Enabling the Manufacturing Future - nihra.org · Enabling the Manufacturing Workforce in the...

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Enabling the Manufacturing Workforce in the Factory of the Future

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1Industry 4.0 2Enabling technologies 3Impact &

challenges 4 PeopleStrategy 5 Conclusion &

Takeaways

AGENDA

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• Personal experience implementing change on the manufacturing floor

• Exposure to advanced manufacturing technology

• Passionate about leadership and technology

Introduction

Why I’m here ?

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Industrial Revolutions

1 st 2 nd 3 rd 4 th

The first industrial revolution used water and steam power to mechanize production

Steam Electricity Computing Smart Manufacturing

The second industrial revolution used electrical power to create mass production

The third industrial revolution used electronics and computers to automate production

The fourth industrial revolution marries advanced technologies with connectivity to create intelligent manufacturing systems

1784 1870 1960 Today (?)

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Everything gets Smart

Smart Phone

Smart Home

Smart Car

Smart Factory

The factory of the future will be “smart”

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Smart Factory • Supplies products with high value added • Flexible enough to respond to swiftly

changing market demand• Fully embraces digitalized production

processes• Exploits the potential of modern

production technologies ( IT/OT)• Carefully handles energy and materials• Human centric vs task centric

Source: http://www.madedifferent.be/en/what-factory-future-40

Smart Factory

Smart factory combine mass production efficiency with custom manufacturing ( on demand) and optimize the supply chain in real time

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Smart Factory

Industry 4.0 is affecting the complete lifecycleAv: Prof. Dr. Detlef Zühlke, Scientific Director, German Research Center for Artificial Intelligence, Innovative Factory systems

HR Too!

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Enabling Technologies

Virtual reality

Blockchain

AI

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Enabling Technologies

Virtual reality

Blockchain

AI

Virtual reality

Senses of Smart Factory

Industrial

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IIoT

A network of Internet connected devices , equipment, machines that are able to collect and exchange data to improve manufacturing and industrial processes

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Augmented reality

overlays information and virtual objects on real-world scenes in real-time.

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Virtual reality & simulation

Create ,test, build, operate and service products and processes in a virtual environment

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Enabling Technologies

Virtual reality

Blockchain

AI Muscles of Smart Factory

Blockchain

Industrial

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COBOT

robots capable to interact with each other and cooperate with humans without the need of safety restrictions

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Additive Manufacturing

Manufacturing objects one fine layer at a time from a 3D model

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BLOCK CHAIN

Incorruptible digital ledger of economic transactions that can be programmed to record not just financial transactions but virtually everything of value

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Enabling Technologies

Virtual reality

Blockchain

AIAI

Brain of Smart Factory

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Cloud Computing

Access information from anywhere, anytime , on any device

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Big Data Analytics

The collection and comprehensive evaluation of large volume of data from many different sources to uncover information including hidden patterns, unknown correlations

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AI / ML

AI works by combining large amounts of data with fast, iterative processing and intelligent algorithms, allowing the software to learn automatically from patterns or features in the data.

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Industry 4.0 Benefits

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Industry 4.0 offers opportunities through a smart combination of:

Digitalization Connectivity Technologies (IT &OT)

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All businesses are made up of PEOPLE

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Industry 4.0 Impact to Job market▪ It will increase the need for certain

jobs

– Automation Engineer

– IT solutions architect

• It will create new jobs

– Robot coordinator

– Industrial data scientist

– Digital twin Engineer

– Predictive Maintenance analyst

– Etc…

Industry 4.0 technologies drive link

between workers, equipment, software,

and machines

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Estimated # jobs directly created by Industry 4.0

Driving growth and directly creating 900K new industry 4.0 jobs by 2025

Jobs along all functions will be affected by Advanced technologies

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Skills Required for Advanced Manufacturing

Social skills• Coordination, persuasion ,

team work , communication, Etc..

Resource Management skills• Time management , work

ethic , priority development , courage to ask questions, etc

General Skills Technical Skills

Technical Skills• Programming , Design and

analysis , trouble shooting , Quality Control analysis, etc..

Learning • Critical thinking ,

mathematics

Complex problem solving

Judgment and decision making

Researching

Adaptive Skills

Basic Complex skills

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Perfect Storm for US manufacturing Strong Economic growth

Baby Boomers retiring ( 10,000/ day)

Misperceptions of manufacturing jobs

Stiff competition from the tech sector for younger workers

STEM education is inadequate for today’s shop floor

Opioid addiction diminish effective pool of workers

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Manufacturing Skill gapStudies show that the skill shortage is expanding

2.0 M 2.4 M

2025 2028

Positions unfilled Source: BLS Data, OEM (Oxford Economics Model), Deloitte and Manufacturing Institute skills research initiative.

600K

2011

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Industry 4.0 People strategy

Retain Retrain Recruit

• Give and request feedback• Invest in employee career

development and re-skilling• Workplace improvement • Flexible work schedule• Paid leave time• Improved benefits package

• Foster a positive perspective on change

• Recognize the adult leaning model• Leverage digital technologies ( Online

competency-based learning programs,)

• Co- mentoring program

• Focus on capabilities, rather than qualifications

• Partnerships with tech programs/schools and community college

• Leverage digitalmanufacturing to attract

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Why do we have to continuously learn and adapt?

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Information Overload

Human Life Spans

Life expectancy

35 years

Life expectancy

45 yearsLife expectancy

80 years…

Egyptian

RomanDark Ages

RenaissanceIndustrial

Revolution

Technological Revolution

Computer Age

Information Age

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Take Away

1 Being competitive in the modern fast-paced business environment requires applying industry best practices in advanced manufacturing technologies , product development processes and organizational culture to the business

2 Knowing what is Industry 4.0, and how it will affect the industry, is only half the battle.

Are you benchmarking, reaching out to industry peers? Do you have a digital transformation strategy ?

Are you meeting with your industry partners to answer the question 5 years out ? What do you see ?

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Take Away

Last but not least, it will have to go beyond teaching the technical skills required by today’s manufacturing world and technologies and teach the adaptive skills that will be needed tomorrow instead

3 The challenge is too complex for a silver bullet solution. It requires a multi-pronged approach

▪ Making the industry more attractive to the new generation ▪ Addressing continual reskilling of workforce.▪ Providing better education and training▪ Developing a digital transformation strategy and new workforce roles

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Do you have partnerships , have you spoken with local universities , do you have intern programs ? How are you communicating about you company ?

Look at your training offering , where are the gaps in your training programs and hiring pool ? Are you looking at those type of skills ?

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Bastien_Carel@fwmetals.com

Thanks