Good, Bad & Ugly of Industry 4.0 Understanding what is possible - - PowerPoint PPT Presentation
Good, Bad & Ugly of Industry 4.0 Understanding what is possible with Industry 4.0, today, tomorrow and in the future Michele Sciuto Chief Commercial Officer www.ats-global.com ATS North America ATS Global Headquarter 1055 East South
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Understanding what is possible with Industry 4.0, today, tomorrow and in the future
ATS Global Headquarter Hofmanweg 5A, 2031 BH Haarlem, Netherlands Michele Sciuto Chief Commercial Officer www.ats-global.com ATS North America 1055 East South Boulevard Rochester Hills, MI 48307, USA
The Independent Solution Provider for Smart Digital Transformation
Smart Automation, Quality and IT Excellence Solutions
year
Consultants + Technical)
Global MES/MOM consulting provider with system integration services
(2018 Gartner Market Guide for MES/MOM Implementation) ATS Canada ATS USA ATS Australia ATS UK ATS Spain ATS Belgium ATS Germany ATS Netherlands ATS Austria ATS Czech Republic ATS Mexico ATS South Africa ATS Singapore ATS Turkey ATS Italy ATS Ireland ATS China ATS Hong-Kong ATS India ATS Indonesia ATS Macedonia
Automation & IT MES / MOM PLM Quality Management Supply Chain Management Smart Manufacturing Industry 4.0
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Practical steps to implement an I4.0 strategy An outlook on the factory of near future How do we see Industry 4.0? Good, Bad and Ugly of it
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Computerization Connectivity Visibility Transparency Predictive Capacity Adaptability
Digitalization Industry 4.0 Value
Seeing Understanding Being Prepared Self-Optimizing
FIR e. V. at RWTH Aachen University: Stages in the industrie 4.0 development path
What happened What is happening? What will happen? How can an autonomous response be achieved?
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It is a Strategy, delivering strong financial benefit Triggers innovation and looking for new business opportunities Generate competition in the manufacturing market Industrial Standards are still very much valid (e.g. ISA-95, 88, 99)
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A lot of Buzz-wording Technology for technology? What’s the risk not to take that road?
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Business Case can be extremely challenging New Technologies are still under finalization Need to complete the digitalization phase first It is a long journey…
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Digital transformation is about business transformation
Define the Ambition Strategy Raising the Maturity Level Industry 4.0
Excellence
Ad-Hoc Planning & Control Standardized Processes Predictable Performance Continuous Improvement Business Benefit Processes Structure Technology People
New Business Models Internet of Services Virtual to Physical World Individualization of Mass Production Self-Organized Smart Factories Cyber Physical Systems
„Most people overestimate what they can do in one year and underestimate what they can do in ten years.“
Business Benefit Business Benefit Business Benefit
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Reduce Total Cost of Ownership Break data silos Effectively collect data from OT and IT systems Enable and foster innovation Enable collaboration among the different systems
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ERP MES PLM
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Leverage on IT and OT investments already in place Enable machine to machine and business to machine collaboration Acquire all the relevant data to create digital product and process representations – Digital Threads Create a secure environment for data exchange Break data silos and unleash untapped potential
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Use the ISO 22400 KPIs to find opportunities for improvement in manufacturing operations Process real time data stream to take decision when process or product deviations happen Make critical factory information accessible from anywhere and any devices Compare KPIs across multiple plants and find what make a certain plant successful Build and configure reports and dashboards to fit your business needs
Solution powered by Microsoft PowerBI
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Reduce maintenance costs and improve asset health and performance Explore asset performance data to learn the cause of failure Provide optimized maintenance recommendations to technicians Calculate asset health scores and predict life spans
match existing defect image and flag product as defective
Solution powered by IBM Watson
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Support major decisions of production capacity: extend workforce, resource capacity and factories Predict effects of change in production and react in real time to lack of resources
match existing defect image and flag product as defective
Solution powered by Siemens Preactor
Import production orders from ERP and create the optimal detailed schedule for the plant
