Unleashing the Potential of Industry 4 · Horizontal integration: Value added networks optimized in...
Transcript of Unleashing the Potential of Industry 4 · Horizontal integration: Value added networks optimized in...
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Unleashing the Potential of Industry 4.0
Ankur Goyal – Head of Business
Development (Industry 4.0)
Digital Enterprise value chain
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Digital
workplace
Digital
Engineering and
Manufacturing
Digital
Supply chain
Digital
Products, Services
and business
models
Digital
Customer and
channel
management
E-finance
Digital HR
Internal knowledge
sharing
Big data process
optimization
Predictive maintenance
Condition monitoring
Augmented reality
Integrated digital
engineering
Digital factory
Integrated planning and
execution
Logistics visibility
Procurement 4.0
Smart warehousing
Efficient spare parts
management
Autonomous and B2C
logistics
Prescriptive supply chain
analytics
Digitally enhanced
products
Intelligent and
connected products and
solutions
Automated and data-
based services
Digital business models
B2B2C customer
interaction
Digital customer
experience
Omni channel sales
integration
Omni channel marketing
Point-of-sale-driven
replenishment
Micro deliveries
Customer lifetime value
management
Technology, processes, organization
Digital Applications
Digital Enablers
Industry 4.0
Long road to Industry 4.0
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Industry 1.0 Industry 2.0 Industry 3.0 Industry 4.0 Digital Ecosystem
The invention of
mechanical production
powered by water and
steam started the first
industrial revolution
Mass production, with
machines powered by
electricity and
combustion engines
Introduction of assembly
lines
Electronics, IT, and
industrial robotics for
advanced automation of
production processes
Electronics and IT (such as
computers) and the Internet
constitute the beginning of
the information age
Digital supply chain
Smart manufacturing
Digital products, services,
and business models
Data analytics and action as
a core competency
Flexible and integrated value
chain networks
Virtualized processes
Virtualized customer interface
Industry collaboration as a key
value driver
1800 1900 1970s 2015+ 2030+
Today
Industry 4.0 Dimensions
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1
2
3
Horizontal integration: Value added networks optimized in real
time
Vertical integration: Business processes and technical
processes
Integrated life cycle management
Industry 4.0 Dimensions
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1
2
3
Horizontal integration: Value added networks optimized in real
time
Vertical integration: Business processes and technical
processes
Integrated life cycle management
Horizontal integration: Value added networks optimized in real time
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Integrated Planning and execution
Logistics Visibility
CustomerDistribution SiteProductionWarehouseSupplier
Procurement 4.0 Smart Warehousing Efficient spare parts management Autonomous and B2C Logistics
Prescriptive Supply Chain analytics
Smart supply chain enablers – Processes, Organisation, Skills, Performance Management, Partnering, Technology
External data
(eg. Weather,
social listening)
Industry 4.0 Dimensions
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Horizontal integration: Value added networks optimized in real
time
Vertical integration: Business processes and technical
processes
Integrated life cycle management
Vertical Integration - Shop Floor to Top Floor
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Technology stack level
Passive device level
Virtual marketplace2
Third party data
Enterprise level ERP system and PLM applications
Workcenter level
Supply chain applications, Asset
performance applications, process
control applications/MES, Big data &
advanced analytics applications
Software
-
Control device level
Device, machine & station control,
Big data & advanced analytics applica-
tions, HMI software, SCADA, Soft PLC
HMI, PLC, motion
controllers,
Field device level Field device applications
I/O (sensors, actuators),
drives, intelligent
mechanics, switches
Assembly lines
Mechanics, IMS
Hardware
"Connec-
ted World"
Integrated offerings
Ma
ch
inery
, s
ys
tem
s,
serv
ice
s
Au
tom
ati
on
so
luti
on
s a
nd
serv
ice
s
SW
/IT
in
teg
rati
on
EP
C1
Co
ntr
act
ma
nu
factu
rin
g
Secu
rity
off
eri
ng
s
Mo
du
le/s
ys
tem
1 Engineering – Procurement – Construction 2 Marketplace in the cloud to sell and distribute “industrial apps”
Intra-logisticsOperationsUpstream
logisticsDownstream
logistics
Demand
ManagementService
Management
Value Driven Smart Manufacturing
Industry 4.0 Dimensions
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1
2
3
Horizontal integration: Value added networks optimized in real
time
Vertical integration: Business processes and technical
processes
Integrated life cycle management
Integrated Lifecycle Management
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Value Driven Smart Manufacturing
Product Development Process
Manufacturing After Sales
Production
PlanningDesign
(func. & phys.)
