visibility in manufacturing: the path to industry 4.0
DESCRIPTION
Industry 4.0 is the next Industrial Revolution. It involves integrating data from many kinds of sensors to gain the necessary visibility to predict issues and self-diagnose as problems occur. To some manufacturers, the coming age of cyber-physical systems is the inevitable next step. For most, however, these concepts feel quite distant from today’s reality where many plants have yet to adopt the automation technologies of Industry 3.0, and are decades away from mass adoption of Industry 4.0. While today Industry 4.0 is an aspiration, every company can benefit from greater visibility throughout the production process. This slide deck explores how the manufacturing plant is evolving from recording the past to controlling the present to predicting the future. What You'll Learn From this Presentation: -Where your company ranks among the four Industrial Revolutions -How to get to the next stage -How increased visibility can have a positive and resounding impact throughout the manufacturing process -What it takes to embrace Industry 4.0TRANSCRIPT
Visibility in Manufacturing: The Path to Industry 4.0
Hosted by Adrian Jennings, CTO - Americas, Ubisense
The Path to Industry 4.0
Adopting Industry 3.0
What the Survey
Revealed
What is Industry
4.0?Introduction
Webinar Agenda
Recovering
Rocket Scientist
Dot-Connector-in-Chief
at Ubisense
Expert in
Location Technology
Published
Photographer
Ex-pat Brit,
Living in Alabama
Dog
Lover
Adrian Jennings
What is Industry 4.0?
X
X
X
X
73%
19%
5%3%
½ – 1 hour
1 – 2 hours
3 – 4 hours
More than 4 hours
How many hours a day do you spend searching
for equipment and products?
13.9%
26.5%
43.7%
29.4%
0.0%
5.0%
10.0%
15.0%
20.0%
25.0%
30.0%
35.0%
40.0%
45.0%
50.0%
No visibility Visibility limited to plantAndon board
Visibility limited to personaloperational dashboard
Have access to instant real-time status of every product
How much visibility do you have into the real-time status of your
company’s manufacturing process? (select all that apply)
SOURCE: Gartner (August 2014)
73.4%To monitor current
performance against plan
68.7%To identify areas for
improvement
56.2%To identify problems
as they occur
40.3%To identify problems
before they occur
How is your company leveraging its visibility data?
(select all that apply)
4.9%
31.7%
82.1%
59.3%
16.3%
What data do you have to support process improvement initiatives?
(select all that apply)
My Team
Observations
My Personal
Observations
Independent
Analysis
Sensors that
Measure Process Flow
Other
Workers not adheringto designed process
33%51% 9% 7%
Inexperience of new line workers
Insufficient process time
Inability to tie qualityrecords to specific products
What is your biggest cause of quality issues?
An important milestone
is missing…
Introduction of
Mass Customization
Introduction of
Mass Production
VariabilityComplexity
Process Complexity Versus Process Variability
55%35%
8%
2%
Better worker training
Fault tolerant process design
More process time
Online repair
Where do you see the biggest opportunity
for decreasing the cost of quality?
0%
10%
20%
30%
40%
50%
60%
70%
80%
0-10% 11-20% 21-50% 51% and up
Now 5 years
What percentage of wireless tools are currently in your plant
and what percentage do you estimate in 5 years?
Measure Control React
Adopting Industry 3.0
Asset
Visibility
Process
Visibility
Error
Proofing
Reactive
Controls
Industry 3.0 Technologies
Asset Visibility
Process Visibility
Error Proofing
Reactive Controls
The Path to 4.0How do you get there from here?
Industry 3.0 Industry 4.0
Be Selfish
Start small and local: that’s the only way to quickly
justify, deploy, and prove visibility solutions.
Be Forward Thinking
Understand both your next step and your ultimate goal,
and invest in the right infrastructure from the outset.
Be Cooperative
Pay it forward: there are significant benefits when the entire
organization invests in visibility solutions.
Be Supportive
Guide other plants through the process to help the
organization prepare for the final step.
The Path to 4.0How do you get there from here?
Industry 3.0 Industry 4.0
Be Collaborative
Get a seat at the table, and trust them:
they really are here to help.
The Path to 4.0Layers of Value
DivisionProcess PlantDepartment Company
Industry 3.0 Industry 4.0
Don’t get lost in the hype Focus on Industry 3.0 and introduce tools that are already available
Questions?
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