180824-industry 4.0-iwf2018 v03 · 2018-08-22 · industry 4.0 also called "industrial...

IWF2018 8/24/2018

Industry 4.0 1

Industry 4.0 Industry status and examples IWF2018 – Session MFG 1

© 2018 White Rocks

Presenters

Bio

•  Urs Buehlmann – Virginia Tech

•  Mathias Schmitt – White Rocks

•  Matthew Bumgardner – US Forest Service

•  Dan Gibbons – Haworth, Inc. •  Georg Frey – Lignum Consulting,

Inc. •  Peter Tuenker, IMA Schelling

Group, USA •  Joerg Rosemeier, IMA Schelling

Group, USA

© 2018 White Rocks

Agenda

Agenda

Introduction 5 minutes

Definition 5 minutes

Recent advancements 5 minutes

The vision of an Industry 4.0 company 10 minutes

The 7 key elements 20 minutes

Applications – how it can be done 15 minutes

What does it take to make it happen? 15 minutes

Key points 5 minutes

Q&A 10 minutes

© 2018 White Rocks

Housekeeping

•  Turn off cell phones and e-devices

•  Let us know about any problems/needs

•  Speak up

•  Copies of the presentations at: http://woodproducts.sbio.vt.edu/resources/

•  or, alternatively, at the MYS Show Planner

Housekeeping

Introduction

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Industry 4.0 promises

•  improved customer interaction

•  enhanced customer services

•  more customized products

•  reduced through-put times

•  reduced costs

•  enhanced efficiency/productivity

•  energy efficiency

Industry 4.0

Industry 4.0 also called "Industrial Internet of Things (IIOT)"

Introduction

IWF2018 8/24/2018

Industry 4.0 2

Nine years of studies in collaboration with Virginia Tech, the U.S. Forest Service, and Woodworking Network/FDMC

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2010 50

2011 38

2012 31

2013 25

2014 21

2015 20

2016 20

2017 19

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© 2018 White Rocks

Over the last 3 years, have you increased use of computerization in:

•  Collaborating with customers

•  Design

•  Manufacturing processes

•  Accounting

•  Inventory tracking

•  Supply chain management

Recent Woodworking Industry Survey

"A majority of firms increased computerization"

Introduction

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Definition

IWF2018 8/24/2018

Industry 4.0 3

© 2018 White Rocks

Industrial revolutions

We are at the threshold of the 4th industrial revolution.

Definition

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Deming's 14 points

Lean Production

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Scientific management (Taylor)

Buyer's market

First standardized processes in ship construction in Venice

Assembly line (Ford)

Quality control (Radford)

Standardization of work (Taylor)

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Mechanical loom (Jacquard)

Toyota Production System (TPS)

Steam engine (Watt)

Programmable logic controller (PLC) (Morley)

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Industry 4.0

Large scale outsourcing

© 2018 White Rocks

Industry 4.0 will:

•  bring change at a speed, scale, and force never seen before

•  affect the very essence of our human experience

•  allow system-wide, radical innovation

•  create realities previously unthinkable

The vision

"Industry 4.0... will improve the state of the world... (www.wef.ch/4ir)"

Definition

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•  Big data and analytics

•  Autonomous robots

•  Simulation

•  System integration

•  The internet of things

•  The cloud

•  Additive manufacturing

•  Augmented reality

The pillars

Industry 4.0 – the digitization of the entire value chain

Definition

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Recent Advancements

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Considerable advancements in:

•  Computing power

•  Networking power

•  Artificial Intelligence (AI)

•  Vision capabilities

•  Communications

Recent Advancements

"We stand on the brink of a technological revolution... (Schwab 2016)"

Recent Advancements

© 2018 White Rocks

Artificial Intelligence and Vision

Artificial Intelligence and Vision are seen as game changer …

Recent Advancements

IWF2018 8/24/2018

Industry 4.0 4

© 2018 White Rocks

Operations example of vision systems

Vision and AI have changed product quality expectations …

Recent Advancements

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Example of AI and Vision in action