Plant
Automation
Production
Execution
Maintenance
and Service
Quality and
Enhancements
Digital Twin of Product Digital Twin of Process Digital Twin of Performance
Integrated Data Model
Industry 4.0 design principles
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Modularity
Interoperability
Decentralization
Virtualization
Service
Orientation
Ability of multiple systems with different hardware and software platforms, data structures, and
interfaces to exchange data with minimal loss of content and functionality
CPS and CPPS will take decisions on their own and autonomously without violating organisation goal.
Processes will adapt to individual product demands enabling custom products
Concept of digital twin in product design, engineering, production and lifecycle management enabling
proactive decision making
Factory based on Service-oriented Architecture renders manufacturing services to customers via IoS
Real time
CapabilityData collection and analysis performed in real time. Ability of the system to respond to changes,
such as changes in customer requirements or the status of the internal production system
Capability of system to be separated and combined easily on plug-and-play basis.
Modular systems are inherently scalable, allowing them to react to rapid changes in demand without
abandoning the initial investment
Industry 4.0 refers to convergence and application of nine digital industrial technologies
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Source : BCG
Industry 4.0 complements actions of Lean implementation
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Lean Tools
Kaizen (PDCA)
TPM
Standardization
Forms of waste
5S
TQM
Kanban
(JIT/Pull)
Takt Time
Value stream
mapping
Smoothing
Andon
Poke-Yoke
SMED
Real Time
capability
Decentralization
Modularity
Interoperability
Service
Orientation(SoA
and IoS)
Virtualization
I4.0 Design principles
Listening to
client
Anticipating
client’s
needs
Lean
Industry 4.0
Focussing
on value
adding
activities
Focussing
on value
adding
information
Make the
product flow
(Takt-time)
Make the
data flow
(Real-time)
Pull
Production
Pull
everything:
Production
and services
*Manufacturing as a service
MaaS*
Identifying
product
Identifying
processFactory
layout
Appropriate
strategy
Striving for
perfection
Continuous
Improvemen
t (Kaizen)
High Morale
Comprehensive framework for Industry 4.0 adoption
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Advanced Robotic
Additive Manufacturing
Augmented Reality
Simulation
Vertical/ Horizontal
Integration
Industrial Internet
Cloud computing
Cyber security
Big Data and Analytics
Industry 4.0 Design Principles
(Real time, Modularity, Interoperability, Decentralization, Virtualization, Service Orientation)
Kaizen (PDCA)
TPM
Standardization
Forms of waste
5S
TQM
Kanban (JIT/Pull)
Takt Time
Value stream
mapping
Smoothing
Andon
Poke-Yoke
SMED
Predictive Maintenance
VR based training
RFID based WIP
tracking
OEE Monitoring
Dynamic production
scheduling
Early warning system
Digital supply chain
Intelligent supermarkets
Digital Maintenance
management
1) Anticipating client needs
2) Focussing on value adding
information and activities
3) Make the data
and product
flow
4) Pull production
and services
5) Strive for
perfection
Best and Traceable
Quality
Low Cost
Flexible lead time
Best safety
Industry 4.0 tech enablers Lean Tools Industry 4.0 enabled lean cycle Lean and Digital Enterprise
7 dimensions of EHS 4.0 framework
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EHS 4.0
framework
Strategic | Opportunity to further elevate the business value of EHS
management
Systematic | Process standardization, harmonized systems, and
advanced analytics
Risk-based | Proactive processes for managing safety and
environmental risks, to predict and prevent adverse business impacts
Connected | Collaboration and communication to break down cross-
functional silos and provides process integration and decision-support
information from "shop floor to top floor“
Smart | Data-driven decision-making includes a sufficient volume of the
right types of data, and the application of advanced analytics technology
to extract actionable insights
Agile | Ability to successfully adapt to internal and external change, and
requires enterprise scalability and the capability to quickly create and
deploy new applications
Engaged | Motivated workforce collaborating to achieve organizational
objectives based on effective competency management and an
organizational culture of operational excellence
Integration of people, processes and technology
Environment, Health and Safety – Technology Enablers
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Connected Worker – Smart Risk Management
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AR/VR enabling Digital Transformation in Enterprise
AR/VR Solutions for Enterprise
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Training Solutions Maintenance & Repair
Virtual Reality : Operator Training made simple
Augmented Reality: Explains complex
components in a realistic and simple manner.
