whirlpool emea industry 4.0 athens public€¦ · whirlpool corporation -confidential smart factory...

Whirlpool Corporation - Confidential Smart Factory Conference 2019

Industry 4.0 transformation in Whirlpool EMEA

Pierluigi Petrali – Manufacturing R&D Manager


$11.7BSALES

26.000EMPLOYEES

NAR

$4.9 BSALES

22.000EMPLOYEES

EMEA

$3.4BSALES

24.000EMPLOYEES

LAR $1.5BSALES

20.000EMPLOYEES

ASIA

A GLOBAL COMPANY


A LEADERSHIP POSITION

WHIRLPOOL CORPORATION

72 million products sold in more

than 170 countries

in the world

World’s leadingmajor home appliance company (NYSE:WHR)

Approximately

$21 billion in sales in 2017

92 000 employees

70 manufacturing

and R&D centers

$1 billion investment in capital and R&D centers annually


OUR GLOBAL PORTFOLIO

*Whirlpool ownership of the Hotpoint brand in EMEA and Asia Pacific regions in not affiliated with the Hotpoint brand in the Americas

*


TODAY

EUROPE, MIDDLE EAST AND AFRICA (EMEA)

14 industrial sites

in 7 countries

Over 14 000 manufacturing jobs

22 000 employees $5 billion in annual sales

*in 2017


EMEA

MelanoItaly

Comunanza Italy

CassinettaItaly

SienaItaly

NaplesItaly

IsithebeSouth Africa

YateUK

WroclawPoland

ŁódźPoland

RadomskoPoland

Lipetsk Russia

Poprad Slovakia

ManisaTurkey

Carinaro Italy

INDUSTRIAL FOOTPRINT


WE SHIP AROUND 23 MILLION PRODUCTS IN 140 COUNTRIES

EMEA

DISHWASHERS DRYERS HOODS OVENS

REFRIGERATORS WASHING MACHINES WASHER/DRYER

v

AIRCONS

v

FREEZERS

v

SDA

v

HOBSFS COOKERS MICROWAVE OVENS

*in 2017


EMEA

BRANDS AND PRODUCT LEADERSHIP

Indesit Built-in Suite

Indesit Innex

Whirlpool SmartCook

Whirlpool SupremeCare

KitchenAid Black Steel Collection

KitchenAid Culinary Center


BRANDS AND PRODUCT LEADERSHIP

EMEA

Bauknecht WM 100 stainsHotpoint 3DZone wash Hotpoint Go Healthy range

Whirlpool Corporation - ConfidentialWhirlpool Corporation - ConfidentialWhirlpool Corporation - Confidential Smart Factory Conference 2019

Industry 4.0 in Whirlpool EMEA


Whirlpool EMEA Industry 4.0 TimelineConcepts of Industry4.0 and Smart Mnafacturing permeate to top management: SCM Invited at WHR Global Operations Commitee.

2013

2015 2016 2017World Manufacturing Forum in Milan consolidate I4.0 concepts in european industries

2013

GE Indutrial Internet of Things

Whirlpool go on the Cloud with complete Google based platfrom

EMEA Deployment Plan

2012

Germany Industrie 4.0 published

EU project FITMAN: Future Internet of Things forManufacturing

2014

SCM study presented at WFM2014

MFG 2020 Program Started

EMEA I4.0 Pilot in Poprad (SLO)

2018

EU project MAN-MADE: First Cooperative Robot experiment in Whirlpool EMEA

2015 2016

EU project PERFoRM: Concept of Middleware and Plug &produce inspire I4.0 Architecture

2017

Whirlpool EMEA in OsservatorioI4.0 Advisory Board


Main steps of I4.0 in Whirlpool

1. Inception2. Concept elaboration3. Strategy development4. Pilot5. Deployment and Governance6. Current Challenges


Concept Elaboration: enabling technologies deep dive

Big Data and Analytics

SimulationAugmented Reality

Automated Material Handling

Collaborative Robots

Additive Manufacturing

Agile Processes

Industrial Internet of Things

Cloud Computing

Traceability

Mobile Devices

Automated/Advanced Testing

Horizontal / Vertical Software Integration


NAR

EMEA

LAR

Asia

Focus:

● Identify key use cases for initial applications

● Leverage external successful implementations - don’t reinvent the wheel

● Push early implementations for lessons learned and improvements

Tactics:

● Upgrade the mfg network infrastructure

● Require all new equipment to be IIoT capable

● Aggressively pursue structured pilots and spread successful systems

rapidly

● Leverage equipment that promotes cohabitation of local and connected

networks on existing infrastructure

Enablers:

● Senior Leadership buy in and support

● Vision and strategy well defined

● Resources for initial applications

● Mobility of assets from site to site

Benefits (to be further defined):

● CapEx savings 10%-30%; Inventory reduction 15%-33%; Innovation

Increase 8%; Quality Improvement 13%-45%

● Increased supply chain flexibility and speed

● Connection of design & mfg

● Unknown connected benefits

2020 2025

Impact on Regions Critical Systems

ConnectedFully Connected Mfg

Plants

Challenges:

● Electronics are our competitor’s strength - Samsung & GE are already

working here. We need strong action to compete.

