View
16
Download
1
Category
Preview:
Citation preview
1
HowtoStartwithIndustry4.0inSMEs
PracticalRoadmapforIndustry4.0IntroductioninSME24thofNovember,2017Chambre deCommerce,Luxembourg
ThomasKorne
PortfolioIPL- InstituteforProductionandLogisticsSystems
EuropeanResearchandDevelopment
Production&logistics
Qualification,coachingandtraining
Managementandorganisation
Globalorientation Strategyconsulting
§ LeanSixSigma§ Companyandsupplierdevelopment
§ Academicresearchmethodology
§ Developmentofinnovativemethodsforpracticalapplication
§ Greenfield-/Brownfield-concepts
§ Developmentandtransformationofproductionsystems
§ Industry4.0Roadmapping
§ Supplychainorganisation
§ Designofmaterialflow
§ Worldwideprojects§ LocatedintheGreaterRegionofFR,LU,DE
§ Projectmanagement§ Interims-management&service
2
AgendaContentofPresentation
§ Introduction§ StrategicneedforIndustry4.0intheSMEsector§ Introductoryexamples
§MethodologyforcreatinganindividualRoadmapIndustry4.0§ Phase1:Companyanalysis§ Phase2:Identifyopportunities§ Phase3:Selectandevaluateopportunities§ Phase4:CreateandrealizeRoadmap
§ Summary
3
StrategicNeedforIndustry4.0Enablers,OpportunitiesandRisks
Enablers Opportunities
Barriers/Risks
Digitalization(„BigData“)§ Increasingavailabilityofdataabout
customer,productandproduction
Connectivityandcommunication(ICT)§ InternetofThings(IoT)§ Real-timecommunication§ Permanentavailabilityofbroad-
bandconnectionsforlargedata
Disruptivetechnologies/software§ CyberPhysicalSystems:lightweight
robots,Automatedguidedvehicles,drones,3Dprinting,VR/AR,mobiledevices,pick-by-tech,etc.
§ BusinessAnalytics,AI,Blockchain
1
2
3
§ Delayduetounclearcost-benefitratio§ Deficitspreventimplementation:lackof
technologyandknowledge,rigidorgani-zational structures,poormasterdata,etc.
§ Cultureofpreservationandlackofcouragegrantscompetitiontime-criticaladvantages
4
§ Vertical/horiz.integration§ SupplyChaintransparency§ Processautomation§ Flexibilityandagility
Efficientproduction
§ Newservices§ Masscustomization§ Newtypesofcooperation
Newbusiness/products
Aclevercombinationofenablersinowncompanyleadstonewopportunities
IndicativeOpportunitiesofIndustry4.0ValueDriversforPotentialsaccordingtoMcKinsey
5Source:McKinseyDigital(2015)
Resource/Process
Assetutilization
Labor
InventoriesQuality
Supply/demandmatch
Time-to-Market
Service/After-Sales
Productivityincreaseby3-5%5
30-50%reductionoftotalmachinedowntime²
45-55%increaseofproductivityintechnicalprofessionsthroughautomationofknowledgework4
Costsforinventoryholdingdecreasedby20-50%3
Costsforqualityreducedby 10-20%6
Forecastingaccuracyincreasedto85+%3
20-50%reductionintimetomarket1
10-40%reductionofmaintenancecosts1
1Cf.McKinseyGlobalInstitute:Bigdata:Thenextfrontierforinnovation,competition,andproductivity2McKinseyanalysis3McKinseyanalysis4CF.McKinseyGlobalInstitute:DisruptiveTechnologies5See,forexample,ABBcasestudy6Cf.T.Bauernhansl,M.tenHompel,B.Vogel-Heuser(Hrsg.):Industrie 4.0inProduktion/Automatisierung/Logistik (2014)
ANewViewonWaste„DigitalWaste“byUnusedInformationaccordingtoMcKinsey
6Source:McKinseyDigital(2015)
IndicativeBarriersforIndustry4.0IntroductionChallengesforaSuccessfulImplementationofIndustry4.0
Source:PWC(2014),Studywithn=235companiesfromGermany,5businesssectors 7
6%
13%
18%
19%
20%
22%
26%
30%
46%
0% 10% 20% 30% 40% 50%
Unsufficientnetwork/storagecapabilities
Slowexpansionofbasictechnologies(broadband)
Lowpriority/commitmentfromexecutive…
Issueswithdatasecurity
Lowmaturityofrequiredtechnologies
Unclearlegalsituationconcerningownershipof…
Missingstandards,normsandcertificates
Unsufficientqualificationofworkforce
Unclearcost-benefit-ratio,unclearinvestments
FactsaboutIndustry4.0inSMEsStatusintroductionandimplementationofIndustry4.0inGermany
Source:StudyandthesisofUniversityAnsbach (2017)withn=333companiesfromdifferentbusinesssectorsinGermany 8
44%
56%
IsyourcompanyusingIndustry4.0applications?