DIY Training Platform & Authoring Tool
Maintenance Service Manual
Maintenance & Repair
Dial an Expert – Step by step guidance from an
expert to fix a complex machinery
Improves Retention &
Recall
Assessment Module to
measure the performance
Dial an Expert with
annotations for easy
understanding
Easy Maintenance functions
with step by step guide
AR/VR Solutions for Enterprise
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Immersive Virtual Reality powered hands on learning
VR platforms enabled high fidelity immersion into Virtual worlds.
Customer Benefits
Hands on experience (similar to a real
world)
No need to halt the production line
No need to tamper process for
Troubleshooting
Expert dependency is reduced
AR/VR Solutions for Enterprise
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Augmented Reality powered training tool
At Bosch we use AR powered training tool to train engineers on latest technologies
Customer Benefits
Self learning Apps on Consumer smart phones
Dependency on expert reduced
24/7 Availability
Consistent training across the organization
AR/VR Solutions for Enterprise
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Key Challenges for Maintenance & Repair
Expert Cost
Machine
Downtime
Effective
Maintenance
High
Travelling cost
of Experts
Downtime of
Machinery
impacting
production
Skilled experts
not available for
efficient
maintenance
AR/VR Solutions for Enterprise
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AR powered Dial an Expert (Mobile-Mobile Standard Solution)
AR powered training tool to train engineers on latest technologies
Customer Benefits
Affordable solution
Mass market
No special devices required
Annotations for easy understanding
Dial an Expert
Case Study #2: I4.0 in a box for SME segment
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Machine and Production Analytics
Bosch Energy
Signature Analyzer
Bosch Mechanical
Signature Analyzer
Backup
Generator
Asset-lite model (Pay-per use)
Retrofit and non-intrusive
Rapid deployment (1-2 weeks)Grid
Bosch Machine
Controller Analyzer
GS
M/G
PR
S
GS
M/G
PR
S
GS
M/G
PR
S
Key Features
Machine OEE & Industry Benchmarks
Production Part OEE
Productivity Improvement Analytics
Machine Capacity Utilization
Production and Capacity planning
Bosch
Energy
Analytics
Active
Time
Power
On/OffMachine
Productivity
Power Quality
ConsumptionProduction
Count
MTBF /
MTTF
Machine OEE
Dashboard and Analytics
Bosch India Journey
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I4.0 movement in India
9 Legal Entities
18 Manufacturing Plants
30,500 employees
>4000 Sales outlets
>1500 suppliers
Digital Immersion:
Build ‘Digital Culture’
– skill building for new
age
Reimagine CIP &
Lean processes for
digital world
Closer to consumer:
Let’s build B2B2C
mind set
I40 Solutions
contextualized to
India
Long-term vision and
roadmap
Building
infrastructure & Data
strategy for future
Business outcome
led use-case
implementation
Agile execution
Bosch in IndiaI40 for India: Key building blocks
Building a ‘Digital Culture’
‘Hyper-Local’
solutions
Long-term vision &
Agile execution
Fostering Eco-
system
Collaboration with
CII for I40 academy
Affordable solutions
for SME
Start-up
engagement
program (DNA)
Bosch Connected Industry
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Nexeed Portfolio
Nexeed Open IntegrationHarmonization solution of different software systems and applications for production and logistics.
Integration of Bosch Connected Industry solutions, Bosch solutions and third-party solutions.
Nexeed Connected Manufacturing Nexeed Connected Logistics
Nexeed
Manufacturing
Execution Nexeed
Manufacturing
Transparency Kit
Nexeed
Automation
Nexeed
Production
Performance
Manager
Nexeed
Remote Shopfloor
Access
Nexeed
Data Analytics
Nexeed
Device Portal
Nexeed
Track & Trace
Nexeed
Intralogistics ExecutionNexeed
Maintenance
Support System
LET`S SHAPE THE FUTURE WITH INDUSTRY 4.0
LET`S SHAPE THE FUTURE WITH INDUSTRY 4.0