Industry

In the factory, the key focus will be on physical AI

Taisch (PoliMi): ‘AI is being integrated into objects.’ Humanoids will not replace cobots designed for a single task

 (Adobe Stock)

4' min read

Translated by AI
Versione italiana

4' min read

Translated by AI
Versione italiana

There are times when a technology seems to arrive out of the blue, and others when one realises that its arrival was inevitable. The introduction of artificial intelligence into factories and humanoid robots has its roots in the 1990s. Now the focus is on so-called ‘physical AI’, that is, artificial intelligence applied to industrial production.

Marco Taisch, Full Professor at the Politecnico di Milano, where he teaches Advanced & Sustainable Manufacturing and Operations Management, is quick to point out that we should not confuse the enthusiasm of the present day with reality. “My first scientific article on neural networks in the manufacturing sector dates back to 1996,” he explains. The technology is not new, but it has been brought to maturity by two recent enabling technologies: computing power and the availability of large amounts of data. This is the springboard for the real leap forward that we are now beginning to see in factories.

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What will change compared to Industry 4.0?

With Industry 4.0, explains Taisch, we had learnt to connect machines and display data: dashboards, indicators, the ‘yellow and green arrows’ that signalled the status of a plant. However, the interpretation of that data was still left to humans. With physical AI, intelligence no longer resides solely in the cloud, but is brought ‘on board the machine’, inside the physical object. The machine no longer merely diagnoses what is happening; it goes on to make a prognosis and, in its ‘agent-based’ form, takes action to resolve the problem.

Taisch uses a striking image: ‘We are shifting the centre of gravity in manufacturing from “working with our hands” to “brain-based manufacturing”’. Whilst the robotics of the 1970s replaced arm muscle power, physical AI works alongside the brain and intervenes where decisions are cognitive but repetitive. However, it is still up to humans to provide the spark of creativity, intuition, risk-taking and non-repetitive decision-making. “It is you who decide where to draw the line, what to entrust to the algorithm and what to keep for yourself,” emphasises Taisch.

Taisch (PoliMi): ‘It’s not just humanoids in the factory’

With regard to humanoids, Taisch acknowledges that Italia, too, is fascinated by them, but for now we are still in the testing phase. He adds, however, that ‘in a factory, humanoids won’t be the only ones needed. We will continue to mill, move objects, and work with collaborative and traditional robots’. According to the professor, many tasks are nevertheless performed better by a robot designed for a single task – a cobot – which remains stationary in front of a machine and requires neither legs, eyes nor arms. In his view, when humanoids become widespread, the reason will be more to do with demographics than with technology. Indeed, in an ageing country, robots will be needed to replace workers who are no longer available.

However, physical AI brings not only innovation, but also new questions. Indeed, as long as the machine merely displayed data, the decision always rested with the operator. Now that the machine decides and acts, we find ourselves having to place our trust in something we do not yet fully understand. It is a new, different kind of trust: not in a colleague, but in a system that makes choices on our behalf. This raises some very practical questions: who is accountable for a decision made by the algorithm? A machine that has been substantially modified after installation must be recertified – but by whom? These are issues that the European framework is beginning to address.

Zanella (Abb): ‘We need a repeatable economic return’

And it is precisely trust that distinguishes initial enthusiasm — the so-called ‘hype’ — from a technology that is here to stay. This is confirmed, from a different perspective, by Luca Zanella, Global e-commerce Channel Manager at ABB’s Electrification division. ‘A technology remains hype as long as it amazes without solving any problems. A robot dancing in a hotel reception is of little use,’ says Zanella. In his experience, a technology becomes a genuine market when it meets a real need and an ecosystem of services — configurators, platforms, support — grows up around the product, making it usable, integrable and sustainable over time. It is at that point, says Zanella, that a technology stops making headlines and begins to generate value: “When it produces a repeatable economic return, not just an isolated demonstration.”

Trust involves another key element: data. When a product becomes connected, the relationship between the technology provider and the customer changes in nature: the provider begins to ‘see’ the data of those using the machine. Zanella interprets this in terms of shared growth: ‘Asking for data not to take it away from the customer, but to grow together.’ This approach is a winning one from a commercial perspective. However, from a governance perspective, data sharing must be carefully structured, particularly when it comes to physical AI. The issues to be addressed are the basis on which that data is collected, for what purposes, and who is permitted to do what with it. Prudent management of these issues transforms a ‘constraint’ into a genuine partnership and confirms that the real barrier, once again, is not technological, but mutual trust.

So when does a factory become ‘smart’? Not when it has a robot that mimics humans, but when both artificial intelligence and machinery support the operators. When they learn to manage the variability of the real world as effectively as possible. When that intelligence demonstrates reliability and trustworthiness in all situations. Despite the technological acceleration we are currently experiencing, both Taisch and Zanella nevertheless urge a pragmatic approach. This journey has only just begun, and it is up to us to determine the return on investment, to understand which decisions to delegate, and to safeguard those areas where responsibility must remain with humans. In short, to shape it in a way that is entirely to our benefit and not merely futuristic.

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