● Payback for small, piece applications is not always substantial

● Different systems across and between regions

● Joining GIS & Operations effectively

Technology deep dive (2016) : example


Strategy Development (2016)


Future Technology impact envision


EMEA I4.0 ROUTE MAP

● Global drive● Pilots implementation● Top Down approach

● Core areas identification● From use cases to 6

workstreams● Setting the basis for an

end to end integration● Governance start-up

2

3

PILOT DEPLOY EXTEND & DRIVE

Transformation

Disruptive technologies introductionSpecific skills internalization

Strategy workstreams

Skills and competencies diffusion. From “Manufacturing” 4.0 to

Industry 4.0

2016-2017 2018-2019 2020+

● Regional Drive● From deployment to roll

out● Full Value chain integration● Strategic partnership

1


I4.0 CORE AREAS IMPLEMENTATION

Supplier Scouting

● Contact/ evaluate/ engage suppliers

● Identify/ develop solutions

Trials

● Technologies try out in the factory

○ Assess technology solution applicability

○ Address process/ organization impact

Pilot

● First complete implementation in a factory narrow context

○ costs/benefits identification

○ process/ organization harmonization

Standardization

● After one/two completed pilot extensions

● Use case ready to be replicated (TO BE):

○ Standardized capabilities

○ Technical/ systems/ process/ organization requirements

Deployment

● Gap analysis for implementation identified in each factory:

○ Technical

○ Organizational

○ Operational

● Handover completed and Local/central competence available

● STD refinement

Rollout

● STD Solution ready for roll out

● Full roll out costs known

● Prioritization and implementation driven by factories

Technology Scouting

● Identify solutions according to knowledge intake process

○ R&D

○ Competence centers

○ Benchmarking

○ Trade shows

FactoryOE - Tech

Technical Readiness

Key Deliverables

First Pilot complete

Communication Events

OE - I4.0Main Accountabilities

Functional Readiness Cost/Organization Readiness

1


I4.0 TECHNOLOGIES MAJOR APPLICATIONS

CoreTechnological

Areas

Use Cases● Scouting: 81● Trial: 8● Pilot: 29● Deployment: 2

Augmented Reality

Human Centered

Automation

Data Visibility

Advanced Testing

Traceability

Training on critical workstations

Augmented Reality

Training on critical workstations

Virtual Reality

3D digitization for full line and equipment

Collaborative Automation

Cobots for panel screwing

Collaborative Automation

Mobile robots for material delivery

Visibility and Analytics

Cloud based KPI’s

Visibility and Analytics

Real Time Energy Management

Vision Systems

Smart Quality Control

Industrial Inspection

Drones for visual and thermal inspection

Real Time Location Systems

Forklifts and tuggers tracking

Tools at Suppliers Location

E Tooling. Remote performance monitoring

1


Challenge #1 Assess and measure progress

DREAMY

Different tools with different starting points/approaches/metrics - apparently complementary

Cassinetta RF* - Machines


Challenges #2 Change Management

• New Skills

• New Jobs

• New Organization Model

• New Business Processes

• Mindset transformation


Challenge #3 Innovation Engine

EU Research Projects

EMEA Mfg R&D + IT Innovation

EIT Manufacturing

Concepts

Core Areas

Technologies


Factory Automation Edge Computing Operating System Reference Implementation

H2020 Research and Innovation Action - This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement N. 723094

The project will research and provide a novel factory automation platform (operating system) based on an edgecomputing architecture and IoT/CPS technologies enabling a decentralized automation solutions for the factories of thefuture.

Allows Smart Factories to take advantage of EdgeComputing – i.e., having computing power in close proximity to where it is actually needed

Smart Machines

EnterpriseSystems

FactoryControl

CPSControl

Distributed Ledger Technology as a key enabler of:Decentralization of process control (orchestration)Decentralization of data analysis (aggregation)Real-to-digital synchronization (digital twins)

Advantages over centralized architectures:Flexibility / Modularity (plug-and-produce)Robustness / Resiliency (no single point of failure)Flexibility / Cost-effectiveness (elasticity with no cloud infrastructure)


WHR Use Case To-Be

24H2020 Research and Innovation Action - This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement N. 723094

• self-contained CPS composed by autonomous smart objects • CPS flexible to adapt to changing environment (factory upstream and needs of warehouse) and easily modified by operators.


Edge Nodes logic

25H2020 Research and Innovation Action - This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement N. 723094

Each bay provides its status:

• Availability to receive products

• Number and type of products in queue

• Recent unload performances

1

The conveyor provides its status:

• Number and type of products in queue

2

Blockchain Smart Contract:

• Elaborates status from bays and conveyor

• Fill-up the Bay Assignment List

3

The bay act:

• Read the Bay Assignment List

• Actuate the Bay selector

4

Whirlpool Corporation - Confidential

TIER 1 SUPPLY

BASE

TIER 1 SUPPLY

BASE

Raw materialRaw material

Change in Tier 2Change in Tier 2

Wrong InstructionsWrong Instructions

SPARE PART CENTERSPARE PART CENTER

Parts deliveryParts delivery

PREDICTION

TOOL

PREDICTION

TOOL

Prod. Orders Request

and wharehouse

management suggestion

Planning and

Quality suggestion

Warning alert,

training and

medium term planning

PRODUCTION FACTORYPRODUCTION FACTORY

WHR Use Case

H2020 Research and Innovation Action - This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement N. 780732

@WhirlpoolCorp #WhatMatters@WhirlpoolCorp #WhatMatters

Standardization and Reference Architecture

Cyber Physical System

Horizontal Integration through Value Network

End to End Digital Integration of Value Chain

Vertical Integration and Networked Manufacturing Systems

Managing Complex Systems

Broadband Infrastructure

Safety and Security

Work Organization and Design

Training and Development

Regulatory Framework

Resource Efficiency

The challenge’s challenge

There is more to Industrie 4.0 than its technical dimension.Industrie 4.0 means a paradigm shift in companies’ manufacturing strategies

Source: Think Act beyond Mainstream The Industrie 4.0 transition quantified - Roland Berger


@WhirlpoolCorp #WhatMattersLinkedInFacebookWhirlpoolCorp.com

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