Keynote "Practical case-studies of Industry 4.0 implementation in the global wire and cable manufacturer community" of Clobbi CEO Dmitry Shapovalov that was held 13 Jun 2019 @CRU 2019 Brussels

1. make your business sexy
and innovative
Digitalization 4.0 for Сable&Wire:
Practical case-studies of Industry 4.0
implementation in the global wire and
cable manufacturing community
Dmytry Shapovalov
Clobbi CEO

2. Issues
- Excess capacity
- Fight for each clients
- Low OEE

3. ? Industry 4.0
Digital transformation

4. Casestudy
Imagine typical cable
manufacturing

5. ?
Digitalization is the future
But what do we have now
at the shop-floor?

6. The most widespread
production management
system in the World
☺

7. 7
1
Case
R&D
Shorter Time-2-Market
Higher Customer
service level

8. R&D
“AS IS” situation

9. to make your R&D faster
with Industry 4.0

10. Calculation Result
1 2 3 4 5 6

11. How the products should be
produced?
1 2 3 4 5 6 7 8
Clobbi.CableDesigner->
Technological parameters
(nominal linear speed,
insulation thickness, etc.)

12. Use Case
1 2 3 4 5 6
20 - 50%
Shorter
Time-2-Market
Clobbi.CableDesigner
to make your R&D faster
with Industry 4.0
>95%
Customer
Service Level

13. 13
2
Case
Shop-floor
Customer satisfaction
Higher OEE

14. Optimal production planning (APS, AI)
1 2 3 4 5 6
• MPS Plan - Orders with client requirements, terms, batches, length, release dates

15. 1Step
Optimal production
planning (APS, AI)

16. Production planning
“AS IS” situation

17. Optimal production planning (APS, AI)
1 2 3 4 5 6
• Clobbi generate optimal production plan – for each machinery, batch of semi-finished product

18. Simulation & optimization
1 2 3 4 5 6
KPIVersionsScenarios Drill down

19. Machinery effectiveness modeling
1 2 3 4 5 6

20. APS planning - > actual order execution terms
1 2 3 4 5 6

21. 2Step
Start of Execution

22. Start of execution
“AS IS” situation

23. DigialEcosystem
Start of Execution!
InTimeMES HubberIIOT / Digital Twins WMS
1. According to optimal schedule Clobbi
automatically starts an orders execution
2. Equipment automatically receive
commands via IoT
3. Personnel immediately receive commands
on their tablets via IoT
1 2 3 4 5 6
New technologies and
approaches to
synchronize equipment
and workers

24. Execution
• IIOT and mobile
technologies
• Labeling each
produced WIP with
QR codes
• Manufacturing
operations’ execution
actual status
1 2 3 4 5 6

25. IIOT-technologies
1 2 3 4 5 6

26. Actual status and control
• You always know what’s happen in your production • Visible progress and current status of the orders in manufacturing
1 2 3 4 5 6

27. 3Step
Intelligent production
DigitalEcosystem =
Clobbi + equipment + people

28. • Manufacturing
events’
monitoring
• Control
deviations,
breakdowns
and
downtimes MES Hubber
1 2 3 4 5 6
Digital Ecosystem

29. 1 2 3 4 5 6 7 8
What is manufactured and
when (time periods)
Green line – linear speed
value according to norms
Blue line – actual linear
speed value
Conclusion from the chart:
Product is systematically manufactured
under actual linear speed of 7% lower
from the nominal parameter.
Way for improvement:
increase speed and output by 7%
Combine real-time
actual and planned data

30. Transparency for each length
As a result, you can access and evaluate all
deviated parameters of every semi-finished
product. These deviations are linked to particular
length segments. You can also see visible ways
for quality improvement and cost reduction
BigData –> systematic deviations’
management
1 2 3 4 5 6 7 8
Transparency for each length

31. Digital Ecosystem
1 2 3 4 5 6 7 8
• Clobbi, equipment and people integration
• Even old machinery

32. Downtime
Industry 4.0 automatic
event response
1 2 3 4 5 6
• Automatic
production
plan
rescheduling
• New orders’
generation for
equipment
and personnel

33. 33
5 - 20%
Increase in
output
volume
Clobbi.SmartFactory
to make you production more
effective with Industry 4.0
> 95%
Customer
service
level

34. 4Step
Transparency
Virtualization
(ARVR)

35. Virtualization - 3D shop-floor models (VR)
1 2 3 4 5 6 7 8
• DigitalTwin. You do not need to go to the shop, you can be at any place of the world

36. 1 2 3 4 5 6 7 8
Increase transparency

37. Virtualization (AR)
1 2 3 4 5 6 7 8
• AR-labeling of machinery • With tablet you know everything about equipment

38. Google Glass Enterprise
Edition

39. 39
DigitalTwins by Clobbi
Do You know how efficient your
production works and how to
improve it?
20 to 30%
Higher OEE

40. 5Step
Predictive
maintenance

41. Digital catalogue
1 2 3 4 5 6
• Digital Maintenance Cards for Cortinovis• Rosendahl RN-M – 172 equipment nodes

42. 1 2 3 4 5 6
Predictive
• Diagnostics of equipment

43. 1 2 3 4 5 6
Predictive
• Diagnostics of equipment

44. 1 2 3 4 5 6
Predictive
RCM2 technical processes for maintenance of most popular
Cable&Wire equipment are in Clobbi
o Equipment and units
o Maintenance cards
o Techniques & diagnostic parameters
Maintenance and repairs cost reduction - 8%
Increased equipment availability ratio +15%
Reduced emergency downtimes - 22%

45. 45
CableEAM by Clobbi
predictive health of equipment
30 to 50%
Less machine
downtime
10 to 40%
Maintenance
cost
reduction

46. 6Step
BigData processing
and analysis (AI, BI)
How to improve
production process
and technology

47. • Intelligent decisions for better results and more profits
Business discovery
(BI, KPI)
1 2 3 4 5 6
• Measure actual and planned KPIs

48. How to
become
digital

49. 49

50. 50
Readiness for the Future
Production Report 2018

51. 51

52. 52

53. - Marketing and Sales 4.0
- Product 4.0
- Operations and Services 4.0
- Administration 4.0
Digital business architecture

54. 1Clobbi. SmartFactory
(MRP, APS/MES, AI)
2Clobbi.CableDesigner
(R&D, Quotation)
3 Clobbi.DigitalTwins
(IIoT, VR/AR)
4 Clobbi.CableEAM
(RCM, Predictive
maintenance)
Digital transformation
Improved effectiveness
Business processes’
optimization instead of just
automation
Measurable
economic benefits
We help large and medium-sized Cable&Wire
enterprises to adjust processes and improve their
management system based on Industry 4.0 ideology:

55. 55
info@clobbi.com
www.clobbi.com
+ 44 203 807 06 40
make your business sexy
and innovative!