Hospodářské noviny - Industrie 4.0
Transcription
Hospodářské noviny - Industrie 4.0
Hospodářské noviny - Industrie 4.0 Strategický plán Mladá Boleslav 07. Juni 2016 Matthias Rausch, DCoC IT & Prozesse Agenda 1 Ingenics AG 2 Forth Industrial Revolution – Revolution or Evolution? 3 I4.0@Ingenics 4 Industry 4.0 Strategy Roadmap Example 5 Conclusion 6 References in Czech Republic © Ingenics; Datei: 9050197_ICP_Industrie40_VM.pptx; Name: MRA; Erstellt: 2016-05-13; Gedruckt: 10.06.2016; Version4.0: 1; Status: A; Seite: 1 1.1 The Company Development and Experience › › › › › › The Board Founded in 1979 35 years of project experience More than 5.300 projects 420 employees Owner-managed without external capital Vendor independent Carlos Schmidt Chief Financial Officer (CFO) Manfred Loistl Chief Human Resources Officer (CHRO) Oliver Herkommer Chief Executive Officer (CEO) University Cooperation › University of Applied Sciences Ulm – Production Technology › University of Applied Sciences Neu-Ulm – Business Administration; Logistic Management Awards Best Consultant Ingenics has been named one of the best consultancies TOP Employer First Place: Overall Ranking Seal of Excellence Education and Talent Management © Ingenics; Datei: 9050197_ICP_Industrie40_VM.pptx; Name: MRA; Erstellt: 2016-05-13; Gedruckt: 10.06.2016; Version4.0: 1; Status: A; Seite: 2 1.5 On-site Worldwide PUEBLA ATLANTA GREENVILLE PARIS TOULOUSE ULM STUTTGART, MUNICH HAMBURG, WOLFSBURG HEILBRONN, INGOLSTADT SHANGHAI SHENYANG PRAGUE BRATISLAVA More information at www.ingenics.com © Ingenics; Datei: 9050197_ICP_Industrie40_VM.pptx; Name: MRA; Erstellt: 2016-05-13; Gedruckt: 10.06.2016; Version4.0: 1; Status: A; Seite: 3 1.5 Center of Competence Factory Planning Intra Logistics Industrial Engineering Supply Chain Management Assembly Operational Excellence Management Systems Body in White Quality- and Supplier Management Operational Excellence Production IT and Processes Ingenics Academy © Ingenics; Datei: 9050197_ICP_Industrie40_VM.pptx; Name: MRA; Erstellt: 2016-05-13; Gedruckt: 10.06.2016; Version4.0: 1; Status: A; Seite: 4 Agenda 1 Ingenics AG 2 Forth Industrial Revolution – Revolution or Evolution? 3 I4.0@Ingenics 4 Industry 4.0 Strategy Roadmap Example 5 Conclusion 6 References in Czech Republic © Ingenics; Datei: 9050197_ICP_Industrie40_VM.pptx; Name: MRA; Erstellt: 2016-05-13; Gedruckt: 10.06.2016; Version4.0: 1; Status: A; Seite: 5 Industry 4.0 - Revolution orEvolution? Productdesign Product and -development Production planning Production Engineering Production Service Geschäftsmodelle Businessmodell Geschäftsprozesse Process 2.2 © hin255 - shutterstock.com Technologie Technology Mensch Human Organisation Organization Politics Society Law The digital transformation towards Industry 4.0 is a profound change for the entire organization: › It has effects over the whole product lifecycle – from development to service › In the business models and the business processes, internally and with partners › But – it can be developed with an evolutionary roadmap © Ingenics; Datei: 9050197_ICP_Industrie40_VM.pptx; Name: MRA; Erstellt: 2016-05-13; Gedruckt: 10.06.2016; Version4.0: 1; Status: A; Seite: 6 Agenda 1 Ingenics AG 2 Forth Industrial Revolution – Revolution or Evolution? 3 I4.0@Ingenics 4 Industry 4.0 Strategy Roadmap Example 5 Conclusion 6 References in Czech Republic © Ingenics; Datei: 9050197_ICP_Industrie40_VM.pptx; Name: MRA; Erstellt: 2016-05-13; Gedruckt: 10.06.2016; Version4.0: 1; Status: A; Seite: 7 3 I4.0@Ingenics Strategy Roadmap Industry 4.0 Logistic 4.0 Production 4.0 Assembly 4.0 - MRK © ArnoMassee - iStockphoto.de Factory 4.0 New Production technologies I4.0@Ingenics Labour 4.0 Lean Data Management, Data Security Smart Factory ERP – MES – PLM © Ingenics; Datei: 9050197_ICP_Industrie40_VM.pptx; Name: MRA; Erstellt: 2016-05-13; Gedruckt: 10.06.2016; Version4.0: 1; Status: A; Seite: 8 Big Data Agenda 1 Ingenics AG 2 Forth Industrial Revolution – Revolution or Evolution? 