Connected factory Digital solutions on the manufacturing floor

Transcription

1 Connected factory Digital solutions on the manufacturing floor

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3 Dawn of 4th industrial revolution The marriage of advanced manufacturing techniques with information technology, data, and analytics is driving another industrial revolution one that enables manufacturing leaders to combine information technology and operations technology to create value in new and different ways. Late 18th century Water and steam power Mechanisation Early 20th century Mass production Electricity 1970s 2000s Computing and automation Internet Industry 4.0 Digital development Digital operations Connected customer Optimise traditional objectives...by better managing Cost Innovation Service Visibility Variability Revenue Quality Safety Flexibility Volume Velocity 01

4 Fuelled by technology and connectivity Digital technologies have changed dramatically in recent years, driven largely by three key developments: lower computing costs, cheaper storage, and less costly bandwidth. This has accelerated the adoption of disruptive technologies. Exponentially decreasing costs are accelerating the adoption of... key disruptive technologies $1,245 per Gbps $569 per GB Internet of Things Automation and Robotics Cost of Performance $222 per million transistors Storage <$0.01 Bandwidth <$10 Blockchain Cognitive and AI Computing <$0.06 Augmented Reality Additive Manufacturing 1992 Today 02

5 Collapsing the supply chain Embracing the power of these new technologies allows a traditional linear supply chain to become a set of dynamic and integrated networks: Digital Supply Networks. Traditional supply chain Digital Supply Networks (DSN) Develop Synchronised planning Connected customer Plan Source Make Connected factory Digital core Intelligent supply Deliver Support Dynamic fulfillment Digital development 03

6 Connected factory Disruptive technologies can impact and transform the heart of manufacturing, creating the Connected factory. Control Systems Data Acquisition and Wearables Inbound Inventory Augmented Reality Processing Data OT Security Environment, Health & Safety Shop Floor Computing Cognitive Connected factory Manufacturing Additive Assets & Maintenance Process Technologies & Methods Security IT Advanced Materials Quality Visualisation Autonomous Robotics Digital Design and Simulation 04

7 A Connected factory has the ability to fundamentally change the production process to enable end-to-end product visibility and predictive analytics to support and optimise decision making. Connected Continuous pull of traditional datasets along with new sensor and location-based datasets Real-time data enabling collaboration with suppliers and customers Collaboration across departments (e.g. feedback from production to product development) Transparent Live metrics & tools to support rapid but effective decision-making Real-time linkages to customer demand forecasts Transparent customer order tracking Optimised Reliable, predictable production capacity Increased asset uptime and production efficiency Highly automated production and material handling with minimal human interaction Minimised cost of quality and production Proactive Predictive anomaly identification and resolution (e.g. using augmented reality for maintenance) Automated restocking and replenishment Early identification of supplier quality issues Real-time safety monitoring Agile Flexible and adaptable scheduling and changeovers Implementation of product changes to see impact in real-time Configurable factory layouts and equipment 05

8 Value from the Connected factory The Connected factory can drive a broad range of benefits. Manufacturing typical value drivers Improved asset efficiency Improved quality Reduced cost Improved safety and sustainability Optimised capacity Scrap rates Labour cost Safety incidents Asset utilisation Fill rate Sourcing cost Employee satisfaction, health, and wellness Changeover time Yield Inventory levels Downtime Lead times Maintenance cost Sustainable practices OEE (Overall Equipment Effectiveness) Warranty cost Environmental impact 06

9 Typical transformation journey for a manufacturer Value creation can begin with, and scale from, a single asset to a complete factory or network of Connected factories. Opportunity value Single asset Maximising the performance of a single asset (e.g. machinery, tools, inventory, equipment, people) Production line Improving the performance of a series of dependent assets (i.e. production line or manufacturing cell) Factory Optimising the performance of an individual plant by better connecting and utilising assets Factory network Maximise network performance by sharing capacity across sites in real time and connecting to the entire supply chain and product development cycle 07

10 Applying this to your business To maximise value and reduce risk, successful manufacturers are adopting a number of techniques as they adopt Industry 4.0 concepts. Think big Start Small & Act Fast Scale Identify opportunities and current challenges Determine direction and roadmap Select and implement pilots Assess business value based on pilots Set foundations Scale pilots Measure success and continue to prioritise Enablers Multi-disciplinary teams and ways of working Value focus and prioritisation Reusability Talent and change management Data management and security 08

11 Partnership The Connected factory immersive experience brings together leading organisations to support manufacturers on the topic of digital manufacturing transformation. World-class centre for industry-focused research and development of technologies used in high-value manufacturing sectors Global leader in Digital Transformation with specific expertise in strategy and implementation of Industry 4.0 across multiple industries Global provider of leading IoT and AR platform, and field-proven solutions 09

12 Contacts Nick Davis UK Industry 4.0 Lead +44 (0) Ben Morgan Head of Factory (0) Paul Haimes VP Pre-Sales +44 (0) AMRC Factory 2050 Europa Avenue Sheffield S9 1ZA (for Sat Nav please use S9 1XZ) Download the PTC ThingWorx View app on your phone or tablet and point it to this ThingMark for further information. 10

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16 This publication has been written in general terms and we recommend that you obtain professional advice before acting or refraining from action on any of the contents of this publication. Deloitte LLP accepts no liability for any loss occasioned to any person acting or refraining from action as a result of any material in this publication. Deloitte LLP is a limited liability partnership registered in England and Wales with registered number OC and its registered office at 2 New Street Square, London EC4A 3BZ, United Kingdom. Deloitte LLP is the United Kingdom affiliate of Deloitte NWE LLP, a member firm of Deloitte Touche Tohmatsu Limited, a UK private company limited by guarantee ( DTTL ). DTTL and each of its member firms are legally separate and independent entities. DTTL and Deloitte NWE LLP do not provide services to clients. Please see to learn more about our global network of member firms Deloitte LLP. All rights reserved. Designed and produced by The Creative Studio at Deloitte, London. J12277