Yes
Nein
53%
4%
43%
DoyouplanspecificinvestmentsinIndustry4.0applications?
Yes,weplanintroduction
No,Industry4.0isoutofquestionforus
No,wedon'tseeneedforaction,currently
CurrentuseofIndustry4.0-applications.Resultofquestionnaire– Industry4.0inSME,n=297
PlanneduseofIndustry4.0-applications.Resultofquestionnaire– Industry4.0inSME,n=202.
FactsaboutIndustry4.0inSMEsApplication
9
10%24%
36%38%40%
89%96%
0% 20% 40% 60% 80% 100% 120%
OthersMarketing
R&DSales
PurchasingLogistics
Production
InwhichareasofthecompanycouldyouimagineusingIndustry4.0applications?
ApplicationofIndustry4.0Resultofquestionnaire– Industry4.0inSME,n=293,multipleanswerspossible.
Source:StudyandthesisofUniversityAnsbach (2017)withn=333companiesfromdifferentbusinesssectorsinGermany
FactsaboutIndustry4.0inSMEsPotentialBenefits
10
9%
9%
6%
7%
26%
24%
25%
36%
36%
41%
36%
53%
61%
25%
29%
41%
43%
38%
43%
47%
44%
45%
44%
53%
40%
32%
53%
52%
48%
39%
28%
26%
23%
15%
17%
12%
9%
6%
6%
13%
10%
5%
11%
8%
7%
5%
5%
2%
3%
2%
1%
1%
0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
FosterWork-LifeBalanceShortentime-to-market
IncreasemotivationofworkforceOverwhemingofemployees
DevelopmentofnewbusinessCustomizedproduction
ReliefforemployeesNewbusinessservices
ResourceefficiencyFlexibleproduction
ImprovedMESEfficiency
Increaselevelofautomation
WhichofthefollowingopportunitiesbyIndustry4.0doyouconsiderrealistic?
doesapply doesratherapply doesrathernotapply doesnotapply
OpportunitiesforIndustry4.0Resultofquestionnaire– Industry4.0inSME,n=295,multipleanswerspossible
Source:StudyandthesisofUniversityAnsbach (2017)withn=333companiesfromdifferentbusinesssectorsinGermany
IntroductoryExampleforMarketing4.0intheApparelIndustry
Industry4.0inMarketing&Sales
11Source:BigDataMonitor,LOCTeam
„BigData Monitor“§ Comprehensiveanalysisofsalesdata
forhighvarietyfashionproducts§ Increaseexpertiseofresponsible
employees§ Developmentofadatamodelfor
earlywarningsincustomerdemand§ Modelprovidesprobabilityofsuccess
ofanewproductbeforemarketentry§ Easesdecisionmakinginproduct
development§ Reductioninnumberofvariants
Industry4.0inProductionIntroductoryExampleforCraftsmanship4.0
12Source:withkindapprovalofBusiness-KompetenzZentrums (eBZ)Kaiserslautern
Observationalstudiesandsituationalanalysisforconstructionsites
Industry4.0inProductionIntroductoryExampleforMaintenance4.0
13
MachineconditionmonitoringatAGFAPeißenberg andmaintenanceviaInternet24/7
Source:PresentationAgfa-Gevaert HealthCareGmbH Werk Peißenberg,AKJAutomotiveKongress Saarbrücken,13./14.September2017
„MobileControlApp“§ Getmachineinformation§ Makeprogramchanges§ Integratedcameratransmitsvideo
fromproductionprocesslivetoiPad§ Onlinemonitoringfrom"outside"
Meetingswithsteering-committeetoalignresults
IndividualCompanyRoadmapforIndustry4.0Approach,PhasesandInstruments
CompanyAnalysis
Identifyopportunities
Chooseandevaluate
opportunities
Establishandrealize
roadmap
1 2 3 4
Phase
Instruments
14
§ Pre-structuredInterviews§ Organisationandtasks§ Infrastructurewith