Detection, learning, and decision making … abnormalities

Recent Advancements

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The Vision

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•  Customer-centric

•  More versatility, optimum resource efficiency, and unlimited personalization

•  Connected production through entire value chain

•  Global connectivity

•  Simulation of entire process

•  Zero errors from first part

One vision for manufacturing

"... No two cars will ever be alike again... (Bosch 2016)"

The vision

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Processes - past

Forest Products Industry

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Processes - present


IWF2018 8/24/2018

Industry 4.0 5

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Processes - future


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The 7 key elements to Industry 4.0

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Summary

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Industry 4.0:

•  customer centric

•  smart factories

•  resource efficient

•  connectivity throughout entire value chain

•  error-free production from the first to the last part

Key Points

"Industry 4.0 encompasses end-to-end digitization... (PwC 2018)"

Summary

© 2018 White Rocks

• All speakers and companies making this session possible

•  IWF for providing the opportunity

•  Jessica Kirn for organizing this session

• Students from Pittsburg State University for managing this session

Acknowledgements

Summary

Thank you for attending this session!

© 2018 White Rocks

Sources

Sources

Slide Housekeeping: http://hardcore-christian.com/manhood-challenges/understanding-your-calling/ Slide Industry 4.0: http://www.xorlogics.com/2017/12/04/industry-4-0-challenges-and-solutions-for-the-digitaltransformation-and-inegration-of-

mobilesolutions/ Slide Recent Survey: https://www.woodworkingnetwork.com/management/housing-markets-impact-woodworking-excusive-study Slide The Vision: http://www.nydailynews.com/news/world/watch-japanese-store-robot-greet-customers-article-1.2192946 Slide Recent Advancements: https://londonlovesbusiness.com/majority-of-brits-welcome-driverless-cars/#prettyPhoto

https://www.weforum.org/agenda/2016/01/the-fourth-industrial-revolution-what-it-means-and-how-to-respond/ Slide One View: https://www.youtube.com/watch?v=ISk64bJ35yM, http://www.bosch.de/de/de/startpage_1/country-landingpage.php Key Points: https://richtopia.com/wp-content/uploads/2017/05/industry-4-0-fourth-industrial-revolution.jpg

https://www.strategyand.pwc.com/industry4-0 Acknowledgements: https://shoppersmallbrandon.com/store-specials/customer-appreciation-day/

IWF2018 8/24/2018

Industry 4.0 1

discover opportunities!

The 7 key elements to industry 4.0 Industry 4.0 - Industry status and examples

Date: !"#"$%&'(%)*&'+,-& by: Georg Frey


Lignum Consulting – a short introduction Consulting, Planning and Organization for the International Wood and Furniture Industry

Who we are

!  We are an independent engineering office, working industry-specific for the international wood and furniture industry.

!  We focus on the technical, organizational and operational consulting of our clients.

!  We create value for wood and panel processing companies, by transforming and aligning business processes. We work hands-on, from concept to project realization.

!  Our team of innovators has extensive industry knowledge and experience required for successful project implementation.

!  A typical profile of our consultants includes an apprenticeship in cabinetmaking, an engineering degree in wood and panel processing, a degree in business and extensive work experience throughout all levels of an organization.

!  Founded in 2003, today we employ a team of 30 in our offices in Kupferzell (Germany), Cary, NC (USA) and Sao Bento do Sul, (Brazil).

"  The leading experts for the wood- and panel processing industry

Introduction of Lignum Consulting

Examples of our work

!  Strategic development of organizations

!  Plant planning and re-organization.

!  Layout and work place design in alignment with the manufacturing-organization concept.

!  Machine specifications and implementation / run-off support

!  Design of process and information flows

!  Introduction of lean production principles, resulting in material flow acceleration, lead time reduction and inventory reduction.

!  Development and implementation of performance measurement systems for controlling and production support.

!  Product value engineering and product variations management.

