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3. Digital and Green Machining and Forming

3.1 Generals on digitalization in Machining and Forming

The main reasons for the transition from traditional machining and forming to digital
manufacturing by these processes come from the increasing of the clients demands regarding
the products. The new products are required to be tailored, high-quality, cheaper and
environmentally friendly. And such demands are very fast increasing, covering large number of
sectors / industries / products. To achieve these new characteristics of the products, research
and innovation and development were performed in order to replace the traditional processes
and traditional equipment with digital ones. These will lead to a crossing between the real and
virtual worlds in an environment called the Internet of things (IoT). In such environment the
machining and forming equipment are connected to the services of supply, mean of transport
and the targeted products by using computers, sensors and actuators.
The main differences between the traditional manufacturing and a digital manufacturing are
presented in Fig. 3.1.

Traditional Digital

Mainly manual or mechanised processes Electronically controlled processes

Distinct managed processes Integrated managed processes

Quality of product depending on human Quality of product independent of human
factor → low quality factor → high quality

Limited innovation, interoperability, High innovation, interoperability,
flexibility and productivity flexibility and productivity
High costs related to operation, Low costs related to operation,
consumables, maintenance and health consumables, maintenance and health
and safety and safety

Fig. 3.1. Traditional vs digital manufacturing - characteristics

The reported statistics highlight the differences between traditional and digital manufacturing.
Details of key statistics to provide an overview are presented in Fig. 3.2.

Traditional Digital

Labor-Intensive: Traditional manufacturing processes often Improved Productivity: Digital manufacturing incorporates
rely heavily on manual labor and require significant human automation, data analytics, and AI, leading to higher
intervention productivity rates
Lower Productivity: Due to the manual nature of Real-Time Data: Digital manufacturing allows for real-time
operations, traditional manufacturing may have lower data collection, analysis, and monitoring, enabling
productivity rates compared to digital manufacturing proactive decision-making and process optimization
Longer Lead Times: The lack of real-time data and manual Reduced Lead Times: By streamlining processes and
processes can lead to longer lead times for production and utilizing real-time data, digital manufacturing can
delivery significantly reduce lead times and response times
Higher Error Rates: Human errors in traditional Enhanced Quality: The use of advanced technologies, such
manufacturing processes can result in higher defect rates as AI-based quality control, can lead to improved product
and quality issues quality and reduced defects

Fig. 3.2. Traditional vs digital manufacturing – effects in key statistics

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