3 I4.0@Ingenics 4 Industry 4.0 Strategy Roadmap Example 5 Conclusion 6 References in Czech Republic © Ingenics; Datei: 9050197_ICP_Industrie40_VM.pptx; Name: MRA; Erstellt: 2016-05-13; Gedruckt: 10.06.2016; Version4.0: 1; Status: A; Seite: 9 4 Beispielhafte Industrie 4.0 Strategie Roadmap Manufacturing Execution System Big Data › Business Intelligence Strategy Roadmap › Advanced Analytics › Business Modell › Organization › Big Data Process › › Predictive Product Maintenance Human Robotic Collaboration wavebreakmedia/Shutterstock.com, asharkyu/Shutterstock.com © Ingenics; Datei: 9050197_ICP_Industrie40_VM.pptx; Name: MRA; Erstellt: 2016-05-13; Gedruckt: 10.06.2016; Version4.0: 1; Status: A; Seite: 10 4.1 Industry 4.0 – Approaches for Strategy development › Technology Quick Check › Industry 4.0 Concrete Industry 4.0 Strategy › Process Maturity › Business Modell Development No matter which way you decide to use – the important thing is to start. © Ingenics; Datei: 9050197_ICP_Industrie40_VM.pptx; Name: MRA; Erstellt: 2016-05-13; Gedruckt: 10.06.2016; Version4.0: 1; Status: A; Seite: 11 4.2 Task: Industry: Real-time MES Increase of production efficiency by implementation of a shop floor Management system Automotive Supplier Basis: › Production processes driven by paper › Confirmations with a time delay › No direct information on machine status Approach: › › › › › Definition and tender for a Manufacturing execution system Implementation of the FORCAM system Graphical real-time production cockpit All confirmations from 350 employees digitalized Automated and manual MDE Integration, depending on machine capabilities › Real-time machine information over secured wireless infrastructure › Real-time SAP integration triggered by events › Use of Industry clients, Barcode and RFID to increase usability © FORCAM GmbH Result: › Increase machine efficiency by 25% › Increase worker efficiency by 3% within three month › Decrease of energy costs by 10% › Return on invest realized within three month © Ingenics; Datei: 9050197_ICP_Industrie40_VM.pptx; Name: MRA; Erstellt: 2016-05-13; Gedruckt: 10.06.2016; Version4.0: 1; Status: A; Seite: 12 4.2.9 OEM – (BI) Customer Analytics Task: Development Early Intervention Recognition System Industry: Automotive OEM Manufacturer Basis: › This application facilitates cross correlation of emerging customer satisfaction and safety issues over vehicle’s lifetime which will augment senior management in decision making process, in order to increase owner loyalty and reduce negative media exposure. Approach: › Data integration & ETL of CFS, NHTSA, IQS & Other relevant data sources in one Big Data Lake › Using VFC(Vehicle Fault Codes) to classify customer comments with an automated machine learning algorithm © ra2studio/Shutterstock.com Results: › › › Visualize results in Qlikview app with possible drill downs & filters for gaining data insights › Development of predictive algorithms in R and Python › › Investigated >20 algorithms and library for solving the problem. SVM performed best! › View customer concerns across multiple systems in Qlikview Application. Manual classification of customer survey comments replaced by a machine learning auto-categorizer Auto-categorizer achieves 90% accuracy Reduction of classification time from 2 weeks to minutes © Ingenics; Datei: 9050197_ICP_Industrie40_VM.pptx; Name: MRA; Erstellt: 2016-05-13; Gedruckt: 10.06.2016; Version4.0: 1; Status: A; Seite: 13 4.4 OEM – Realization Human-Robotic Collaboration (MRK) in Assembly Task: Define concept for a Human Robotic Collaboration Industry: Automotive OEM Basis: › New production technologies should be introduced to workers › Evaluation of possible areas for robotic support without safety cases Approach: › Definition of evaluation criteria › Systematic analysis of the band portions BA 0, 1, 2, 3, door mounting, cockpit installation, door installation regarding possible applications against the evaluation criteria › Classification of possible MRK-use fields › Roadmap with presentation of applications sorted by probability of realization over time › Development of concepts › Derivation of fields for an "assembly of the future" Results: › Pilot area defined › First pilot Implementation in assembly realized › Planning and Implementation of further