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Top 15 use cases of RPA in Manufacturing

Updated: Jan 5, 2023

Manufacturing organisations are shifting their production units from human resources to physical industry robots to assemble, inspect, and ship their products. Even though these robots assist in the maintenance of the assembly line, manufacturing companies continue to struggle to manage their operational procedures and back-office tasks.

Manufacturing automation has attracted advanced developments in factories across a wide range of industries. Significantly, the industrial sector is witnessing error-free and streamlined procedures without completing full performance to provide the best products with the use of RPA.

Businesses are increasingly turning to robotic process automation (RPA) to perform repetitive and routine activities, despite the hurdles provided by a pandemic that shows no signs of slowing down. Thanks to robotic process automation, jobs that used to take days or weeks to accomplish can now be finished in minutes or hours.

The advantages of Business process automation use cases in the manufacturing business are assisting organizations in optimising costs, efficiency, accuracy, less wastage, increased focus, improving stakeholder productivity, adhering to compliance better, and building system agility.

According to industry data, the losses caused by these manual efforts are close to 30-40%. So, in addition to the production process, it is now time for the manufacturing industry to use RPA throughout all operations. They can achieve up to 40-50% cost savings in various areas of work by utilising Robotic Process Automation technologies in their back-end operations.

Why the Manufacturing Industry Requires RPA Bots

Manufacturing industries are under constant pressure to remain competitive in the global market and to do so, they must reduce costs while improving overall effectiveness, such as customer responsiveness, business-enhancing, transparency for both regulatory and commercial reasons, and business agility. Attaining these goals is dependent not only on core manufacturing activities but also on the correct top reasons.

As a result, manufacturers should implement innovative technologies such as RPA to improve the effectiveness and efficiency of their non-core actions, which influence gating limitations. With the increasing challenge of finding trained resources and expertise to support system enhancement and system maintenance, discovering additional productivity improvements and cost savings becomes increasingly compelling.

So, what are the ideal RPA Functional Areas and Use Cases in Manufacturing to understand?

To help you understand the processes, we've compiled a list of the Top 15 RPA Use Cases in the Manufacturing Industry. Look through each of the use cases listed below individually.

Top 15 RPA Use Cases in the Manufacturing Industry

Supply chain management & optimization

Invoice Processing

Invoice processing is critical to a manufacturing company's procure-to-pay (p2p) or source-to-pay (s2p) operations.

Invoice processing is difficult owing to invoices in various forms such as pdf, email, or pictures, reviewing relevant details such as bank information or supplier details, and data representation from many systems such as ERP, CRM, banks, suppliers, and so on. Companies that use manual processes waste time receiving, assigning, and approving bills. Invoice processing begins with the receipt of an invoice and finishes with the completion and recording of payment.

RPA (Robotic Process Automation) is a more efficient payment method. The above-mentioned invoice processing difficulty can be overcome by automating the entire process with RPA. Without any human intervention, all data will be updated in the appropriate systems. The method of collecting data from vendor invoice data, which are rule-based tasks, and sending it to the target system capturing invoices or matching invoices to accounts that run at configured intervals while sending a mail with the bills to be approved, is referred to as automation.

RPA bots can automate invoice processing by doing the following:

  • Using OCR to extract specific data from invoices

  • Creating a structured format from the extracted data

  • Invoices should be compared against purchase orders.

  • Check for duplicates.

  • Invoicing records in the ERP system are being updated.

Bill of materials (BOM)

A bill of materials (BOM), often known as a product structure, is one of the most important papers in the manufacturing industry. The Bill of Materials (BOM) contains a comprehensive inventory of raw materials, components, sub-components, and other goods required for the manufacturing of a new product. When it comes to the development of new products and commodities, employees rely heavily on information.

They must have specific instructions on what to buy and when to buy it, as well as the vendors/dealers that must be contacted for the transaction. This is the most challenging aspect of the production process. If an error occurs, the industry will suffer a large loss. Using RPA in this sector can allow businesses to develop products considerably faster, with higher data accuracy, and on time.