Introduction of Lignum Consulting


The 7 key elements to industry 4.0


Connected Factory

big data

Digitalization Internet of Things

smart products cloud computing

Data Integration Advanced manufacturing

Industry 4.0

Factory of the future

IWF2018 8/24/2018

Industry 4.0 2

Why - „Connected Factory“? The 7 key elements to industry 4.0

…to manufacture more customized, more

flexible, faster and more reliable…

…to continuously enhance the entire process chain

…from order configuration at the POS &

Order Processing, to Production, to Assembly and Installation…

The 7 key Elements to the connected factory The 7 key elements to industry 4.0


How does your company rate on the 7 Key elements? Are you ready for industry 4.0?

The process The 7 key elements to industry 4.0

!  We will walk together through the 7 key elements of the connected factory. #  Meanings, questions and examples

!  Based on examples you can rate your company in each topic. #  Use your own judgment (the idea is to generate potential

for discussion & improvements)

!  Mark your rating on the form #  Center – poor to Outside – excellent

!  Connect the marks with a straight line #  This will help to visualize your profile

!  Write down your company name, industry and contact #  Or if you like do it anonymously

!  Write down your key topics/issues #  Where do you see the biggest need for improvement.

!  Take the original document with you – for discussions with your team.

The process - create your company profile The 7 key elements to industry 4.0

x

x

x

x

x

x

x

ACME Custom Kitchens 100 Employees

Strategy The 7 key elements to industry 4.0

Key Questions: Is your company strategy aligned towards the connected factory?

!  Are the investments and projects in alignment with the requirements for the targeted key competencies. Which processes will the company focus on and strategically develop/invest in (automate)?

!  Are integrated processes to strategic network partners in place?

!  Is the goal to become more automated/integrated a clearly defined company target – communicated to all employees.

!  Is capital planning not only done for machinery investments, but also for investments in training, organization/processes and systems?

!  Is the company willing to invest in automation and systems, even if longer payback times are required?

!  Is the company willing to invest in people who can take company to the next level?

x

IWF2018 8/24/2018

Industry 4.0 3

Product The 7 key elements to industry 4.0

Key Questions: Is your product offering in alignment with your market needs and internal capabilities?

!  Are standardized construction principles in place to allow fast product/project development in place w/o “re-inventing the wheel” all the time. #  Pick and choose from standard construction principles that give the impression of custom product.

!  Is your “casework” product construction rule based and can be handled by product configurators? #  No manual intervention required to generate product data.

!  Is your product designed to fit more automated manufacturing processes? #  Avoid “additional”/”manual” processing outside the defined processes/

manufacturing capabilities of the main processes. "  E.g. utilization of defined reveals vs. flush-mount case construction

!  Do product platforms get used to generate variants and keep the internal stock at a min. and simplify order processes.

X

x

x

Organization The 7 key elements to industry 4.0

Key Questions: Is your organizational model defined and can be used to drive integrated processes.

!  Are the roles and responsibilities clearly defined? #  E.g. programming done in the office – not at the machine | all machining is done prior to assembly

!  Do you have defined and documented processes for the main business functions. #  E.g. production (defined routings for all parts), defined organizational loops for part families or

processes, such as re-work. Or do you rely on tribal knowledge to process orders?

!  Do your production information fully support and align the manufacturing processes? #  Do operators have to modify or enhance provided information to get to the information they really

need? #  Are parts identified by bar-code or RFID, or do operators need to identify parts on “shop-

drawings”?

!  Do you have scheduling rules in place? #  Does the system provide a sequence for the operators or are people choosing their own priorities?

!  Do you have functioning continuous improvement process in place? #  5S, preventive maintenance, quality systems, tool management, etc.

x

x

x

Organization - Example: Defined processes and information flows The 7 key elements to industry 4.0

Technology The 7 key elements to industry 4.0

Key concept:

…Develop the ideal level (not necessarily highest possible level) of integration of the main equipment based on the process requirements.

!  Is the equipment ready to be data-driven/ integrated? #  Or is the equipment more standalone, depending on operator input?

!  Is there an automation/integration strategy in place (growth plan in steps)? #  “Growing into automation”. Building in “manual processes” that will be automated over time as

the organization learns to deal with automation.

