How AI Is Driving Efficiency, Safety, and Sustainability in Manufacturing and Product Design

Organisations Leveraging AI for Operational Gains

Product manufacturing companies are increasingly applying artificial intelligence (AI) to enhance operations and service outcomes. These efforts focus on improving design quality, forecasting market trends, and boosting efficiency across the supply chain.

Amcor's AI Applications

Amcor, a global packaging manufacturer based in Switzerland, integrates AI to improve workplace safety, customer management, supply chain optimisation, and maintenance prediction. Serving sectors like healthcare and food and beverage, Amcor produces flexible and rigid packaging, including cartons, food containers, and PET bottles. The company operates in 140 markets, with manufacturing and office locations across Singapore, Thailand, and Indonesia.

Workplace safety is a priority due to the many moving parts on production floors. Amcor uses AI-powered computer vision and cameras to monitor potential risks, such as workers standing too close to machines or fire hazards. When detected, alerts are sent to prevent accidents. These systems initially deployed 2.5 years ago at plants with past incidents or strong safety cultures are planned to be expanded company-wide.

In cybersecurity, AI analyses about 2 billion logged events daily to identify unusual behaviour, such as network logins from unexpected locations. The system flags 10,000 to 15,000 notable events, with 5 to 10 requiring deeper investigation, enabling faster response times.

Amcor also explores AI in product design to reduce waste and support sustainability goals. Partnering with startup Greyparrot, which uses AI-powered waste analytics to optimise sorting at recycling plants, the company aims to increase recyclable waste recovery. Greyparrot’s system, deployed in 20 countries, detects billions of waste objects and maps waste flows to assess recyclability. This data informs improvements in packaging design and recycling processes.

Avnet's AI-Driven Product Design

Avnet, a US-based distributor offering manufacturing services including product design and engineering, uses AI to accelerate design cycles and deliver customised products. Operating globally with design centres across Asia-Pacific, Avnet leverages supplier and customer data to generate insights on past market trends and forecast demand more accurately.

These insights help Avnet and its customers plan product development and inventory management proactively. For example, AI identifies potential component shortages, enabling recommendations for alternative solutions. AI also streamlines adapting product designs to meet local market requirements, such as modifying electronics to comply with different power standards in regional markets.

Enhancing Quality Control with AI

AI accelerates product development by enabling exploration of alternative materials and improving quality testing. Similar to how AI supports pharmaceutical drug discovery, it helps packaging manufacturers develop materials that protect contents better and withstand environmental factors. Amcor is investigating AI applications to reduce the impact of climate conditions on packaging.

Quality control is critical in packaging, as defects can lead to product loss and brand damage. Amcor employs AI-powered computer vision to detect defects like misaligned seals or damaged packaging on fast-moving production lines. Internet of Things (IoT) sensors combined with AI-driven automation help identify machine anomalies and predict maintenance needs, reducing downtime and waste.

Research firm IDC forecasts that by 2026, 20% of industrial operations in Asia will use AI and machine learning in vision systems, robotics, and automation to improve efficiency, reduce downtime, and enhance safety. Additionally, 57% of Asia-Pacific organisations plan to invest in generative AI tools for operational data analysis. An Avnet study of over 1,200 engineers worldwide found that 42% are already integrating AI into product design, particularly in simulation, hardware design, and software code generation. Most respondents expect AI to increase automation and enable more personalised design.

AI enables modular product solutions, offering faster development paths. Avnet’s design centres allow customers to create products without owning manufacturing facilities, improving efficiency and speeding time to market, especially for smaller production volumes.

For product development professionals interested in expanding AI skills and knowledge, exploring targeted courses can be valuable. Resources like Complete AI Training's courses by job function offer practical training tailored to roles in product development and manufacturing.