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The role of shop floor assistance in creating Smart Factories


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Shop floor assistance systems are key to achieving efficient Smart Factory digital transformation goals. Focusing on key success factors such as run time optimization and quality assurance, this session will discuss Fujitsu's business consulting approach for the manufacturing industry as well as implementation experiences in live factory environments. The session includes hands-on experiences and demonstrations for a successful implementation.

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The role of shop floor assistance in creating Smart Factories

  1. 1. The Role of Shop Floor Assistance in creating Smart Factories Thomas Bechtel Portfolio Manager & Business Development Fujitsu Dr. Steffen Link Senior Business Consultant Fujitsu
  2. 2. 3 © 2019 FUJITSU Business & Leadership • Princedoms: factory, quality processes, sourcing, planning, etc. • Silos per workplace, machine, technical equipment vs. E2E view & common KPIs • Fixed cost structures vs. pay per use Technology • Machines not or inefficiently connected to IT services • Analog processing of workflow and data: paper, batch, manual rework • Data / information processing @ shop floor level kept to the minimum , Typical Challenges of many Manufacturers
  3. 3. 4 © 2019 FUJITSU Mid Term Expectations of Manufacturers ◼ Lot size 1 / customized products at the cost of mass production ◼ Increase & stabilize production performance – Efficiency ◼ New business models - Connected value chains - Effectiveness
  4. 4. 5 © 2019 FUJITSU Digital Assistent System for the Shop Floor Digital Services as Assistant – decision support for shop floor operators • Real time view on current line performance • Suggestions for improving production efficiency Key Goal: Help to increase Overall Equipment Effectiveness (OEE) sustainably
  5. 5. 6 © 2019 FUJITSU Digital Assistent System – Value Adds Run Time Optimization • Transparency: Online visualization of production line performance (i.e. OEE) • Reduce unplanned downtime systematically and sustainable Quality Assurance @ Shop Floor • Increase quality level of produced goods • Increase efficiency of quality process • Stabilize and standardize quality process & auto control the quality Complementing Lean Manufacturing Methods Total Productive Maintenance Process ControlQuick problem solving
  6. 6. 7 © 2019 FUJITSU Project Approach Business Modell & Company Strategy Organization, People, Processes Data Strategy Lean Manufacturing Kaizen Digital Assistent System @ Shop Floor Run Time Optimization Quality Assurance @ Shop Floor Readiness Assessment
  7. 7. 8 © 2019 FUJITSU Data Strategy & Data Management DATA STRATEGY Data Value & Analytics Data Management Data Technology Data Organization How do I add value to my business with the data? How do I create standards for an effective use of the data?How do I transform my IT to become a data accelerator? How do I enable my organization to be data-driven?
  8. 8. 9 © 2019 FUJITSU Overview of Typical Technologies Dashboard Alerting Preventing Edge Computing Analytical Platform Edge Connectivity C y b e r S e c u r i t y Factory Simulator
  9. 9. 10 © 2019 FUJITSU Turning data into value at the production shop floor From knowledge to action
  10. 10. 11 © 2019 FUJITSU From knowledge to action
  11. 11. 12 © 2019 FUJITSU From knowledge to action Runtime optimization
  12. 12. 13 © 2019 FUJITSU From knowledge to action Quality assurance decision support Option 1.2 Option1 pass Test Station fail production line Option 1.2
  13. 13. 14 © 2019 FUJITSU From Knowledge to Action Quality assurance decision support
  14. 14. 15 © 2019 FUJITSU Fujitsu Consulting Approach Screen challenges and reduce complexity Carve out & define analytic use cases from specific business challenges. Calculate profitability. Identify low hanging fruits. Start. Achieve quick wins Realize „proof of Value“ in selected simulations and pilots. Scale up Install and run a scalable analytics environment. Deploy the analytic models to all production lines. Take advantage of economies of scale. Add further use cases. Month Assess readiness Screen critical dimensions, develop an innovation road map.
  15. 15. 16 © 2019 FUJITSU From Knowledge to action Self Assessment Radar Data Governance People & Organization Technology Strategy & CultureBusiness case Example result radar
  16. 16. 17 © 2019 FUJITSU FUJITSU Forum 2019 Where to find Digital Services for the Shop Floor? 17 © 2019 FUJITSUUnclassified Manufacturing Area Production Line ▪ Run Time Optimization – T.07 ▪ Quality Assurance @ Shop Floor – T.08
  17. 17. 18 © 2019 FUJITSU
  18. 18. 19 © 2019 FUJITSU Contacts Dr. Steffen Link Senior Business Consultant Thomas Bechtel Portfolio Manager & Business Development +49 171-7620043
  19. 19. 20 © 2019 FUJITSU Shopfloor optimization framework Operate Model Q-Gate Q-Gate Q-GateQ-Gate Understand Business Acquire Data Build Model Assess Readiness Develop Use Cases Understand Data Prepare Data Deploy Model Evaluate Model BUILD RUNPREPARE DEPLOYSCOPE
  20. 20. 21 © 2019 FUJITSU
  21. 21. 22 © 2019 FUJITSU