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A D V A N C E D M A T E R I A L S & P R O C E S S E S | F E B R U A R Y / M A R C H 2 0 2 0 2 7 with developments in tooling design. And while the process is getting fast- er and more complicated, there have been no improvements in understand- ing process influences. Stamping has been an industry that relies on expe- rience and interpretation rather than physical measurements. The challenge being that so many process influences have wide windows of variability that can fluctuate not only from job to job, but also across a single run of materi- al. Simulation shows how specific pa- rameters impact the formability of a part, but is limited in that it considers only one set of parameters, not the full window of variability that occurs in re- ality and without real-time ties to the process parameters as they fluctuate. This is where Industry 4.0 and the col- laboration of monitoring technologies with analytical tools can expand under- standing of the process (Fig. 2). A new initiative in stamping is using machine learning for pattern recognition, or an algorithm-based ap- plication that will identify the cause and effect of product results across multi- ple data streams; connections not oth- erwise visible to the process observer. With the utilization of pattern recogni- tion Ford has identified the potential of using process monitoring technologies for real-time production information, data analysis to identify correlations in regards to formability, and ultimately improved part design and process oper- ations (Fig. 3). These initiatives provide statistical analysis to remove waste, op- erate with absolute understanding, and launch new vehicles with a competitive advantage over traditional methods. This ideology revolves around using the technologies available to the industry and developing a continuous loop of feedback that improves stamping en- gineering and the production process (Fig. 4). This task of intuitive manufac- turing is not just a project with a start and finish, this is a change in mindset with infinite solutions; operating smart- er rather than achieving a goal and moving to the next task. SUMMARY Traditional products have compe- tition, a market leader and those try- ing to catch up. Industry 4.0 is about collaboration and building momen- tum for the improved capability of 4.0 itself. While not changing the deliv- erable of the stamping industry, Ford Motor Company is still looking to ef- ficiently build quality vehicle body panels, but now with self-reliant orga- nizations that share information from start to finish and replace assumptions with data driven decisions. This is the first step toward processes that moni- tor themselves, anticipate issues, and most importantly optimize to avert fail- ure. The strength of Industry 4.0 being that you can start small and then con- tinue to grow, evolve, and learn. ~AM&P For more information: Elizabeth Bull- ard, Stamping New Technologies, Ford Motor Company, 6000 Mercury Drive, Dearborn,MI48126 ,ebullar3@ford.com . References 1. B. Sniderman, M. Mahto, M. Cotteleer, “Industry 4.0 and Manufacturing Eco- systems,” Deloitte Insights, 23 Febru- “THE ADVENT OF INDUSTRY 4.0 IS NOT ONLY AUGMENTING THE NATURE OF EXISTING MANUFACTURING ROLES SUCH AS LEAN MANAGERS, BUT ALSO LEADING TO THE CREATION OF COMPLETELY NEW ROLES SUCH AS COLLABORATIVE ROBOT EXPERTS AND INDUSTRIAL BIG DATA SCIENTISTS.” [3] Fig. 4 — A continuous feedback loop improves stamping engineering and the production process.