Inventory management

The failure to foresee and match supply and demand levels is one of the most common issues in the manufacturing supply chain. Inventory management is a time-consuming task in the manufacturing industry. Demand supply planning is done manually, which includes data collection, standardisation, cleansing, and running simulations using a tool. Inventory management is the auditing and tracking of assets and stock from manufacturing to the point of sale. Robotic Process Automation can automate emails, file invoices, dispatch activities, and digitise papers to automate inventory management successfully.

RPA-based automation offers inventory managers real-time data on inventory levels, allowing them to monitor them and make better decisions based on historical data. As a result, operational efficiency is improved, costs are reduced, and communication is improved.

RPA bots are capable of automating:

  • Keeping track of inventory levels

  • Making purchases and creating receipts

  • Delivery Tracking

  • Responding to quotations and enquiries via email, as well as gathering and updating inventory data

  • Making inventory reports and reporting to selected staff or people

Fulfilment of orders

Order fulfilment encompasses all processes that occur after a client's order is received until it is delivered. Bots can automate the entire order fulfilment process by:

  • Order emails and alerts must be identified.

  • Order required files are being downloaded.

  • Updating order fields and establishing an order in the ERP system after extracting required data.

  • Responding to clients with product availability and shipping alternatives.

Delivery confirmation

Proof of delivery (POD) documents are a sort of receipt that demonstrates that products or goods were delivered to the client. To track delivery, RPA bots can be connected with logistics ERP systems. If delivery data is identified, the bot will extract it, update delivery fields in the ERP module, and issue a delivery receipt internally or send an email to the customer or both.

Data automation in logistics

Every manufacturing company has a Logistics department, which supervises the transportation of finished items to customers. To provide increased services as quickly as possible, the transportation management system should be connected with RPA.

We can properly monitor product transit by integrating RPA Transport Management System. It will lessen the number of human errors. When a company has numerous carriers and insurances, the RPA will provide a report indicating which option provides better cost, insurance, and transit time, all while tracking freight in real-time.

Customer Success

Customer-facing operations are one of the most critical company’s overall functions in manufacturing firms. Customers nowadays expect prompt and precise service. RPA helps here too. Let's find out.

Customer Service and the Service Desk

Incompetent Customer Service Management with manual customer request processing results in tracking information mistakes and customer dissatisfaction due to delayed response/resolution times. Resolving client complaints necessitates navigating several company systems, which is time-consuming and labour-intensive.

To be able to assist them quickly and in real time, you must be able to access multiple company systems, which can be time-consuming. However, by using RPA to automate customer support, things can change radically.

Providing these is critical for gaining client loyalty and preventing them from switching products or brands. RPA will be used to send a reminder to employees who are following up with customers, to maintain the contact schedule, and to notify them if a client has complained.

The majority of customer service inquiries are repetitive, with multiple consumers experiencing the same issue and customer service needing to deliver the same remedy. Bots can do routine diagnostics and troubleshooting. By automating alert management, RPA speeds up collaboration automation and ChatOps in the customer care department. RPA in conjunction with AI can be used to map the customer journey and improve customer targeting.

Sales Order Integration

While relationship development and communication are important in sales, it is well-recognised that sales order integration does not end there. It entails a variety of tasks such as estimating, checking product availability, processing orders, managing logistics, and so on. Not to mention the coordination required among various departments as a result of these processes.

This is where automated work OCR (Optical Character Recognition) comes in handy. We can easily read the text and extract information from the Purchase order. The bot can assist in simulating the precise process of updating the data on the system, and now RPA can be used to update the details into ERP and create Sales Orders. Validation checks can also be used to determine whether or not an item is in stock. Triggers can also be used to generate an invoice when an order is ready for shipment.

IT Automation

Managing IT infrastructure and operations is a difficult task. RPA allows IT teams to gain improved visibility into IT infrastructure and operations, allowing them to manage IT resources strategically without necessitating a human procedure.

