The e-learning platform offers flexible, on-demand training options that supplement on-site instruction, equipping employees with foundational knowledge while addressing challenges like employee turnover and onboarding. Key benefits of the platform include the flexibility for employees to learn at their own pace, the ability to maintain productivity despite staff turnover and the chance to reduce on-site training downtime. With versatile purchasing options, including a la carte courses, subscription plans and real-time payment via credit card, the platform also integrates seamlessly into broader training and service programs. For customers with unique needs, BW Converting’s training team can create tailored e-learning content specific to their equipment and requirements. “This digital solution allows customers to save on costs related to extended on-site training, minimize production interruptions and access a consistent knowledge base for improved workforce competency,” said Scott Kupsky, Technical Training Leader at BW Converting. “By streamlining training processes and offering custom content, BW Converting is setting a new […]

Manufacturing and Production Industry is Fighting a 41% Increase in Ransomware Attacks over Four Years

By Sandra Lee, Managing Director of Southeast Asia and Korea, Sophos Wrapping up the first half of 2024, the Asia-Pacific region (APAC) is set to be the fastest growing region of the world economy1. It accounted for more than half of global GDP growth with the manufacturing industry becoming one of the key drivers over the years2, paving the way for APAC to be the world’s manufacturing and production hub. However, the industry is claiming a sad record in Sophos’ latest report with the highest growth in the percentage of organisations hit by ransomware in 2023, emphasizing the potential risk to the global production chain. Compared to all other industries that recorded a decrease in attacks last year, the manufacturing and production industry is one of the only three sectors with an increased attack rate of 9% other than healthcare (+7%) and financial services (+1%). A concerning percentage (65%) of organisations reported they were hit by ransomware last year, which was a notable increase from the previous years since 2020 (i.e. 24% in 2020). A majority (93%) of manufacturing organisations hit by ransomware in the past year claimed that cybercriminals attempted to compromise their backups during the attack. Of them, 53% of backup compromise attempts were successful. Additionally, three out of four ransomware attacks on manufacturing organizations (74%) resulted in data encryption, hitting the highest encryption rate for the sector in the last five years and the cross-sector average of 70% in 2024. Although most organisations hit by ransomware were able to identify the root cause of the attack, which exploited vulnerabilities and compromised credentials — malicious e-mails were identified as the root cause. Some organizations are still failing to implement key security measures that can demonstrably reduce their overall risk profile, resulting in a higher attack recovery cost. In […]

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