input/output§ Coreprocessesand
communication§ Typicaldeviations§ Strength/Weaknesses§ Strategicfieldsof
actions
§ Quick-CheckI4.0(Form,examples)
§ BusinessModelCanvas§ DesignThinking
Workshop
§ Catalogueforevaluation(Workshopwithkeyquestions)
§ Benefit-feasibility-matrix§ Checkofpre-requisites
human,technology,organisation(Workshopwithkeyquestions)
§ Investmentcalculations§ Evaluationofnon-
monetarybenefits(WorkshopwithExtendedPerformanceAnalysis)
§ Roadmapping I4.0§ Projectplansforstepwise
introduction§ Operationalsupportof
implementation
Source:AK4.0model,Seiter M.etal.(2016),modified
Phase1:CompanyAnalysisPre-structuredInterviewsInterviewsMaptheCurrentStateoftheCompany
15
A)Organizationandtasks B)InfrastructureandI/O C)Coreprocessesandcomm.
D)Defectsanddeviations E)Strength/Weaknesses F)Strategicfieldsofaction
§ Organisation,R&R§ Tasksandfocusof
departments§ Qualificationofemployees
§ Importantresources(machines,licenses,etc.)
§ Inputandoutputsfromrelevantdepartments
§ Importantprocesses/productsin/fromdepartments
§ Communicationstructures
§ Typicalissuesanddeviationsindifferentdepartments
§ Issuesbetweendepartmentsaswellascustomers/suppliers
§ Strength/weaknessesofdepartments,products,company
§ Strength/weaknessestocustomersorwithsuppliers
§ Strategicchangerequests§ Futuremarketpotential§ Differentviewpointsfrom
employeesandexecutives
Infra-structure
Input Output
Fehler✓ ×
CompanyAnalysis
Identifyopportunities
Chooseandevaluate
opportunities
Establishandrealizeroadmap
1 2 3 4
Phase2:IdentifyOpportunitiesQuick-CheckI4.0forProduction
16Source:VDMA(2016),modified
1
2
3
4
5
6
Sixapplicationlevelswithfivetechnologicalandsequentialdevelopmentstages supportbrainstormingofideas
Quick-Check-interviewsorworkshopsreveal
Currentstate
Futurestate
CompanyAnalysis
Identifyopportunities
Chooseandevaluate
opportunities
Establishandrealizeroadmap
1 2 3 4
iBin:automizedinventorydetection
andtriggerforpurchaseorders
Quick-CheckProduction:DataprocessingExample:InventoryManagement
17
Automaticprocessplanning/control
Evaluationforprocessplanning/control
Analysingdataforprocessmonitoring
Storageofdatafordocumentation
Noprocessingofdata
Manualdisposition(orderpoint)forC-partsintraditional
containers
DataAnalyticswithdatabasedinventory
reduction
Know-howauto-mation forinventoryplanning(Cognitive
Computing)
Documentationofreplenishment;manualordering
process
Technology:Traditional
HumanManualprocess
Organisation:Skilledlabor required
Technology:traditional
Human:Manualprocess
Organisation:Standardizedwork
Human:Competencyindata
SAPDeutschlandSE&Co.KG
Organisation:ConsistentMasterdata
Technology:DataAnalyticsTool
Human:Acceptancebyworker
SAPDeutschlandSE&Co.KG
Organisation:Clarifiedlegalbasis
Würth Industrie ServiceGmbH&Co.KG
10)6) 7) 8) 9)
CompanyAnalysis
Identifyopportunities
Chooseandevaluate
opportunities
Establishandrealizeroadmap
1 2 3 4
Source:forpicturereferencesseeendofpresentations
Technology:ERP&Software
Human:Onlyforescalation
Technology:RFID,opticalcamera,ERP
