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Innovation Cluster Connected Industry | Bosch India | Digital | 23 Nov 2018
© Robert Bosch Engineering and Business Solutions Private Limited 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.1
Industry 4.0, Game ON!Dattatri Salagame , Vice President & Head of Digital Business, Bosch India
Bosch India | Digital | 23 Nov 2018
© Robert Bosch Engineering and Business Solutions Private Limited 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.2
Bosch India | Digital | 23 Nov 2018
© Robert Bosch Engineering and Business Solutions Private Limited 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.3
Digital
Enterprise
#JumpStart Digital
Connected ProductsConnected Industry
Frameworks, Tools and Methodology to craft strategic roadmap
Strategy & Change Management
Driving Efficiency Enabling Business Design
Automation Applications
Access to technology across digital stack for ideation to PoC to New Business Models
Sensors Software Services
Driving Data -> Intelligence -> Action to optimize
Industry 4.0
Simplifying DIGITAL!
Bosch India | Digital | 23 Nov 2018
© Robert Bosch Engineering and Business Solutions Private Limited 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.4
An Unprecedented Rate of Change
Connectivity
Computation
Storage
Cognitive
Digital Native Worker Highly Automated Work
hared
ensorizedSEconomy
Technology-The Common Denominator
10101011111110001010101111000111001001101010100010110000111001010101010101000010111010101010
10101100010100101010101010101010101010111001110101010101001111001011011001110010101100101010
Bosch India | Digital | 23 Nov 2018
© Robert Bosch Engineering and Business Solutions Private Limited 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.5
Digital: The Game ChangerIndustry 4.0 – A level playing field
Small Investment leading to
Disproportionate Value
Creation
Quality
Productivity
Enterprise silo to ecosystem
collaboration
A level playing Field
for all
Affordable technology
• Advanced technologies are made affordable through innovative As-a-service model
Availability of large technical competency
Option to start small
• Small iterative low investment led approach being followed by small and large players
Democratization of Market Access
Enterprise
Customer
End Consumer
Supplier
Digital: The Game ChangerOpportunity for India
Mechanical Assembly Mass Production Industrial Automation
Re
lati
ve S
ign
ific
ance
Natural Resources
Automation & Data
Low Cost Production
Timeline
China won the cost arbitrage game. Lost opportunity for India.
India poised to win: - 3 decades of IT expertise - Technology leadership- Engineering talent hub
1.0 2.0 3.0 4.0
Factors Driving Industrial Revolutions
Bosch India | Digital | 23 Nov 2018
© Robert Bosch Engineering and Business Solutions Private Limited 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.7
Digital: The Game ChangerHolistic Approach to Define Strategy
Why are we doing this?From growth as a commercial agenda to growth as a visionary agenda
How do we build ‘Automation Culture’?From people as managers of competitive advantage to makers of competitive advantage
How are we
managing our
plant & infra?
Are our
processes
evolving?
What are we
doing?
How are we
engaging
customers?
Are we integrated with
our partners?
Bosch India | Digital | 23 Nov 2018
© Robert Bosch Engineering and Business Solutions Private Limited 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.8
Digital: The Game ChangerDecide on entry point
Option 1: Design
Strategic drive; Flexible design and multi-directional layout
Option 2: Point Solutions
Implementing multiple point solutions to improve sub-parts, parts of the process
Option 3: Digital Infra
Connecting machines, IT/OT integration, setting up network, platform integration etc. to set up the entire digital infrastructure for ‘Factories of the Future’
Bosch India | Digital | 23 Nov 2018
© Robert Bosch Engineering and Business Solutions Private Limited 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.9
Digital: The Game ChangerMulti-faceted approach for Transformation
ExploreDesign of Experiments
Transformation Strategy
Change Management
InfraPoC
RoI to Scale
Idea
Frameworks, Tools and Methodology to craft digital strategic roadmap
Assess Readiness, Define Strategy
Idea to PoC
Enterprise Architecture
Connected Industry Automation
Digital baselining for enterprise readiness – architecture, data readiness etc.
Commercial Off the shelf products
1 2
4 3
Access to technology across digital stack for ideation to proof of concept
Begin the change: KPI-Led digital interventions
ApplicationsSensors Software Services
ExploitProven solutions for transformation
Ind
ust
ry 4
.0 I
nn
ova
tio
n l
eve
l
2013 2014 2015 2016 2017 2018 2019 2020
1) Pilot projects
2) Value streams
3) IPNs
IPN = International Production Network
Bosch’s JourneyOur journey towards future has begun…..