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Show electronic work instructions to operators Dispatch the jobs to the right work centers Deliver part programs and recipes to shop-floor machines If any, plug your MES system into the ecosystem
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ATS CM4D - Dimensional Quality (Discrete Manufacturing)
Validate accuracy of supplied parts Create the Digital Twin and compare product to Original Design Predict Assembly Problems and avoid production issues
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Improve Right First Time KPI and Prevent Defective Products from Leaving the Plant Create a dynamic inspection process with the support of 3D models Eliminate Paper Checklists Minimize Costs of Rework and Scrap
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Employ cognitive and human expertise to attain the highest confidence levels of defect detection Reduce Inspection cost and time while improving throughput Increase consistency of defect detection and classification
Images captured Defects compared Real-time monitoring
existing defect image and flag product as defective
Store Machine Learning system Match
Solution powered by IBM Watson
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Improved lab efficiency through reduced administration, errors, scrap and rework Automatic data capture and centralized data consolidation for fast and easy quality data retrieval and reporting Full traceability of quality data resulting in improved regulatory compliance Improved lab efficiency through reduced administration, errors, scrap and rework
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Predictive Maintenance Planning and Scheduling
Cognitive Quality Quality Management Manage Production Process Visibility
Laboratory Management
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in your Digital Roadmap and focus on gradual measurable improvements
in place
Industrial Revolution can only come later
learning journey…
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Let’s start the journey
Computerization Connectivity Visibility Transparency Predictive Capacity Adaptability
Digitalization Industry 4.0 Value
Seeing Understanding Being Prepared Self-Optimizing
FIR e. V. at RWTH Aachen University: Stages in the industrie 4.0 development path
What happened What is happening? What will happen? How can an autonomous response be achieved?
The Independent Solution Provider for Smart Digital Transformation
ATS North America 1055 East South Boulevard Rochester Hills, MI 48307, USA
ATS Global CCO
http://www.ats-global.com mobile: +31 6 46764766 email: michele.sciuto@ats-global.com ATS Global Headquarters
Haarlem, The Netherlands
The Independent Solution Provider for Smart Digital Transformation
CCO
ATS Global B.V.
NL-2031 BH Haarlem http://www.ats-global.com mobile: +31 6 46764766 email: michele.sciuto@ats-global.com
Discover more
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Traditional Traditional Bronze Bronze Silver Silver
Maturity Model
Reactive... Reactive... Monitor... Monitor... Vision... Vision... Control... Control...
Inherited local operational rules base on local key performance metrics Making the hidden factory visible to enable informative decisions Taking control of manufacturing through standardisation World class flexible and responsive manufacturing
Us
Paper Based Solution Plant Scheduled Weekly Low Efficiencies Manual Reliance Push Philosophy Firefighting Mentality WIP Tracking Production Scheduling Manual Data Capture / OEE Electronic Work Instructions Visual Inspection Standard Accurate Reporting Quality Management Auto Data Capture / OEE Changeover Management Order Management Machine Connectivity Resource Compliance Advanced Production Scheduling Supply Chain Management Predictive Maintenance Inventory Management Product Lifecycle Management Industry 4.0
You
Gold Gold
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and LIMS)
tomorrow and in the future
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1. Strategy 2. Raise Maturity Level with gradual Benefit Realization 3. Implementations???
The Independent Solution Provider for Smart Digital Transformation
The Independent Solution Provider for Smart Digital Transformation
Problem
Need perfect robotic welding and painting processes with an automated self correction process
The Solution – ATS ADOS
Capture all the data generated, no matter the type or source Automated validation for the quality of welding and painting processes Enable manufacturing traceability for each component and validate vehicle variants at every gate
Business Case
2% improvement in overall quality of robotic operations 10% reduction in scrap rate due end-to-end traceability and root cause analysis
Checklist Points Automated Decision OK NG
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Problem
A carmaker knew that not all the defects found in the quality inspections made it to the reports due to lost paper sheets and informal communication. They wanted to go paperless, provide KPI reporting to the plant floor and send real-time alarms for critical issues to the production supervisors for immediate containment to increase their FTR%.