Organisation:Skilledlabor,consistency
Phase2:IdentifyOpportunitiesQuick-CheckI4.0forProduct/BusinessModel
18
Sixapplicationlevelsarealsoavailablefornewproductsorbusinessmodels,eachwithfiveconsecutivedevelopmentstagesforbrainstorming
Source:VDMA(2016),modified
CompanyAnalysis
Identifyopportunities
Chooseandevaluate
opportunities
Establishandrealizeroadmap
1 2 3 4
1
2
3
4
5
6
Quick-CheckProduct:MonitoringExample:ProductSafetyinTransportation
19
Independentlyadoptedcontrolmeasures
Prognosisofitsownfunctionalcondition
Recordingofoperatingconditionfordiagnostic
DetectionoffailuresNomonitoringbytheproduct
Technology:Properpackaging
HumanManualprocess
Organisation:Skilledlabor required
Technology:Tags
Human:Manualprocess
Organisation:Controloftags
Human:Actbasedondata
Organisation:ConsistentMasterdata
Technology:Sensors,Software
Human:Escalationonly
Organisation:Reliabledata/limits
CompanyAnalysis
Identifyopportunities
Chooseandevaluate
opportunities
Establishandrealizeroadmap
1 2 3 4
Source:forpicturereferencesseeendofpresentations
Technology:Sensor,App,Server
Human:Escalationonly
Technology:Innovationrequired
Organisation:Customeracceptance
1) 2) 3) 4) 5)
Packagingwithself-correctionincaseofenvironmentalissues
Passivesecuritywithwarning,sturdy
packaging,bubblewrap
DropTagEVENT:Low-costtoolforcondition
monitoring
Packagingprovidesprognosisabout
functionalityofgoods
Tiltingindicatorfortransportcontrol
EnviroPackGmbH TransPack-KrumbachGmbH
CambridgeConsultantsLtd&Inc
DBSchenker SecurityGuard
Phase3:ChooseandEvaluateOpportunitiesEvaluationCatalogueandBenefit-Feasibility-Matrix
20
Feasibilitydifficult easy
low
high
Mon
etaryBe
nefits
TOP-OpportunitiesEconomicallyattractive and
feasible
Economicallyattractive,butdifficulttoimplement
Economicallynotattractive,anddifficulttoimplement
Economicallynotattractive,buteasytoimplement
Source:Seiter M.etal.(2016)
⇒Keyquestionssupportafactualassessmentofcost-effectivenessandfeasibilityoftheplannedmeasures
CompanyAnalysis
Identifyopportunities
Chooseandevaluate
opportunities
Establishandrealizeroadmap
1 2 3 4
Phase3:ChooseandEvaluateOpportunitiesDeriveandEvaluateNecessaryPre-requisitesforIndustry4.0Transformation
21
Workshopwithkeyquestionswillrevealrequiredmeasuresandadditionalinvestmentstocreatepre-requisitesintermsof
§ Human§ Technology§ Organization
Source:Seiter M.etal.(2016)
CompanyAnalysis
Identifyopportunities
Chooseandevaluate
opportunities
Establishandrealizeroadmap
1 2 3 4
MonetarybenefiteffectsNon-monetary,direct
quantifiablebenefiteffectsNon-monetary,qualitybenefit
effects
Lowpersonnelcostsduetonetworkedmachines
Optimizedemployeeutilizationthroughtheuseofefficient
machines
Employeesatisfactionthroughattractiveworkplacedesign
LowcoststhroughPredictiveMaintenance
Lowernumberoferrorsduetoearlyerroranalysis
CooperationsthroughjointITplatforms
Lowerinventorycoststhroughoptimizedutilization
Highadherencetoschedulethroughefficientplanning
Transparencyduetohighdataavailability
Lowercost,higherrevenueetc.
Optimizedleadtimes/utilizationetc.
