Manufacturing August 2026 | Page 52

OPERATIONS

A ny manufacturer can run an AI pilot, but few can scale it globally across hundreds of thousands of different products. TE Connectivity produces and manages more than 500,000 unique SKUs, creating electrical connectors, sensors and passive electronic components. From designing the barrel of a contact to crimping or stitching pieces together, its operations are enormous and varied.

Jim Tobojka is the company’ s Senior Vice President of Global Operations across all of the business’ s segments and supply chain. Under his leadership, the business has streamlined its processes, reduced costs and improved standards, including a range of digital transformation and AI initiatives.
Jim discussed the reality of scaling AI, the maintenance these systems require and how the modern workforce is changing with Manufacturing Digital.
Q. WHAT DOES DIGITAL TRANSFORMATION MEAN TO TE CONNECTIVITY? HOW WOULD YOU DEFINE A SUCCESSFUL TRANSFORMATION?

» At TE, digital transformation is embedded into our daily operations and in our approach to problem solving. We have an AI-first mindset and use new technology alongside traditional tools to improve our quality and speed of delivery. This work is led by our AI Hub, which we founded in Singapore a few years ago. An important piece of what this group does is governance. Before AI use spreads in an uncontrolled manner, a company should set parameters around cybersecurity and data accuracy and integrity. Innovation is great, but it has to be done in a safe and controlled manner. Success is defined by scale and repeatability. It’ s not enough to find solutions to isolated use cases, because true transformation happens when a solution can be deployed consistently across multiple plants and product lines. Any organisation can run pilots, but what drives value is an organisation’ s ability to standardise and replicate successful pilot programs globally.

Q. HOW HAS THE CONTACT AI INSPECTION TOOL CHANGED YOUR MANUFACTURING?

» We have successfully deployed AI-driven inspection systems in several of our factories, which helped us raise the bar in quality control and deliver what our customers expect. The tool delivers full 360-degree inspection coverage and achieves approximately 99.9 % accuracy in identifying and scrapping defective parts. Near perfection.

Operationally, this innovation also shifted defect detection much earlier in the process. Instead of identifying issues downstream, which can be very costly, the system enables near realtime detection and, in some cases, even prevention. The result is reduced scrap, lower conversion cost and a measurable improvement in overall process stability.
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