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The role of Artificial Intelligence in increasing the quality of manufactured products – Mohammad Reza Sabzevari – Project Manager for increasing the capacity of the pellet factory

The production quality of any product is a measurable quantity and has a direct relationship with all the activities carried out from the beginning to the end of the production process. Human labor plays a role throughout this process. However, due to differences in abilities (such as experience, knowledge, cognitive, and physical abilities), human labor will inevitably have some errors and variations, which can directly impact the quality. Therefore, it is essential to minimize these errors and discrepancies.

Artificial intelligence is the best way to eliminate human error, because in artificial intelligence we manage all the steps from the beginning of identification and preparation of raw materials until the final product reaches the customer by defining machine algorithms and deeply using the results of the processes intelligently and automatically analyzing it and fixing the identified defects, or even by analyzing the opinions of customers and employees and defining it as a systematic model and using it continuously, a quality product is achieved, so it can be said that with the benefit of Artificial Intelligence, it is possible to achieve the highest level of quality.

One critical factor affecting quality is the discussion around machinery and equipment. The closer machinery and equipment operate to standard performance and design, the better the quality of the final product. By employing AI, we can automate equipment and production lines to the extent possible. Since the operation is based on predefined patterns and eliminates human error, we achieve the desired quality.

Every production involves several processes, each incurring costs. Therefore, we have two approaches to managing costs and reducing them. First, we can eliminate some activities and processes. For example, minimizing material handling or production line setup time leads to increased production. Second, we can focus on improving efficiency. Increasing the setup time of production lines is the result of proper maintenance and timely repairs, using consumables and equipment according to factory needs, and employing experienced personnel (with knowledge and experience). In short, it can be said that what causes additional cost to the organization is the decrease in the efficiency of equipment and human resources.

 

AI deployment can control production time by managing constraints, and by eliminating human errors, improve equipment performance, and define maintenance algorithms (using failure analysis and preventive maintenance programs), AI plays a huge role in reducing costs or managing costs. It can also identify suitable raw material supply points, assess the working time of parts and equipment, and replace them promptly based on analysis. By managing daily, weekly, monthly, and yearly service requirements for parts, equipment, and production lines, AI ensures cost-effective resource utilization. In summary, AI provides the most desirable process methods.

Since the dawn of humanity, we have sought change and evolution. Explorations across various regions reveal the creation of tools such as knives, axes, weapons, etc., using animal bones, wood, and stone. These innovations were driven by the pursuit of well-being and safety. The discovery of fire, the production of pottery, and humanity’s ability to melt metals represent the pinnacle of early human progress.

The invention of the wheel marked the beginning of technology and knowledge entering human life. The revolutionary invention of the steam engine had a significant impact. The invention of computers opened a new gateway for humanity, and all of these developments led to the current shape of human societies, which thrived economically due to industrial transformations. Alongside these advancements and increasing reliance on the results from these industries, the need for further development intensifies. Competition becomes tighter, and there is a forced shift towards both high-quality and cost-effective production. In this context, either having a unique product or achieving a lower total cost becomes essential for survival in the competitive market. Regardless, identifying and implementing the relevant resources is crucial. Shortening production process paths (combining technologies), minimizing errors (where humans play a significant role), and using the most desirable materials and components are critical factors for cost reduction and, in some cases, enhancing product quality.

These needs compelled industries to adopt new methods in the industrial world, such as Artificial Intelligence (AI) or smart automation. Advanced countries like Germany, Japan, and the United States quickly embraced these technologies and are diligently working to integrate them into various industries, even impacting people’s daily lives. Without a doubt, any delay in this regard will result in annual setbacks. Industries such as automotive, military, steel production, medicine, and many others have already embraced these innovations.

 

In summary, AI allows us to overcome limitations and optimize resource utilization. It has found its place in military, automotive, and steel industries, as well as agriculture and medical fields. Governments worldwide strive to create a strategic plan and establish suitable infrastructure to thrive in the new world shaped by AI, focusing on economic growth and development.

AI can analyze and process information efficiently, considering standards, acceptance criteria, guidelines, images, and even feedback from customers and personnel in the shortest time and with the best performance, and informs about providing deviating points or lack of value, so when the information required for quality production of a product from iron ore mining to loading and delivery of a steel product, all of which are the result of several processes and activities, the output of each step is the input of the next step, you can be sure that the most desirable result has been achieved, for example, the size of raw pellets in the disk, it will be discharged to the desired and standard level, so we will not have the amount of pellets below the standard size and above the standard size, which will cause us problems in the next processes. Therefore, the maximum efficiency is created, or we have minimum waste in the rolling and sheet sizing lines. Therefore, artificial intelligence will lead to the optimal selection of raw materials and, naturally, the reduction of returned materials, material waste, energy consumption, downtime, as well as increasing efficiency and increasing the safety factor. Also, Artificial Intelligence can help us reach new and diverse products according to the properties of elements and materials and according to the existing conditions of production lines and the needs of our customers.

Examining the impact of technological advancements on different societies reveals that each technology has its pros and cons. These advantages and disadvantages, akin to opportunities and threats, directly relate to the cultural and social perspectives of governments and communities.

Perhaps the best example in this context is the discovery of radioactivity. While its positive effects in various fields, including medicine and treating incurable diseases like cancer, are evident, the creation of atomic bombs and the tragic memory of the mass killing of people in Japan during World War II serve as a stark reminder. The same technology that brought hope also posed a significant threat. Therefore, proper cultural awareness, education, and explicit definitions are essential for integrating AI effectively into society.

 

Occupations affected by these changes should be identified and communicated. Educational institutions, from elementary schools to universities, need to incorporate relevant skills and replacements into their curricula. Adopting appropriate methods in dealing with the violators of this field should be done simultaneously with the growth and development of this generation of the industry and all ways of abuse should be limited.

From another point of view, we must accept the fact that the world ahead is a world with Artificial Intelligence, in the future you will see driverless cars, operating rooms without surgeons, restaurants without waiters, etc. Therefore, infrastructures should be provided, culture building and education should be started, and with a principled, continuous plan, step into this new world with firm and steady steps.

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