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Playing with data and industry 4.0
The document summarizes key points about smart manufacturing and moving to Industry 4.0. Part 1 discusses the value of data collection from machines and processes, and provides case studies on using sensors to monitor machine efficiency and oven temperature. Part 2 defines Industry 4.0 as the fourth industrial revolution, outlines its 6 design principles, and notes benefits for small businesses including faster response, improved productivity and flexibility. It concludes with an interactive quiz to self-assess a company's readiness for Industry 4.0.
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Playing with data and industry 4.0
- 1. “It’s all aboutthe data” Smart Manufacturing: Playing with Data & Moving to Industry 4.0 – 24th February, 2016
- 2. Part 1: Playingwith Data ● “What is the Value of Data?” ● World Exclusive : Awesome data-based game ● Case Studies Part 2: Moving to Industry 4.0 ● “What is Industry 4.0 anyway?” ● SMEs: benefits & what to do next ● Quiztime: How Industry 4.0 are you? Welcome
- 3. What is thevalue of the data? You can’t manage what you can’t measure! Shop floor data capture: Enabling continuous improvement! On paper vs Digital collection Real time vs Historical data
- 4. Real time Data Ihad better take an umbrella with me! Weather forecast Historical Data It has been cold this week everyday so it’s likely that tomorrow will be cold too Your production plan Real time Data Rapid decisions to avoid waste and improve efficiency Historical Data Informed decisions on what your production plan will be in 3 weeks’ time
- 5. Capture data tomake better business decisions!
- 6. Part 1: Playingwith data
- 7. The beer game- a game about (lack of) data • Classical Lean Management exercise • Show the effect of delay on a Supply Chain • Whimsical customer ⬅ ⬅ŇĂŝůŝŶŐĚŝƐƚƌŝďƵƟŽŶ despairing brewery Now, let’s run it again with a bit more information Rules: 1. Decide how much to order from your supplier (yellow box) 2. You will receive an order from the customer 3. At each turn, it costs you £100pi for over and £50pi for under stocking
- 8. • Small piecesof information – simple sensors, manual actions ➡ easy to collect – Time and duration, temperature, position, presence, open/close, number, job number • Can be combined in a simple way in a single process e.g. duration vs number ➡ average cycle time, costing, production planning • Can be combined in complex ways across processes ➡ not stealing Scott’s thunder What is data? What data? Why?
- 9. Wickens Engineering • Cutter/punchermachine - production bottleneck Machine underperforming? Do we need another machine? • Simple sensor - position versus time • System analyses patterns to determine if the machine is doing anything useful • Measure ➡ Analyse ➡ Change ➡Measure again Case Study - Machine Efficiency
- 10. • The companyhas identified quality issues with some of their vacuum formed parts • Possible problem: – Misuse of the oven (oven not at temperature, part removed too early) • Solution: – Combine simple sensors (temperature, oven opened, part number) – Feedback to the user (stack light) • The sensor monitors the temperature of the oven • Operator is notified through the stack light – oven at temperature – part ready – open sensors to monitor compliance (six-sigma) Case Study - Oven monitoring
- 11. Part 2: Theroad to Industry 4.0
- 12. Fourth Industrial revolution ●It’s new: Term first used in 2012 ● Small SME involvement and uptake to date ● 6 design principles German Government initiative ● Industrie 4.0 ● “implementation still in its infancy” ● http://www.plattform-i40.de/ What is Industry 4.0 anyway?
- 13. 6 design principles 1.Interoperability (internal integrations, IIoT sensors) 2. Virtualization (factory simulation, data display, augmented reality) 3. Decentralization (connected machines and mobile computing) 4. Real-Time Capability (Big data, The Cloud, data analysis) 5. Service Orientation (external integrations, cybersecurity) 6. Modularity (production line flexibility, robotics, additive layer manufacturing)
- 14. 2 views fromGermany
- 15. faster response times improvedproductivity increased flexibility increased revenue more jobs (NB: skills) + eventually your clients might ask you to integrate into their Industry 4.0 supply chain…! … but all still uncertain! 5 benefits of Industry 4.0 for SMEs
- 16. (You’re on ajourney here… it’s about evolution, not revolution) What do SMEs need to consider? what internal facing data do you have/need? • machines • products • production • human what external facing data do you have/need? • quotes • orders • supply times • stock levels how digital is your organisation? • infrastructure • documents • machine setting • humans ?!? Do you have the adequate IT skills and support needed to take an Industry 4.0 journey?
- 17. Nearly there... Real timefactory performance data in 3D
- 18. Even if youdon’t believe Industry 4.0 is the next revolution, you should still look to digitise as it helps reduce wasted time in your business processes. Our View
- 19. How Industry 4.0 readyare you? Quiz Time!
- 20. Q1/10: Email How digitalis your communication? 0 105 Office 365 on smartphones Office 365OutlookNo email !
- 21. Q2/10: Documents What doyou use to work on documents? 0 105 Collaborative cloud docs! Office 365 / Google Docs Word Paper only !
- 22. Q3/10: Internet connectivity Howmodern is your infrastructure? 0 105 3G/4G roaming connectivity Wifi Cabled internet to PCs No internet !
- 23. Q4/10: IT Support Howdo you maintain your business tech? 0 105 Proactive IT support Dedicated IT maintenance Part time role“my mate John”
- 24. Q5/10: Production Planning Howdo you plan for making things? 0 105 Integrated / Cloud software Specific planning software Use ExcelNo planning !
- 25. Q6/10: Machine performance Howdo you track how your machines are running? 0 105 Real time data capture Historical data reports Paper loggingNone logging !
- 26. Q7/10: Assets/Logistics How welldo you track your goods and assets? 0 105 RFIDbarcode systemPaper loggingNo tracking
- 27. Q8/10: Stock/Inventory How welldo you monitor stock levels? 0 105 Integrated / Cloud software Computer logsPaper logging“Had a look”
- 28. Q9/10: Costings How doyou calculate how much to charge? 0 105 Using actual manuf. costs based on past production data based on past costings “Finger in the air”
- 29. Q10/10: Quotes/Billing How doyou manage financial flow? 0 105 Integrated Cloud software “We use Sage”pdf and emailverbal / phone
- 30.
- 31. Mobile based casktraceability system Smarter Factories
- 32. Assets can besearchable on the map Real time delivery and signature - Invoicing is under 24 hours Web based - accessible from everywhere and all devices ● Incredibly easy to use ● Data exported to a Cloud Spreadsheet for easy reporting QR Code based tracking for company’s fridges ● Lost/misplaced assets ● Invoicing can take up to 5 days and paperwork can be lost sometimes ● Too much paperwork and admin overhead ● Everything is manual - No digital capture Before After
- 33. Thankyou And remember, the futureis digital !