The SAIMC Computer Engineering Council, also known as MESA Africa, recently held its annual summit. The two days were jam-packed, with an excellent balance between theory, thought leadership and practical case studies. The general consensus among the delegates was that the insights gained were incredibly valuable.
A total of 15 local and international guest speakers shared their thoughts and research on the manufacturing sector in South Africa and technology development globally. The user case studies were especially insightful in that they portrayed the practical aspects of the theories presented. The speaker lineup included presenters from big business and big technology, system integrators, and international guests. I decided not to try to summarise the two days according to speaker, but rather to paint my interpretation of the proceedings in broad strokes.
Several presentations covered mining and manufacturing technology, systems and data architecture, with a deep dive into The Open Group Architecture Framework (TOGAF), including standards and models for data architecture, modelling and analytics. One case study described a manufacturing operation’s management solution developed using a low-code development platform. The presenter explained how low-code platforms can be used to create new solutions and enhance existing solutions in a shorter time than when using traditional techniques, and with less technical software resources. In a country where we need to become more competitive globally, where we are losing valuable skills, and where we have numerous unemployed graduates, these low-code solutions can contribute not only to increasing manufacturing competitiveness, but also to helping software entrepreneurs and reducing unemployment.
In South Africa, we need scalable and affordable solutions that can be easily adapted to local conditions and have an impact at the society level. There is a lot of untapped potential in this country. For example, we have designed and developed products that are used globally every day − like the CAT scan, the Kreepy Krauly, the Speed Gun, Pratley Putty, and Q20. It may come as a surprise to some, but South African companies are contracted to design and build machinery and develop automation technology that is exported to first-world countries like Germany and the USA. We have no need to feel like observers on the world stage. In some instances, we are already ahead of the curve. We need to exploit and grow this ability.
As a country and continent we need more exposure, trust, and investment to tap into our full potential. We also need this in the right sectors. Exporting raw materials is not complex. Converting raw materials through various processes to produce a saleable product is complex. The more complex a process or supply chain, the more jobs are created. With our level of unemployment we need investment in more complex manufacturing and supply chain processes. Factors making this difficult are the lack of infrastructure (connectivity and power) and illiteracy. Without these basics, it is difficult to implement more complex manufacturing systems.
This, however, should not prevent companies from developing more complex supply chains and operations. If we do not, we are wasting resources such as skills, energy, water and food. If we can resolve our infrastructure issues, we can still develop complex smart factories, and with technology, even employ illiterate people to work in them. Combined with AI technology, vision systems and camera technology can guide people to execute tasks without extensive training or the ability to read or write. This will allow the efficient use of resources; we will have less waste, and we will be more sustainable.
Two different speakers phrased it differently. One said: “It should not be a project, it should be a lifestyle”. The other said: “It is not a diet, it is a lifestyle”. Both conveyed the message that we need to be introducing more complex processes through the intelligent application of technology in manufacturing, in order to move us toward a more sustainable future.
One fascinating presentation focused on recycling by low-income or unemployed people. Here the model of raw material and product is switched around. A product that is in demand is not designed and then the raw materials sourced to manufacture that product. Rather, where a raw material is found, then a product is developed based on that raw material in the hope that a demand can be created. If that specific material is not available the next day, another raw material is found and the process is restarted. Although often overlooked (or people avoid looking), this industry provides employment opportunities and develops entrepreneurial skills. The one thing impeding its growth is the lack and availability of real engineering skills. Most people in this industry need equipment to manufacture their products, but they have no access to engineers to assist them in the design, development and manufacturing of this equipment. They have excellent ideas, but they lack the ability to execute them.
A big theme in all the presentations was the need for collaboration between systems, companies and people to increase information sharing and reduce waste. To make companies, countries, and the world sustainable we need transparency and real-time information sharing. We need to break down data silos, and enable synergy and collaboration. This will involve consultants, big tech providers, cybersecurity, IT and automation − all working together to create and maintain the vision of digitalisation. In one presentation, global statistics on the convergence of IT and automation showed that:
• 25% of companies are in the early stages of digitalisation.
• 50% of companies have made medium progress.
• 25% of companies have already made significant progress.
This shows that it is happening now, it is driving innovation, and it is a common theme globally.
Some of the discussions explored the barriers to the adoption of technology on a larger scale, especially in South Africa. It was felt that the human barrier is the biggest one. People fear that technology will take away their jobs, especially at the middle-management level. This topic was also debated by a panel of experts, and the general consensus was that technology (AI in particular) will only replace some job tasks, but not the human. However, companies that do not adopt technology will most likely become unprofitable and die, while companies that do adopt and invest in technology will become more competitive and survive.
Another barrier to the adoption of technology is the disconnect between big technology companies and consulting giants with real-world issues. These corporates often lose touch with the needs of manufacturing, or believe they can easily use big technology to solve manufacturing requirements. In some cases, this may be partly true, but it requires almost the same amount of work as developing solutions from scratch. For small and medium enterprises specifically, this becomes impractical and unaffordable.
One of the reasons for this is that connecting IT to plant machinery is hard. IT and automation use different communication protocols, and their security requirements and priorities differ. Typical IT personnel are not familiar with plant automation environment architecture, and automation engineering teams are not always familiar with IT security requirements and architecture. This delays progress, as the priorities of these groups differ and misunderstanding is rife. We need to work towards educating and converging these groups within the manufacturing environment if we hope to ensure long-term sustainability.
Some of the sessions explored the use of AI in manufacturing, showing not only the benefits derived, but also the pitfalls that can be encountered during design and deployment of these solutions. One case study showed that a reasonably simple process had 2,4 trillion combinations of variables that could potentially influence the production of scrap. As a human, how do you sift through and test all of these? By applying AI, it was found that improving control for only 19 of the parameters would reduce scrap by around 10%. This shows that AI can be used to find hidden improvement opportunities, but also that it needs to be reliable and based on accurate data.
Another major learning point was that regardless of the industry, the requirements for enabling sustainability remain the same. Moving from management by spreadsheet to managing via digitalisation requires process understanding, digital architecture understanding, and establishing a foundation for data capture to bridge the gap between the current state and the digital future. Without reliable and accurate data, decision making cannot be data driven and objective, but will remain subjective and be based on assumptions rather than fact.
The SAIMC Computer Engineering Council explained why it is important for computer engineers to register with ECSA to ensure that they are operating within the legal framework of engineering, and showed what is being done to influence tertiary education institutions to develop fit-for-purpose skills for the market, specifically in the mining and manufacturing industries. This will go a long way toward ensuring that the brain drain is negated and new talent is developed.
The conference has reinforced my belief that as a country we have the skills and ability to ensure long-term sustainability, to reduce unemployment, and to contribute meaningfully to the world at large, even if we are losing valuable skills.
The MESA Africa Summit has been expanded and rebranded for 2025 as the SAIMC User Conference for Mining and Manufacturing Enterprises.
Gerhard Greef
Gerhard Greeff has qualifications in chemical engineering, production management and quality management. He has been involved in manufacturing since 1987 and with software development and integration in the manufacturing operations management (MOM) field since 1999. Gerhard believes that a properly designed and implemented MOM system will improve operational effectiveness and efficiency and can add tremendous business value for any manufacturing company.
For more information contact Gerhard Greeff, Implementation Manager, TransLution Software,
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