!  Are the supporting functions in place to run the automated equipment on high performance? #  Pro-active Maintenance management; On-line support from machine suppliers; Engineering

support; Tool and materials management; Data support.

!  Is technology/data used to guide operators? #  Use of laser positioning of hardware vs. jigs and fixtures?

x

x

x

x

Fully integrated processes – for mass custom product The 7 key elements to industry 4.0

Source: 3tec

!  Example for automation in the industry

!  Fully integrated material handling

Automated production islands for flexible production needs The 7 key elements to industry 4.0

!  Examples for automation custom shops

!  MES driven for synchronized production flow (same data drives all processes)

!  Material handling with flexible carts

Central control (MES functionality)

Integrated board storage / Saw / Nesting

CNC Drilling/routing/doweling

CNC controlled edgebanders

Box on demand

Source: Internet

IWF2018 8/24/2018

Industry 4.0 4

Data integration The 7 key elements to industry 4.0

Key concept

!  The upfront effort of data generation requires time and effort (esp. for 1-off/custom product) – therefore the data must be utilized well throughout the processes. #  Higher efforts in the preparation speed up the production processes.

!  Be it fully automated or with people who bridge the media breaks amongst the applications, today it is important to establish a seamless data integration throughout all system layers.

!  It’s important to look at the entire process chain, today’s as well as tomorrows, from order generation to product and process data generation all the way through to the machine integration

Key questions

!  Can the data model be used to generate product and process data?

!  Do the systems provide all required information with the least amount of data generation effort?

!  Are the functionalities of the different software layers (ERP, CAD/CAM, MES, Machine data) clearly defined and system components used at their strength?

!  Is there a interconnected, integrated, automated data flow from dealer to factory to final consumer?

x

x

x

x

x

flexibility speed

Data Integration


ERP Enterprise Resource Planning Order Entry, Capacity Planning, Material Managment, Shipping, Finance, Human Resources

Production Planning Level

Production Control Technology MES Manufacturing Execution System

Production Control and Execution Level

Equipment Management

Detail planning and control

Material Management

Employee Management

Data- Collection

Output Analysis

Quality Management

Information

Management

Machines and Equipment Machines Integration, Automation, PLC Controls

Machine execution and data feedback level

Plan

ning

Dat

a C

olle

ctio

n Engineering Data BOM generation, Production data generation,

Optimization data CNC Codes Materials demad

CAD/CAM (2D/3D) Engineering configurator

Total custom product Mass custom product

Production data Level

(internal)Logistics The 7 key elements to industry 4.0

!  Key Questions: Are your logistics process geared to be data driven?

!  Does the applied technology and equipment for material logistics and transport match the business requirements? #  Warehouse management systems (WMS), Automated storage and retrieval systems (ASRS) #  Pick by light/voice, Self-guided vehicles, Logistic carts, RFID's

!  Are all material and inventory locations clearly identified and can be used for data driven processes? #  No material request forms to be filled out manually, etc.

!  Does the layout design accommodate self guided vehicles or logistic trains? #  Clear, wide aisles, large enough turning points, no dead-ends.

!  Does your IT support automated logistics processes?

x

x

x

x

x

x

(internal)Logistics - examples The 7 key elements to industry 4.0

Source: Linde

Material flow routing Industry: Supply routes (Milk run) or AGVs

Before After

Source: dpm

Smaller shops: intelligent material staging

hardware panels

Material flow Input

Work – in - Progress

Closed Cycle

Output

Input

Output

Work – in - Progress

Pull-System

Push- System

(internal)Logistics - examples


Kanban for standard items

Order Picking Systems

Inventory management

Supermarket

Pick-by-light

Pick-by-voice

Pick-by-vision

Quelle: Fml TUM

Quelle: swisslog

SupermarktSupermarket

Pick-by-light into cart

Put-to-light from rack or VLM

Rack

Cart

VLM

parts parts

WMS / MES

People The 7 key elements to industry 4.0

Key concept

!  Automation/integrated processes require less, but higher skilled and highly motivated people. #  Turnover will be more costly.

!  A shift will take place from shop-floor workers to support functions. #  Traditional white collar vs. blue collar metrics will not work anymore.

