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What is Industry 4.0?
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MIKE SHEW'S HOW TO CREATE A SMART FACTORY - INDUSTRY 4.0
The Value of Implementing Industry 4.0!
Companies that fail to optimize their plants for Industry 4.0 implementation will not survive in the near future. To move into Industry 4.0, companies must have Industry 3.0 fully implemented and optimized. Computer technology, electronic systems, and automation became the dominant force in the industrial market, which was the catalyst for Industry 3.0. Old factories became automated and shifted from analog and mechanical systems to electrical and digital strategies—industry 3.0 automated processes on the production line, replacing blue-collar jobs with white-collar jobs.
Leading the pack, companies capture all the benefits across the entire manufacturing value chain, increasing production capacity and reducing material losses, improving customer service and superior delivery lead times, achieving higher employee satisfaction, and reducing their environmental impact.
Across a wide range of industry sectors, it is common to see (30 to 50 percent) reductions in machine downtime, (10 to 30 percent) increases in throughput, (15 to 30 percent) improvements in labor productivity, and (80 to 85 percent) more accurate forecasting.
What is #Industry #4.0?
#Smart #Factory!
What is #Industry #4.0? Industry 4.0, in simple terms, is transforming a manufacturer into an intelligent factory that marries advanced manufacturing techniques with the IoT (internet of things) to create manufacturing systems. Interconnected to communicate, analyze, and use the information to drive further intelligent action back in the physical world.
Step 1: Assess the current stage as a benchmark.
Step 2: Focus on 3.0 to set the foundation to advance.
Step 3: Discover/plan, Step 4: use the theory of constraints.
Step 5 Creates a manufacturing ecosystem wherein the physical and the digital elements of your business communicate..
Step 6 Focuses on end-to-end process improvement and anything else that will promote collaboration, from hardware to systems to personnel issues..
Industry 4.0 will manage and optimize all aspects of your manufacturing processes and supply chain. It gives you access to the real-time data and insights you need to make smarter, faster decisions about the business, which can ultimately boost the efficiency and profitability of the entire operation.
What Is Downtime Costing You?
Industry estimates suggest that anywhere from 5-30% of a manufacturing organization’s revenue is lost.
Create a Smart Factory.
What Is #Downtime #Costing You?
Machine downtime, out-of-compliance final product, rework, warranties, and any expense incurred due to production quality slipping. These costs don’t include losing customers, as those costs are hard to track.
Example: Automotive industry: Estimates for the cost of machine downtime sit roughly at $22,000/minute. So, if just one piece of equipment sits idle for an hour while a service tech is en route, that’s more than 1 million dollars lost. Imagine the impact on your bottom line if you could cut that by even 10%? Technology like IoT (Internet of Things) sensors that report on machine health and predictive maintenance can do this and “MUCH” more.
How do you start?
It would be best if you did a core value assessment (uncertified valuation) to understand the red flags in your operation fully. The bright-line separating struggling manufacturers from prosperous ones were the presence of an MRP/ERP.
If you don’t innovate your business, it will die in the coming hyperinflation. Hyperinflation within months will drive most operations out of business. So this is your wake-up call to act now.
What is #Industry #4.0? and Create a Smart Factory.
#Statistic #Benefits of a #Smart #Factory
UP TO 30%
- INCREASE IN FACTORY OUTPUT
UP TO 50%
- INCREASE IN SERVICE PROFITABILITY
UP TO 90%
- REDUCTION IN (NPI) TIME (New Product Introduction)
UP TO 33%
- REDUCTION IN LEAD TIME
UP TO 90%
- DECREASE IN LOT SIZE
UP TO 30%
- IMPROVEMENT IN OEE (Overall Equipment Effectiveness)
We will cover what downtime costs you with an example, and you will be shocked. Machine, rework, scrap, warranties, any expense incurred due to production or quality, not at 100% capacity.
What is #Industry #4.0? and Create a Smart Factory.
#Industry #4.0 (or Fourth Industrial Revolution (4IR)) future).
MFG. does not realize Industry 4.0 is not immediately possible in facilities that have been famished with capital, antiquated or poor performing operations, paper-based systems, etc. The implementation will not work if dysfunctionality must be dealt with before achieving these aspirational goals or the implementation will not work.
First, the focus must be on bringing new digital capabilities to internal facilities, equipment, and workforce, before a more externally focused Industry 4.0 approach. The inward direction often captures many new kinds of data at more granular levels. Focus on improving worker productivity, providing greater machine-to-machine integration, acquiring new manufacturing technologies, and adding further quality and traceability capabilities.
Industry 4.0 defines a new data-rich manufacturing world powered by the output from capital equipment, sensors, scanners, customer reviews, suppliers, etc. This data is being used to enrich techniques, tools, and insights possible in manufacturing today. For example, unstructured, structured Big, dark information, biometric, geospatial, and many other kinds utilized by new powerful analytic tools, machine learning algorithms, augmented reality tools, and much more.
What is #Industry #4.0? and Create a Smart Factory.
How Will, Your Operation, Achieve a More #Digital #Future?
Data is being analyzed by smart machines that direct the actions of other machines and people. This method takes mistake-proofing (Japanese Equivalent Poka-Yoke) to the next level. Therefore, plants, warehouses, machine tools, and more are becoming fully automated and interconnected. Industry 4.0 technologies and data change how manufacturers design, prototype, and produce new products. These technologies shorten development cycles and help bring manufacturers closer to suppliers and customers. In addition, the digital exhaust or digital thread created by the industry 4.0 devices may be a source of new revenues for manufacturers.
What is abundantly clear: incremental change won’t win the race. It will take considered thought, vision, and strategy. Those who choose leadership will win, while those who lurch from one incremental patch to another will not.
What approach will your operation take?
A recent McKinsey report highlighted three major findings/priorities for adaptive U.S. manufacturers:
- New technologies and other changes are presenting new market opportunities for manufacturers.
- The U.S. could increase manufacturing GDP by $530 billion.
- The U.S. manufacturers must make changes on several fronts to improve their competitive position.
What is #Industry #4.0? and Create a Smart Factory.
What Exactly Are the Drivers and Enablers Behind These Changes?
- Capital spending within the manufacturing sector is up.
- Investments in the plant, equipment, and equipment automation are up.
- A primary focus of those investments is on improving worker productivity.
- Technology is no longer a highly constrained and expensive obstacle to change.
- Manufacturers can access many more technologies to improve ops beyond basic ERP.
Your customer is your primary reason for staying in business. Without customers and suppliers to create a progressive digital ecosystem to develop and provide your products, you will fail.
Changing customer demands are triggering these digital solutions.
Customers now want shorter supply chains and faster production times. They want brighter, digital-readied products. They want manufacturers to monitor, repair and/or replenish their products just before a customer/user needs them.
As a result, the entire value chain around manufactured goods is changing, and it requires manufacturers to re-imagine what they make, how they’ll make it, and what additional value-added services, capabilities, and information they can provide with these products.
What is #Industry #4.0? and Create a Smart Factory.