collaboration workplaces © Ingenics; Datei: 9050197_ICP_Industrie40_VM.pptx; Name: MRA; Erstellt: 2016-05-13; Gedruckt: 10.06.2016; Version4.0: 1; Status: A; Seite: 14 4.2.12 OEM – (BI) Predictive Maintenance Body Shop Task: Tool to steer maintenance activities to reduce Body Shop downtime Industry: Automotive OEM Manufacturer Basis: › The goal of this production line analysis is to determine a correlation between a piece of equipment’s current performance and future failure. The focus for the pilot implementation will be on equipment measures from the body shop. Expected results are to find a trend with a machine‘s performance prior to failure. Approach: › After merging different data sources, derivation of new variables, feature selection of relevant variables (e.g., fault codes), and anomaly detection, various prediction models will be built to establish a confidence of on coming equipment failure. › Development of predictive models with Python › Data visualization with iPython notebooks and Bokeh © ra2studio/Shutterstock.com Results: › Ongoing POC with targeted completion in 2016 › Control Charts & Other Visualizations for downtime trend visualizations › Integrated sensor data with other data sources for better root-cause identification © Ingenics; Datei: 9050197_ICP_Industrie40_VM.pptx; Name: MRA; Erstellt: 2016-05-13; Gedruckt: 10.06.2016; Version4.0: 1; Status: A; Seite: 15 Agenda 1 Ingenics AG 2 Forth Industrial Revolution – Revolution or Evolution? 3 I4.0@Ingenics 4 Industry 4.0 Strategy Roadmap Example 5 Conclusion 6 References in Czech Republic © Ingenics; Datei: 9050197_ICP_Industrie40_VM.pptx; Name: MRA; Erstellt: 2016-05-13; Gedruckt: 10.06.2016; Version4.0: 1; Status: A; Seite: 16 5 › › › › › Conclusion It’s no a question of “IF”, but of “HOW” – Solutions have to be created individually for each company. There are no extensively solutions available yet. Go for specific solutions, which both fulfill current needs and future requests It is not about “Google glasses”. Technology just creates business value if it’s use is harmonized with the organization and the processes. If you start Industry 4.0 project, be aware to lean your process landscape. Lean methods can be used in indirect departments as well. Only with a combined approach you will realize real business values. Each project has to have a clear goal. There will be no stable Industry 4.0 plant model. Due to the rapid development of technology, companies have to get more agile to adopt technology and adjust their processes on a regular level. © Ingenics; Datei: 9050197_ICP_Industrie40_VM.pptx; Name: MRA; Erstellt: 2016-05-13; Gedruckt: 10.06.2016; Version4.0: 1; Status: A; Seite: 17 5 Conclusion Without knowing your goals and your current situation, you can not choose the right way. The definition of your individual, sustained and successful strategy roadmap should have highest priority. Start today – Get ready for Industry 4.0 © Ingenics; Datei: 9050197_ICP_Industrie40_VM.pptx; Name: MRA; Erstellt: 2016-05-13; Gedruckt: 10.06.2016; Version4.0: 1; Status: A; Seite: 18 Agenda 1 Ingenics AG 2 Forth Industrial Revolution – Revolution or Evolution? 3 I4.0@Ingenics 4 Industry 4.0 Strategy Roadmap Example 5 Conclusion 6 References in Czech Republic © Ingenics; Datei: 9050197_ICP_Industrie40_VM.pptx; Name: MRA; Erstellt: 2016-05-13; Gedruckt: 10.06.2016; Version4.0: 1; Status: A; Seite: 19 6 References in Czech Republic › › › › › › › › VW Koncern – Skoda Auto, Ml. Boleslav Bombardier, Liberec ZF, Pilsen Schott, Val. Mezirici F.X. Meiller, Slany GEA LVZ, a.s. , Liberec Ciret , Pelhrimov arvato - services , Stochov © Ingenics; Datei: 9050197_ICP_Industrie40_VM.pptx; Name: MRA; Erstellt: 2016-05-13; Gedruckt: 10.06.2016; Version4.0: 1; Status: A; Seite: 20 Díky za váše pozornost. Prosím váše otázky. Your personal contact Matthias Rausch Dipl. Wirtschaftsmathematiker Director Center of Competence IT und Prozesse Udo Richter Dr. rer.nat. Director Sales [email protected] +49 151 10849361 [email protected] +420 605 343 091 Ingenics AG · Schillerstraße 1/15 · 89077 Ulm · Tel. +49 731 93680 0 · [email protected] · www.ingenics.de