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 Boulevard Hofmanweg 5A, 2031 BH Rochester Hills, MI 48307, USA Haarlem, Netherlands The Independent Solution Provider for Smart Digital Transformation

ATS Global Business • 30 Years leadership in ATS Germany ATS Netherlands Smart Automation, Quality ATS Czech Republic ATS Canada and IT Excellence Solutions ATS Austria ATS UK • Double digit growth year on ATS Macedonia year ATS Ireland ATS China • 900+ people (>75% ATS Turkey ATS Belgium Consultants + Technical) ATS USA ATS Hong-Kong • 4000+ customers worldwide ATS Spain ATS Singapore • Selected by Gartner as ATS Italy ATS Mexico Global MES/MOM ATS Indonesia consulting provider with ATS India system integration services (2018 Gartner Market Guide for MES/MOM Implementation) ATS South Africa ATS Australia Supply Chain Smart Manufacturing Automation & IT MES / MOM PLM Quality Management Management Industry 4.0 The Independent Solution Provider for Smart Digital Transformation

Agenda How do we see Industry 4.0? Good, Bad and Ugly of it Practical steps to implement an I4.0 strategy An outlook on the factory of near future The Independent Solution Provider for Smart Digital Transformation

Industry 4.0: Strategy to Raise Maturity Digitalization Industry 4.0 How can an autonomous response be achieved? Self-Optimizing What will happen? What is Being Prepared Value happening? Understanding What happened Seeing Predictive Computerization Connectivity Visibility Transparency Capacity Adaptability FIR e. V. at RWTH Aachen University: Stages in the industrie 4.0 development path The Independent Solution Provider for Smart Digital Transformation

The Good 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) The Independent Solution Provider for Smart Digital Transformation

The Bad A lot of Buzz-wording Technology for technology? What’s the risk not to take that road? The Independent Solution Provider for Smart Digital Transformation

The Ugly Business Case can be extremely challenging New Technologies are still under finalization Need to complete the digitalization phase first It is a long journey… The Independent Solution Provider for Smart Digital Transformation

Need a Solid Strategy Cyber Physical Systems Business Technology Benefit Self-Organized Smart Factories Business Benefit Define the Ambition Business Individualization of People Excellence Benefit Mass Production Continuous Improvement Business Predictable Performance Benefit Virtual to Physical World Structure Planning & Control Standardized Processes Internet of Services Ad-Hoc Processes New Business Models Strategy Raising the Maturity Level Industry 4.0 Digital transformation is about business transformation „Most people overestimate what they can do in one year and underestimate what they can do in ten years .“ The Independent Solution Provider for Smart Digital Transformation

Manufacturing Technology Landscape Enable collaboration among the different systems Break data silos Enable and foster innovation Effectively collect data from OT and IT systems Reduce Total Cost of Ownership The Independent Solution Provider for Smart Digital Transformation

Bridging the IT/OT Gap Enable machine to machine and business to machine collaboration Acquire all the relevant data to create digital product and process representations – Digital ERP Threads PLM Create a secure environment for data exchange MES 01001001001010100010 Break data silos and unleash untapped potential Leverage on IT and OT investments already in place The Independent Solution Provider for Smart Digital Transformation

Process Visibility Collect, Calculate and Visualize KPIs 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 The Independent Solution Provider for Smart Digital Transformation

Process Transparency and Prediction Explore asset performance data to learn the cause of failure Calculate asset health scores and predict life spans Provide optimized maintenance recommendations to technicians Reduce maintenance costs and improve asset health and performance match existing defect image and flag product Solution powered by IBM Watson as defective The Independent Solution Provider for Smart Digital Transformation

Dynamic Planning and Scheduling Import production orders from ERP and create the optimal detailed schedule for the plant Predict effects of change in production and react in real time to lack of resources Support major decisions of production capacity: extend workforce, resource capacity and factories match existing defect Solution powered by Siemens Preactor image and flag product as defective The Independent Solution Provider for Smart Digital Transformation

Production Management Dispatch the jobs to the right work centers Show electronic work instructions to operators Deliver part programs and recipes to shop-floor machines If any, plug your MES system into the ecosystem The Independent Solution Provider for Smart Digital Transformation

Quality Management 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 The Independent Solution Provider for Smart Digital Transformation

Quality Management ATS Inspect, Visual Quality for Discrete Manufacturing Eliminate Paper Checklists Create a dynamic inspection process with the support of 3D models Improve Right First Time KPI and Prevent Defective Products from Leaving the Plant Minimize Costs of Rework and Scrap The Independent Solution Provider for Smart Digital Transformation

Quality Management Cognitive Visual Quality for the Discrete Manufacturing Real-time monitoring Employ cognitive and human expertise to attain the highest confidence levels of defect detection Images captured Increase consistency of defect detection and classification Machine Learning system Reduce Inspection cost and time while improving throughput Match Store existing defect image and Defects compared flag product as defective Solution powered by IBM Watson The Independent Solution Provider for Smart Digital Transformation

LIMS Laboratory Management for the Process Industry 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 The Independent Solution Provider for Smart Digital Transformation

Realize the Factory of the Future Planning and Scheduling Process Visibility Cognitive Quality Quality Management The Independent Solution Provider for Smart Digital Transformation Manage Production Laboratory Management Predictive Maintenance

What to do then? • Create a step-by-step business case reflected in your Digital Roadmap and focus on gradual measurable improvements • Leverage on IT and OT investments already in place • Complete the digitalization phase first , the 4 th Industrial Revolution can only come later • Start as soon as possible, it will be a long learning journey… The Independent Solution Provider for Smart Digital Transformation

Industry 4.0 Let’s start the journey Digitalization Industry 4.0 How can an autonomous response be achieved? Self-Optimizing What will happen? What is Being Prepared Value happening? Understanding What happened Seeing Predictive Computerization Connectivity Visibility Transparency Capacity Adaptability FIR e. V. at RWTH Aachen University: Stages in the industrie 4.0 development path The Independent Solution Provider for Smart Digital Transformation

Thank You Michele Sciuto ATS Global CCO http://www.ats-global.com mobile: +31 6 46764766 email: michele.sciuto@ats-global.com ATS Global Headquarters ATS North America A. Hofmanweg 5a, 2031 BH 1055 East South Boulevard Haarlem, The Netherlands Rochester Hills, MI 48307, USA The Independent Solution Provider for Smart Digital Transformation

Thank You Michele Sciuto CCO ATS Global B.V. A. Hofmanweg 5a Discover more NL-2031 BH Haarlem http://www.ats-global.com mobile: +31 6 46764766 email: michele.sciuto@ats-global.com The Independent Solution Provider for Smart Digital Transformation