The Solution – ATS Inspect Business Case
Number of defects decreased 84% in 18 months at constant volume. Paper removed from the plant Real-Time Analysis
Inspection Points Rework Points
Ship / No Ship Decision
Sites: 10 | Countries: 5 | Inspection Points: 100+ | Benefit: Quality Improvement | Savings: Millions
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The Independent Solution Provider for Smart Digital Transformation
Problem
Easily integrate IT and OT layer Send work order information between machines on shop floor and MES platform. Track location of each part on the production line. Collect all data through the production process
The Solution – ATS Bus Business Case
Full process visibility and product traceability thanks to data contextualization All data are securely transferred Low TCO and ability to easily extend the architecture with new IT and OT components
Representative image
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Problem
Simplified, system driven, Planning & Scheduling process Ability to present various short-term schedule scenarios to the planning team(s) Obtain medium-term forecasts to support internal forecasting requirements
The Solution – APS integrated in the application landscape Business Case
25% reduction in customer complaints relating to deliveries. >5% yield improvement through optimised scheduling 10% increase in on-time deliveries Improved Forecasting Ability that enabled scenario planning
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The Independent Solution Provider for Smart Digital Transformation
Problem
Ensure production is in sequence, track vehicles and improve efficiency
The Solution – ATS Ignition Solution
instructions
production is in sequence to the main line.
controlled based on the production schedule
Business Case
Zero mistakes on production sequence, every vehicle is built according to the specs with no quality issues, world class OEE
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Problem Process innovation and built in quality with end-to-end traceability Mind-set shift, introducing excellent process with robust gatekeeper and “zero outflow” management The Solution – ATS ADOS (phase-wise rollout approach) Phase 1 – Trim & Chassis and Vehicle Quality Assurance (VQA) – Using ATS Inspect and ATS Bus Phase 2 to encompass all earlier manufacturing processes Phase 3 to encompass all variable production data stored within ATS CM4D Business Case Unified European QMS Major advances in data availability and process reporting Reduction in re-work and production errors due to end-to-end traceability
Global plants where solution is being used
The Independent Solution Provider for Smart Digital Transformation
Digital transformation is about business transformation
Define the Ambition Strategy Raising the Maturity Level Industry 4.0
Excellence
Ad-Hoc Planning & Control Standardized Processes Predictable Performance Continuous Improvement Business Benefit Processes Structure Technology People
New Business Models Internet of Services Virtual to Physical World Individualization of Mass Production Self-Organized Smart Factories Cyber Physical Systems
„Most people overestimate what they can do in one year and underestimate what they can do in ten years.“
Business Benefit Business Benefit Business Benefit
The Independent Solution Provider for Smart Digital Transformation
The Independent Solution Provider for Smart Digital Transformation
The Independent Solution Provider for Smart Digital Transformation
Awareness and Strategy Business Assessment Business Case Selection and Specification Implementation and Integration Support Packages Benefits Realization and Consulting WP1 WP2 WP3 WP4 WP5 WP6 WP7 A successfully proven process developed by ATS in delivering Manufacturing IT and OT solutions to customers Based on the ISA-95 standard model It comes with a defined set of deliverables It incorporates lessons learnt and best practices gained from ATS and other implementations It provides a guideline in implementing Manufacturing IT and OT solutions but it can be tailored to our customer needs
SUCCESSFULL STANDARD DEFINED EXPERIENCED FLEXIBLE
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On Time parts delivery Minimize Inventory Level
Trace delivery of external suppliers Quality of supplied parts
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Ensure visibility of work in Progress (WIP)
Improve efficiency and equipment availability Optimize production schedule and allocation of resources Ensure quality of produced parts Dispatch the right job to the right work center at the right time
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Minimize setup and change
Ensure quality of painted part Minimize consumption of utilities
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Synchronize sub-assemblies with the main line
Support customizations (MTO/CTO/ETO) Timely dispatch EWIs and recipes to the line Be ready for quality audits Trace direct and indirect material consumption
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Feedback to engineering any need of business improvement
Deliver a perfect product on time Minimize inventory of finished goods
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Validate accuracy of supplied parts Create the Digital Twin and compare product to Original Design Predict Assembly Problems and avoid production issues
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