Customersatisfaction,transparency
Phase3:ChooseandEvaluateOpportunitiesMonetaryandNon-monetaryBenefitEffects
22
⇒Bettertransparencyincost-benefitratiothroughconsiderationofnon-monetarybenefiteffects
Source:Seiter M.etal.(2016)
CompanyAnalysis
Identifyopportunities
Chooseandevaluate
opportunities
Establishandrealizeroadmap
1 2 3 4
Phase3:ChooseandevaluateOpportunitiesFinancialEvaluationofNon-monetaryBenefits
23
CompanyAnalysis
Identifyopportunities
Chooseandevaluate
opportunities
Establishandrealizeroadmap
1 2 3 4
Actual Desired Delta750 80 80.67 1%
Actual Desired Delta Actual Desired Delta5.73 10 10.08 1% 10 9.6 -4%
Actual Desired Delta Actual Desired Delta210 206.91 -1% 3 3.19 6%
Actual Desired Delta Actual Desired Delta
25% Delta
10Desired
8Actual
Revenue increase in T € per year
Cost cutting in T € pro Jahr
Monetary effect in T € per year
755.73Actual Desired Delta Actual
Route optimization Maintenance planningTravel cost per maintenance per day in € Number of maintenances per day
Storage costs WarehousingCalculated storage costs in T € per year Inventory turnover rate on filter
Long-term optimizationReclamation quote
Reclamation costsCalculated reclamation costs in T € per year
19%23.7520
Product qualityDowntime plant in h per year
Needed maintenances per dayDesired Delta Transparency
Non-monetary, direct quantifiable benefit effects
Revenue new customers in Mio. € per year
-6%18.7420
Monetary benefits
Existing customersRevenue existing customers in Mio. € per year
Existing customers
Non-monetary, quality benefit effects
20%
20%
40%
25%
20%
10%
40%
25%
10%
Strengthofeffect
Strengthofeffect
Strengthofeffect
Strengthofeffect
Strengthofeffect
Strengthofeffect
Strengthofeffect
Strengthofeffect
Strengthofeffect
Phase4:EstablishandRealizeRoadmapRoadmapforstepwiseintroduction Compnany
AnalysisIdentify
opportunities
Chooseandevaluate
opportunities
Establishandrealizeroadmap
1 2 3 4
24Source:Seiter M.etal.(2016),modified
ARoadmapIndustry4.0⇒visualizesthelong-termtransformationstrategy⇒isflexibleandmaybecontinuouslyadaptedbyorganizationallearning⇒detailsnecessarymeasuresinto§ manageablestepsand§ financiallyviablesub-projects
2019
2018
2021
+20
20
20192018 2021+2020
Human
Organization
Technology
Continuousdigitalawarenessandqualificationofemployees
Modifymachines
InstallcontinuousIT
support
Integrationinproduction
Re-alignworkplaces
Definitionandroll-outofdigitalRoles&Responsibilities
Defineandcascaderoadmap
Technologicalassessment
Developmentandtrainingof
digitalcompetences
Efficientcommunication
Softwaretraining
IntegrateITconcept,step
IIIntegrateIT
concept,stepI Processmodification
AlignwithcustomerITnetwork
=stepwisemeasuresforintegrationofIndustry4.0
ChangeManagement
concept
SummaryImportantAspectsofCreatingandImplementingIndustry4.0Roadmaps
§ Industry4.0offersfutureopportunitiesthroughclevercombinationof§ Digitization§ Connectivityand§ Disruptivetechnologies/software
§Benefitsneedtobeindividuallyandmonetarilyassessable§Quick-CheckI4.0supportsandsimplifiesbrainstormingforideas§ Industry4.0roadmapconsolidatesatransformationstrategy§ Thetimefactorcompetitionplaysacrucialroleincompetition§ SimilartoLean,Industry4.0willfailwithoutstrongcommitmentfromleadership
25
Q&A
26
Thankyouforyourattention!
