Why AI? Dimitris Zarpalas answers manufacturers’ critical question

Dimitris Zarpalas, Executive VP for Innovation of D-cube, answers the most common questions about the use of AI in aluminum industry

In today’s rapidly advancing technological landscape, Artificial Intelligence (AI) is becoming increasingly pivotal across various industries, including industrial manufacturing. D-cube is a  leading company in this transformation. In this article, Dimitris Zarpalas, Executive VP for Innovation of D-cube, answers all the questions regarding the use of AI in manufacturing, drawing insights from D-cube’s experience and expertise.

AI in Industrial Manufacturing

Q: We hear a lot about AI lately, but how is it used in industrial manufacturing?

Dimitris Zarpalas: AI contributes significantly in industrial settings by enhancing product quality, reducing malfunctions and defects, and optimizing yields. Through multi-level data analysis, AI can detect anomalies, predict maintenance needs, ensure consistent standards, and minimize waste.

The Role of AI in Aluminum Extrusion

Q: Can you explain what role Artificial Intelligence currently plays in the aluminum extrusion industry?

Dimitris Zarpalas: Until 2019, AI was virtually absent in the aluminum extrusion sector. This changed when D-cube piloted our AI system, CYRUS, at the ALUMIL factory in Kilkis, Greece. By 2023, ALUMIL proudly became the first extrusion factory worldwide to enhance its production using AI, as announced by their Chairman and CEO, Georgios Mylonas.

Q: How does AI technology integrate with the existing machinery and systems in aluminum extrusion plants?

Dimitris Zarpalas: The integration involves creating cyberphysical systems, a core component of Industry 4.0. This requires connectivity of machines through sensors and cloud technology for real-time data gathering, essential for enabling machine learning and AI technologies. These systems provide advanced analytics to enhance production efficiency.

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Key Benefits of AI in Aluminum Extrusion

Q: What are the key benefits of applying AI in aluminum extrusion processes?

Dimitris Zarpalas: Applying AI in aluminum extrusion processes offers several key benefits. The robotics and manufacturing industry uses AI for its consistent and reliable performance. AI performs repetitive tasks without fail. This means higher productivity and cost-saving in the long run. Traditional AI needs labeled data abundance for learning.

For example, learning, reasoning, problem-solving, perception, language understanding and more. Instead of relying on explicit instructions from a programmer, AI systems can learn from data, allowing them to handle complex problems (as well as simple-but-repetitive tasks) and improve over time.

Deep learning models, particularly when they have access to large amounts of data, can achieve remarkably high accuracy. Unlike traditional machine learning models that plateau at a certain level of performance when you feed them more data, deep learning systems thrive on big data. The more data you provide, the more refined the model.

Q: What challenges or limitations have you encountered while integrating AI technologies into aluminum extrusion operations?

Dimitris Zarpalas: One of the foremost issues is the interoperability of machines. Integrating new technologies in modern industries presents several significant challenges. One key issue is ensuring the interoperability of machines, where different systems must work together seamlessly to maintain efficiency and avoid costly disruptions. Standardized protocols and interfaces are essential to address compatibility problems.

Developing robust sensing technologies is another critical challenge. Reliable sensors are necessary for accurate data collection, which is vital for automated systems to function effectively. These sensors must be sensitive, durable, and adaptable to various conditions to provide precise measurements.

Additionally, gaining workers’ trust in new technologies is crucial. Fear of job loss due to automation can lead to resistance. Addressing these concerns involves reassuring workers about job security, demonstrating seamless integration into current production flows, and providing adequate training and support.

Sustainability and Artificial Intelligence in Aluminum Extrusion

Q: How does the implementation of AI in aluminum extrusion align with sustainability goals, particularly in energy consumption and carbon footprint reduction?

Dimitris Zarpalas: Key benefits of utilizing CYRUS in the extrusion lines are yield optimization, early scrap identification, and avoidance of downstream processing of scrap material. All the above have an obvious impact on factory’s energy consumption, reducing production costs and factory’s carbon footprint. Furthermore, objective and accurate scrap detection will minimize customers’ claims, thus helping to avoid unnecessary shipping and increasing carbon footprint reduction.

Ethical Considerations and Job Impacts from Artificial Intelligence

Q: What are the ethical considerations and potential job impacts of integrating AI into industrial manufacturing?

Dimitris Zarpalas: Ethical considerations primarily involve employment impacts. While AI and automation may replace some jobs, human oversight remains crucial for AI systems. Additionally, privacy concerns arise as AI relies on vast data collection. Ensuring secure data access and transparency in data usage is essential.

Future Advancements in AI

Q: What advancements in AI do you anticipate will further transform the aluminum extrusion industry?

Dimitris Zarpalas: Future advancements in aluminum extrusion processes will likely involve higher levels of automation and deeper integration with more machinery and data modalities, further enhancing productivity and efficiency. Advanced AI and machine learning algorithms will provide precise control, reduce waste, and improve product quality. Real-time data analytics will enable predictive maintenance and optimize workflows, reducing downtime and operational costs. Additionally, advanced robotics and smart sensors will streamline processes, allowing for more complex and customized extrusion profiles with greater consistency and speed. These innovations will drive economic gains and support sustainable manufacturing practices.

Q: What advice would you give to companies in the aluminum extrusion sector looking to adopt AI technologies?

Dimitris Zarpalas: My advice is to prepare thoroughly. Establish a solid sensing infrastructure and ensure data interoperability with IoT standards. This groundwork is vital for a smooth transition to AI-driven processes.

The integration of AI in aluminum extrusion represents a significant leap forward in industrial manufacturing. AI not only boosts productivity and sustainability but also sets the stage for future innovations. As AI technology continues to evolve, the aluminum extrusion industry is poised for remarkable transformations

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