industry 4.0 and lean; the time is now · lab –why have most firms been slow to adopt i4.0? •at...
TRANSCRIPT
Industry 4.0 and Lean; the Time is NOW
Ron Crabtree, CPIM, CIRM, CSCP, MLSSBB, SCOR-P
Michigan Lean Consortium August 2019
1© MetaOps, Inc. 2019
Agenda
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What Industry 4.0 is and is not
Elements of Industry 4.0 most manufacturing firms can leverage
Determining the value proposition of Industry 4.0 in the practice of Lean
Roadmap for Industry 4.0 adoption to enable Lean execution
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Let’s Get to Know One Another
Ranking your knowledge about Industry 4.0 - 1 to 5 scale; “Get from this workshop?”
At your tables…
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– Wikipedia
Industry 4.0 is a name given to the current trend of automation and data exchange in manufacturing technologies. It includes cyber-physical systems, the Internet of things, cloud computing and cognitive computing. Industry 4.0 is also sometimes referred to as the fourth industrial revolution.
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Adobe Stock
What is Industry 4.0 – Forbeshttps://www.forbes.com/sites/bernardmarr/2018/09/02/what-is-industry-4-0-heres-a-super-easy-explanation-for-anyone/#1c1331989788
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WHEN COMPUTERS WERE INTRODUCED IN INDUSTRY 3.0, IT
WAS DISRUPTIVE THANKS TO THE
ADDITION OF AN ENTIRELY NEW TECHNOLOGY.
NOW, AND INTO THE FUTURE AS INDUSTRY 4.0 UNFOLDS,
COMPUTERS ARE CONNECTED AND COMMUNICATE WITH
ONE ANOTHER TO ULTIMATELY MAKE DECISIONS WITHOUT
HUMAN INVOLVEMENT.
A COMBINATION OF CYBER-PHYSICAL
SYSTEMS, THE INTERNET OF THINGS
AND THE INTERNET OF SYSTEMS MAKE
INDUSTRY 4.0 POSSIBLE AND THE SMART
FACTORY A REALITY.
What is Industry 4.0 – Automation Alley
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WHAT IS INDUSTRY 4.0?
The fourth industrial revolution: The
convergence of digital and physical technologies
disrupting the manufacturing industry.
Research & Study
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Internet of Things (IOT)
Machine to machine info feeds
Approaching a high level of implementa-tion
ROI potential is dropping
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Source: Automation Alley 2019 Technology in Industry Report Industry 4.0: From Vision to Implementation
Big data
‘the application of big data’
Much potential, but still very early
Volume of data is the challenge
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Source: Automation Alley 2019 Technology in Industry Report Industry 4.0: From Vision to Implementation
Ubiquitous in Manufacturing
Use will continue to grow
Question –Robotics favor or limit Lean?
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Robotics
Source: Automation Alley 2019 Technology in Industry Report Industry 4.0: From Vision to Implementation
Linked to other technologies like Robotics and Big Data = big potential
But, ROI is illusive
Evolving
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Artificial Intelligence (AI)
Source: Automation Alley 2019 Technology in Industry Report Industry 4.0: From Vision to Implementation
Applications –Training, Production Workflow, Logistics,
Material Handling, Product Design
Not yet mature or pervasive
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Modeling, Simulation, Visualization & Immersion
Source: Automation Alley 2019 Technology in Industry Report Industry 4.0: From Vision to Implementation
3-D Printing to on-site construction
Not novel, not mature
Printer unit shipments to exceed $14.6 B in 2019
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Additive Manufacturing & Advanced Materials
Source: Automation Alley 2019 Technology in Industry Report Industry 4.0: From Vision to Implementation
More Example Applications of I4.0 in Manufacturing
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Integrated Andon/OEE to mobile devices 24 x 7 x 365 to any device, anywhere
Reliability Centered Maintenance; TPM/OEE on steroids –Lean Practitioners take note:
• Failure Modes and Effects Analysis (FMEA), Failure Modes Effects and Criticality Analysis (FMECA), and Condition Based Maintenance (CBM) are steps RCM process
Seamless record-keeping and traceability
More Examples in
Manufacturing
• Mixed Reality
– I.e.; Repair personnel, ‘see inside' the machine that needs repair; 'see through walls' to the cables and pipes to know exactly where to drill or cut“
– Simulate hazardous events for practice and testing
• Real-time monitoring of productivity
• Autonomous Robots
• Horizontal and Vertical System Integration – automated supply chain collaboration
More Examples in Manufacturing
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IoT in the production process
IoT-powered supply chains
Blockchain production in the 3D printing industry
Voice of Customer feedback loops to design, sourcing,
production, fulfilment & service in real time
Digital Supply Chain Network
What it’s NOT
• A replacement for – Lean Six Sigma best
Practices
– Operational Excellence best practices
– Engaging people in a unified vision / strategy
– The mandate to develop human capital
• It is a unique journey for each firm – no ‘formula’ exists
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Lab – Why have most firms been slow to adopt I4.0?
• At your tables – facilitator, scribe, time keeper (2 min.)
• 2 minutes – Identify a ‘case’ company at the table – what they produce (industry)
• 5 minutes – Why is (or was) the firm a slow adopter? – Top 3 reasons
• Scribes report-out: Type of firm – what they produce; Top three reasons for slow adoption
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Determining the value
proposition of Industry
4.0:Taking a
Functional View
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Lab – What is the Value Proposition of I4.0 – Diverse, Cross-Functional View
• At your tables – facilitator, scribe, time keeper (2 min).
• 7 min. - For the Function your group represents at your subject company – what are the top 3 to 5 ways I4.0 can bring value, disruptive potential, differentiation, innovation?
• 5 min. – Which 2 have the biggest potential and how could that be valued? % sales lift, % cost down, % time reduced, % quality improved, impact to human capital, etc.? Be creative!
• Scribes report out table’s findings
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Roadmap for Industry 4.0 adoption to enable Lean
• Automation Alley Executive Report
– Understand
– Plan
– Train
– Implement
– Partner
© MetaOps, Inc. 2019 21Source: Automation Alley 2019 Technology in Industry Report Industry 4.0: From Vision to Implementation
Roadmap Lab – “Lean integrating I4.0”
• Facilitator, scribe, time keeper (2 min.)
• Top two disrupter / value driver opportunities for your subject firm:– 3 min. Who needs to understand
these? Why?
– 2 min. Who needs to own the plan (s)?
– 2 min. Who needs to learn new skills?
– 2 min. Partner Opportunities? Who?
• Scribes report-out
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What we covered today; Q & A
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What Industry 4.0 is and is not
Elements of Industry 4.0 most manufacturing firms can leverage
Determining the value proposition of Industry 4.0 in the practice of Lean
Roadmap for Industry 4.0 adoption to enable Lean execution