ReferencesUsed/RecommendedLiterature
MaturityModels
BusinessModelCanvas
FinancingandInvestment
§ BCG(2017):DigitalAccelerationIndex,downloadat21.10.17,link:https://www.bcg.com/capabilities/technology-digital/digital-acceleration-index.aspx
§ McKinseyDigital(2015):Digitaler Kompass Industrie 4.0,Industry4.0Howtonavigatedigitizationofthemanufacturingsector,downloadat21.10.17,link:https://www.mckinsey.de/files/mck_industry_40_report.pdf
§ PWC(2014):Strategy&,Chancen undHerausforderungen dervierten industriellen Revolution,downloadat24.10.17,link:https://www.strategyand.pwc.com/media/file/Industrie-4-0.pdf
§ Seiter,M.etal(2016):RoadmapIndustrie 4.0:Ihr Weg zur Erfolgreichen Umsetzung vonIndustrie 4.0,Verlag tredition GmbH,Hamburg,2016§ Schuh,G.etal(2017):Industrie 4.0MaturityIndex:Diedigitale TransformationvonUnternehmen gestalten,Acatech Studie,downloadat
21.10.17,link:http://www.acatech.de/fileadmin/user_upload/Baumstruktur_nach_Website/Acatech/root/de/Publikationen/Projektberichte/acatech_STUDIE_Maturity_Index_WEB.pdf
§ VDMA(2017):Leitfaden Industrie 4.0:Orientierungshilfe zur Einführung indenMittelstand,downloadat21.10,17,link:http://industrie40.vdma.org/documents/266693/9670777/4%20I40%20konkret%20B-und-R.pdf/6a2d2f93-cd8a-4c11-9287-a63cd7a4dc43
§ Osterwalder,A.,Pigneur,Y.(2011):BusinessModelGeneration:Ein Handbuch für Visionäre,Spielveränderer undHerausforderer,CampusVerlag,FrankfurtamMain,2011
§ Becker,H.P.(2015):Investition undFinanzierung:Grundlagen derbetrieblichen Finanzwirtschaft,7.Auflage,Verlag SpringerGabler,Wiesbaden,2015
§ Seiter,M.etal(2007):Wirtschaftlichkeitsanalyse mit dem ExtendedPerformanceAnalysis- AnsatzEPA– AmBeispiel vonRFIDInvestitionen,IPRIResearchPaperNr.10,Stuttgart,2007
27
1) Enviro PackGmbH:https://www.enviropack.de/sperrschicht-luftpolsterfolien.html?gclid=Cj0KCQjwgIPOBRDnARIsAHA1X3Q9YyjidXk1UddUPs0tJPFLyKoy7qnuqryrybpYfM-Dz7a8Fa-jGwQaAjhnEALw_wcB
2) TransPack-KrumbachGmbH:https://www.transpack-krumbach.de/transportkisten-ladungssicherung-export/transportueberwachung/tiltwatch-kippindikator?gclid=CjwKEAjwgIPOBRDn2eXxsN7S4RcSJABwNV90XbOACS0sujUfwxepREZOFSnhicqjWYs0MRvjFmAlThoCLRPw_wcB
3) CambridgeConsultantsLtd&CambridgeConsultantsInc:https://www.cambridgeconsultants.com/droptag
4) DBSchenkerSecurtiy Guard:AKJAutomotivePresentation,DBSchenker
5) Vontobel HoldingAG:https://rogerstuder.vontobel.com/wp-content/uploads/sites/379/zukunft-der-digitalen-welt-wie-wir-dem-digitalen-wandel-begegnen-muessen-e1443169203873.jpg
6) UltimoBeratungsgesellschaftmbH:http://www.ultimo.co.at/theorie.htm
7) BEYER-MietserviceKG:https://www.beyer-mietservice.de/unternehmen/news/berufliche-perspektiven.html
8) SAPDeutschlandSE&Co.KG:https://www.sap.com/germany/products/analytics/business-intelligence-bi.html
9) CreativeMarket:https://creativemarket.com/sjagiello/574425-Cognitive-Computing-Icons
10)Würth Industrie ServiceGmbH&Co.KG:https://www.wuerth-industrie.com/web/de/wuerthindustrie/cteile_management/kanban/ibin_intelligenterbehaelter/ibin.php
28
OtherReferences
Recommended