connected factory digital solutions on the manufacturing floor · dawn of 4th industrial revolution...

Connected factoryDigital solutions on the manufacturing floor

The marriage of advanced manufacturing techniques with information technology, data, and analytics is driving another industrial revolution – one that enables manufacturing leaders to combine information technology and operations technology to create value in new and different ways.

Dawn of 4th industrial revolution

Optimise traditional objectives…

Late 18th century• Water and steam power• Mechanisation

Early 20th century• Mass production• Electricity

1970s – 2000s• Computing and automation• Internet

Industry 4.0• Digital development• Digital operations• Connected customer

...by better managing

Cost

Quality

Innovation

Safety

Service

Flexibility

Revenue

Visibility

Volume Velocity

Variability

01

Connected factory | Digital solutions on the manufacturing floor

Digital technologies have changed dramatically in recent years, driven largely by three key developments: lower computing costs, cheaper storage, and less costly bandwidth. This has accelerated the adoption of disruptive technologies.

Fuelled by technology and connectivity

Additive Manufacturing

AugmentedReality

Cognitive and AI

Blockchain

Automationand Robotics

Internet of Things

Cost

of P

erfo

rman

ce

1992 Today

…key disruptive technologies

Exponentially decreasing costs are accelerating the adoption of...

$1,245per Gbps

Bandwidth<$10

$569per GB

Storage<$0.01

$222per milliontransistors

Computing<$0.06

02


Embracing the power of these new technologies allows a traditional linear supply chain to become a set of dynamic and integrated networks: Digital Supply Networks.

Collapsing the supply chain

Traditional supply chain Digital Supply Networks (DSN)

Synchronisedplanning

Connectedcustomer

ConnectedfactoryConnectedfactory

Intelligentsupply

Intelligentsupply

Digitaldevelopment

Dynamicfulfillment

Digitalcore

Develop

Plan

Source

Make

Deliver

Support

03


Disruptive technologies can impact and transform the heart of manufacturing, creating the Connected factory.

Connected factory

InboundInventory

ShopFloor

ProcessTechnologies

& Methods

Quality

Assets &Maintenance

Environment, Health & Safety

Connectedfactory

OT

Secu

rity

Data A

cquisi

tion and

Contro

l Syste

ms

WearablesAugmentedReality

Data

Processing

Cognitive

Computing

and SimulationDigital Design

Visualis

ation

ManufacturingA

dditiveSe

curi

tyIT

Materials

Advanced

Robotics

Autonomous

04


A Connected factory has the ability to fundamentally change the production process to enable end-to-end product visibility and predictive analytics to support and optimise decision making.

Connected • Continuous pull of traditional datasets along with new sensor and location-based datasets

• Real-time data enabling collaboration with suppliers and customers

• Collaboration across departments (e.g. feedback from production to product development)

Optimised • Reliable, predictable production capacity • Increased asset uptime and production efficiency

• Highly automated production and material handling with minimal human interaction

• Minimised cost of quality and production

Transparent • Live metrics & tools to support rapid but effective decision-making

• Real-time linkages to customer demand forecasts

• Transparent customer order tracking

Proactive • Predictive anomaly identification and resolution (e.g. using augmented reality for maintenance)

• Automated restocking and replenishment

• Early identification of supplier quality issues • Real-time safety monitoring

Agile • Flexible and adaptable scheduling and changeovers • Implementation of product changes to see impact in real-time • Configurable factory layouts and equipment

05


The Connected factory can drive a broad range of benefits.

Value from the Connected factory

Manufacturing typical value drivers

Improved safety and sustainability

Reduced costImproved quality

Improved asset efficiency

Optimised capacity

Asset utilisation

Changeover time

Downtime

Scrap rates

Fill rate

Yield

Lead times

Labour cost

Sourcing cost

Inventory levels

Maintenance cost

Safety incidents

Employee satisfaction, health, and wellness

Sustainable practices

Environmental impact

Warranty cost

OEE (Overall Equipment Effectiveness)

06


Value creation can begin with, and scale from, a single asset to a complete factory or network of Connected factories.

Typical transformation journey for a manufacturer

Opp

ortu

nity

val

ue

Single asset Maximising the performance of a single asset (e.g. machinery, tools, inventory, equipment, people)

Production line Improving the performance of a series of dependent assets (i.e. production line or manufacturing cell)

FactoryOptimising the performance of an individual plant by better connecting and utilising assets

Factory network Maximise network performance by sharing capacity across sites in real time and connecting to the entire supply chain and product development cycle

07


To maximise value and reduce risk, successful manufacturers are adopting a number of techniques as they adopt Industry 4.0 concepts.

Applying this to your business

Multi-disciplinaryteams and ways

of working

Enablers

Think big Start Small & Act Fast Scale

Value focusand

prioritisationReusability

Talent andchange

management

Datamanagementand security

Set foundations

Scale pilots

Measure success and continue to prioritise

Select and implement pilots

Assess business value based on pilots

Identify opportunitiesand current challenges

Determine directionand roadmap

08


World-class centre for industry-focused research and development of technologies used in high-value manufacturing sectors

Global provider of leading IoT and AR platform, and field-proven solutions

Global leader in Digital Transformation with specific expertise in strategy and implementation of Industry 4.0 across multiple industries

The Connected factory immersive experience brings together leading organisations to support manufacturers on the topic of digital manufacturing transformation.

Partnership

09


Nick DavisUK Industry 4.0 Lead +44 (0)7798 924574 [email protected]

Ben MorganHead of Factory 2050+44 (0)1142 [email protected]

Paul HaimesVP Pre-Sales+44 (0)7768 [email protected]

Contacts

AMRC Factory 2050Europa Avenue Sheffield S9 1ZA (for Sat Nav please use S9 1XZ)

Download the PTC ThingWorx View app on your phone or tablet and point it to this ThingMark for further information.

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Notes

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Notes

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This publication has been written in general terms and we recommend that you obtain professional advice before acting or refraining from action on any of the contents of this publication. Deloitte LLP accepts no liability for any loss occasioned to any person acting or refraining from action as a result of any material in this publication.

Deloitte LLP is a limited liability partnership registered in England and Wales with registered number OC303675 and its registered office at 2 New Street Square, London EC4A 3BZ, United Kingdom.

Deloitte LLP is the United Kingdom affiliate of Deloitte NWE LLP, a member firm of Deloitte Touche Tohmatsu Limited, a UK private company limited by guarantee (“DTTL”). DTTL and each of its member firms are legally separate and independent entities. DTTL and Deloitte NWE LLP do not provide services to clients. Please see www.deloitte.com/about to learn more about our global network of member firms.

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Designed and produced by The Creative Studio at Deloitte, London. J12277

connected factory digital solutions on the manufacturing floor · dawn of 4th industrial revolution...

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