Identifying key AI challenges in make-to-order manufacturing organisations: A multiple case study

Artificial Intelligence can make manufacturing organisations more effective and efficient, but it is not clear which AI tasks hold the greatest potential. Make-to-order manufacturers must constantly adapt to customers’ unique and rapidly changing needs, and therefore have different challenges than make-to-stock manufacturers. Our ambition is to develop an AI-enabled software system to support manufacturing organisations in improving their processes. To this end, we first seek to understand the data and technology requirements for key AI-enabled tasks in a make-to-order setting and determine the level of performance and explainability needed to address them. We perform a multiple case study of five make-to-order packaging manufacturers, interviewing personnel from sales, production, and supply chain to identify and prioritise operational challenges suitable for AI approaches. Demand forecasting emerges as the most important task, followed by predictive maintenance, quality inspection, complex decision risk estimation, and production planning. Participants emphasise the importance of explainable techniques to ensure trust in the systems. The results highlight a need for a greater control of the production process and a better understanding of customer needs. Although most of the tasks could be solved with current techniques, some, such as intermittent demand forecasting and complex decision risk estimation, would require further development. The study clarifies the potential of AI-enabled systems in make-to-order manufacturing and outlines the steps required to realise it.