Plant Maintenance
Supplier Quality
Quality Management
Process Engineering
Planning
Logistics
Plant Operations
Bosch India | Digital | 23 Nov 2018
© Robert Bosch Engineering and Business Solutions Private Limited 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.11
Digital: The Game ChangerAssessment: An I4.0 example
Current State• Plant Maintenance function not in any integrated ERP system; Spare parts
planning not optimized; Condition monitoring not used (4.5)• Supplier Quality information is captured in SAPQM, lot# is used for
tracking supplier material. Scope for improving SAP process (5.5)• Quality Management information capture is in multiple siloed systems;
not data integration and analysis possible. Traceability is manual (5)• Process Engineering in-process parameters in standalone application;
machine setup parameters not integrated with MES (4.5)• Planning and production scheduling driven from SAP – Material and
Machine is covered; scope for including manpower planning (6)• Plant Operations scope for online OEE reporting and plant connectivity (5)
The State of each process is benchmarked with respect to Transparency,Interaction and Intelligence• Transparency – Complete capture and visualization
of data on HMIs and Andons or Mobiles (6)• Interaction – Integration with different platforms for
immediate availability of data acrossthe departments in the organizationwithout latency (8)
• Intelligence – Insights based on historic dataanalysis and trend recognition withminimal human interference (10)
Transparency Interaction Intelligence
5 6 7 8 9 10
Industry 4.0 MaturityCurrent State Expected State
4
Bosch India | Digital | 23 Nov 2018
© Robert Bosch Engineering and Business Solutions Private Limited 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.12
Digital: The Game ChangerBuild a Roadmap and Iterate with Use cases
Note: Use-case position within a box does NOT indicate relative priority
Value Stream Mapping1
Use Case Identification2
Use Case Prioritization3
Build a roadmap4
Case Studies
I4.0 in a box for SME segment
Bosch India | Digital | 23 Nov 2018
© Robert Bosch Engineering and Business Solutions Private Limited 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.13
Machine and Production Analytics
Bosch Energy Signature Analyzer
Bosch Mechanical Signature Analyzer
Backup Generator
➢ Asset-lite model (Pay-per use)➢ Retrofit and non-intrusive➢ Rapid deployment (1-2 weeks)
Grid
Bosch Machine Controller Analyzer
GSM
/GP
RS
GSM
/GP
RS
GSM
/GP
RS
Key Features
➢ Machine OEE & Industry Benchmarks➢ Production Part OEE➢ Productivity Improvement Analytics➢ Machine Capacity Utilization ➢ Production and Capacity planning
Bosch Energy Analytics
Active Time
Power On/OffMachine
Productivity
Power Quality Consumption
Production Count
MTBF / MTTF
Machine OEE
Dashboard and Analytics
Bosch India | Digital | 23 Nov 2018
Energy Management - Kwh Saved, Dollars Earned
© Robert Bosch Engineering and Business Solutions Private Limited 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.14
11+Sites Covered
900+Machines Connected
60+Gateways Installed
20+ Data points collected
million
Jaipur
Ahmedabad
Pune
Bangalore
Chennai
Nashik
800+MWh Energy Saved
640+Ton of CO2 Reduced
ISGF Award 2017
640+Ton of CO2 Reduced
Bosch India | Digital | 23 Nov 2018
Smart Manpower Planning – Efficient Plant Operations
© Robert Bosch Engineering and Business Solutions Private Limited 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.15
Ton of CO2 Reduced 640+
Before AfterINPUT PROCESS OUTPUT
FLM Task:
▪ Associate manual attendance every shift
▪ Manpower allocation according to skill matrix
▪ Shortage/Excess manpower allocation
▪ In case of allocation, additional documentation for productivity calculation
▪ Job rotation of associate done manually
▪ Manual record of production output in log book
Time/shift
~4 minutes
~4 minutes
~7 minutes
▪ Auto attendance & manpower allocation according to skill matrix
▪ Value stream priority setting for advance planning (VE & NHA)
▪ Auto trigger for Shortage/Excess manpower allocation for all value streams
▪ SMS information to associates on allocation workstation / machines
▪ Interlocking of critical station with associate ID card (RFID)
▪ Paperless working in production (digital log book)
▪ Online display of available Emergency Response Team (ERT) in plant
InControl –Assisted Outflow Prevention
Bosch India | Digital | 23 Nov 2018
© Robert Bosch Engineering and Business Solutions Private Limited 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.16
Vehicle 1
VIN-NUMBER-1234567890
B-NO-1234 E-NO-1234
Smart & Connected Hydraulic Machines
Bosch India | Digital | 23 Nov 2018
© Robert Bosch Engineering and Business Solutions Private Limited 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.17
Specialized Bosch sensors for hydraulic machines
Data and specialized algorithms hosted on cloud
Bosch IoT Gateway to collect data from sensors
❑ 28 Hydraulic and 17 Energy parameters monitored real-time
Light-weight protocol to solve connectivity issues in semi-urban and rural areas
Real-time Condition monitoring & Diagnostics
Alerts & Notifications Higher Machine utilization & lower break-down costs
New service models
Field inputs to improve product design
Competitive Advantage
Customer Benefits Bosch Advantage
Track and Trace -Improving supply chain traceability and reliability
Bosch India | Digital | 23 Nov 2018
© Robert Bosch Engineering and Business Solutions Private Limited 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights.18