Key questions

!  Is the company willing to hire higher skilled people and pay a premium?

!  Is the company actively searching and acquiring the talent needed to drive integration? #  Shift from “cabinet maker” to “mechatronics” - hire a different skill set

!  Does the resource pool of the company provide the skills required? #  Do you have a network of professionals to “buy out” certain skills?

!  Is there a formal system in place to continuously train and educate the people instead of passing on tribal knowledge on the job?

!  Are there initiatives/ systems in place that keep people motivated and engaged?

x

x

x

x

x

x

x

IWF2018 8/24/2018

Industry 4.0 5

The process - what needs to be done to create an even profile The 7 key elements to industry 4.0

x

x

x

x

x

x

xx x

x

x

x

x

x

Align strategy Document all processes Eliminate data gaps Implement MES


x

x

x

x

x

x

x


Write down your key topics/issues - Where do you see the biggest need for improvement.

Final thoughts The 7 key elements to industry 4.0

…Industry 4.0 is there and it is there to stay - for the industry and smaller businesses!

Thank you very much for your interest and participation.

Lignum Consulting

Contact

Germany Lignum Consulting GmbH Am Wasserturm 23 74635 Kupferzell

President: Dieter Rezbach Phone: +49 (0)7944 941970 Fax: +49 (0)7944 941979 e-mail: [email protected]

www.lignum-consulting.de

USA Lignum Consulting Inc. 1135 Kildaire Farm Road, STE 200 Cary, NC 27511

President: Georg Frey Phone: +1 (919) 415 4242 e-mail: [email protected]

www.lignum-consulting.com

Brazil Lignum Consulting Ltda. Av. Argolo, 4 Edif. Dona Erica, Sala 31 89280-061 São Bento do Sul Santa Catarina/ Brasil

President: Oliver Barge Phone: +55 47 3633 3427 Fax: +55 47 3633 3427

[email protected]

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Keys to Success with 4.0 Automation

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Industry 4.0 – What does it take to make it happen ?

IWF 2018

Industry 4.0 in the furniture industry

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IMA Network – Integrated solution for the turnkey process

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Industry 4.0: How it works !

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Outlook

•  Increasing product diversity, individualization, automation and flexibility •  More complex customer demands on material colors, haptics and optics •  Low material inventories •  Furniture manufacturing with a push of a button

!  Economic implementation with efficient logistic needs a batch size 1 system with intelligent control systems

Example Concept - Smart Kitchen Cabinet Factory

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Project definition

Fully automated batch size 1 manufacturing concept for kitchen, bathroom and residential furniture consisting of: •  Storage & retrieval system with rest board material handling •  Cutting •  Edgebanding •  Commissioning •  Drilling and assembly line

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Batch Size 1 Smart Factory Design

Layout Schelling Storage & Retrieval System + IMA Performance Cut

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Layout IMA Performanc.cut & transport logistic with smart tag label application

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Layout IMA Buffer + IMA Novimat Edge Circulation Loop

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Layout IMA Buffer & On Demand Sorting

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IMA Robotic: •  Sorting and commissioning of cabinet

parts for the assembly line •  Pick-up and drop-off of parts from

roller conveyors with two (2) lifting racks –  Lifting rack 1. pick-up –  Lifting rack 2. drop-off

•  Variable stack heights •  Capacity: up to 1500 parts,

depending of " –  Part dimensions –  Batch sizes, …

Sorting

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Overall Layout

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Control system / control level

IWF 2018 – Industry 4.0

Overall material flow

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Bypass strategy & quality control

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•  Bypass on the rear side of the Jalousie buffer

Quality control •  Removal of parts

after the edge circulation loop

•  Re-introduction of

parts after the Jalousie buffer (with wireless handheld scanning device)

Smart Factory Video

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Smart Factory Installation

8/22/18 IWF 2018 – Industry 4.0 19


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Vielen Dank für Ihre Aufmerksamkeit!

... thank you for your attention!

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180824-industry 4.0-iwf2018 v03 · 2018-08-22 · industry 4.0 also called "industrial...

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