ERP Integration

The integration of RPA with ERP could be the next step in resource planning. Inventory, Accounts Payable and Receivable, Pricing, and other reports are automatically generated and can be sent through email or uploaded to a share point folder. In the inventory sector, the manufacturing industry can check current inventory and inform them when stock is running short. Then you can automate the reordering process. They can also automatically update the SKU on a massive scale.

Data Migration

The Internet of Things (IoT) is becoming an essential component of the manufacturing ecosystem. However, the difficulty originates from older systems' inability to share data with others in the industrial ecosystem. RPA comes to their aid in accomplishing this difficult and time-consuming task because bots may work independently of APIs.

RPA combines several applications by acting as a bridge between old and new systems, allowing for seamless data migration. What makes RPA so powerful is its capacity to detect and repair problems in real-time time result, it improved its service quality and client experience, which had previously been hampered by backlogs.

RPA with a web interface

A well-established enterprise may have many factories and locations. It may be more difficult to modify data in a specific system. A Manufacturing Industry can quickly monitor, access, and update any changes in web-connected systems while using RPA in this region. This minimises the amount of time it takes to communicate from one branch area to another.

Corporate Function

Compliance and Risk Management

In the manufacturing domain, safety measures are continually evolving. There are specific product restrictions to consider, plus a handful of compliance obligations to comply with. RPA alleviates the stress of regulatory compliance by guaranteeing that your manufacturing operation is audit-ready with precise data processing and detailed records.

All bot operations are constantly monitored and accessible via a centralised record. RPA also allows for rapid and easy process updates, ensuring that you are constantly in compliance with requirements.

RPA can provide proactively automated audits of business processes to industrial companies. Automated procedures can predict risk and notify stakeholders of potential concerns.

Payroll Management

Payroll processing is a time-consuming, repetitive task for any organization's HR team and necessitates a high volume of data input efforts. This might lead to data inaccuracies, which can lead to payment delays and employee unhappiness.

RPA can validate timesheets, load earnings, and deductions, as well as verify employee data consistency across several systems. It can also automate the creation of paychecks and the administration of benefits and reimbursements. To eliminate inconsistencies and delays, RPA may automate payroll-related processes from start to finish.

Human Resources Automation

Human Resources Automation

It is a difficult task to store and process HR information. It takes a long time and can be a difficult procedure. A successful organization can create massive amounts of personnel data, which can be challenging to filter and arrange. The RPA system can collect and arrange all of the information required by your HR department.

RPA can organise and store information such as employment history, payroll, reimbursements, and level of training. It can handle all your day-to-day chores, freeing your HR staff to focus on the human side of things. They can concentrate on increasing staff productivity and work culture, something automation cannot manage.

To survive and grow, any company must invest in technology, and understand its customers' needs, and market sentiment. There are numerous more benefits to robotic process automation depending on the industry.

Let’s wrap up

Robotic Process Automation is the next big thing in the manufacturing business. Manufacturing industries have now begun to deploy Manufacturing Automation with the assistance of RPA to eliminate human errors.

A manufacturing industry that wants to maximise its efficiency, management, and administration should probably consider implementing RPA in all functional areas. They may get a substantial 40 per cent cost savings in several task areas by utilising Robotic Process Automation technologies in their back-end operations. It could be any of the above-mentioned RPA Use Cases in Manufacturing.

Implementing RPA in various areas can result in major benefits such as:

  • Service line inefficiency can be eliminated by automation.

  • Getting items to where they need to go as quickly as possible

  • Lowering costs

  • Accelerating back-end finances

  • Adoption of new technologies on a larger scale

  • Increase your productivity.

  • Improve your employees', customers', and vendors' experiences.

if you have started your journey of Automation, it's time to think about how can you drive orchestrated automation across your enterprise. Hyperautomation plays an important role here. Read more about what is Hyperautomation.

Connect with us, get a free consultation on a hyperautomation orchestrated solution and also for your need to begin the automation journey. You can follow our LinkedIn page and our hashtag - #dxsolutionadvisor, on LinkedIn.

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