The Transformative Journey to M4.0: Challenges and Opportunities

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1 BOLD IDEAS - POWERFUL CONNECTIONS - WINNING STRATEGIES The Transformative Journey to M4.0: Challenges and Opportunities September 13, 2017 Smart Manufacturing Seminar Series

2 Today s Speaker Jeff Moad Executive Editor & Research Director Manufacturing Leadership Council Frost & Sullivan jeffrey.moad@frost.com

3 Today s Agenda About the Manufacturing Leadership Council Manufacturing 4.0 in Context Momentum is Building M4.0 Challenges Progress is Being Made Case Studies The Way Forward 2018 Manufacturing Leadership Awards & Summit Imagine a Better Future for Manufacturing

4 The Transformative Journey to Manufacturing 4.0 ABOUT THE ML COUNCIL

5 Imagine a Better Future for Manufacturing Manufacturing Leadership Council Vision To create and inspire a global community of manufacturing executives who believe in the proposition that manufacturing is the fundamental driver of economic and social prosperity, and that its growth will lead to a better future and a higher standard of living for all people. Manufacturing Leadership Council Mission To enable manufacturing executives to achieve transformational growth for themselves, their companies, and for the industry at large through enlightened leadership. In support of this, the Council focuses on the intersection of advanced technologies and the business, identifying growth and improvement opportunities in the operation, organization and leadership of manufacturing enterprises. The Council delivers thought leadership, networking events, exclusive research, and a portfolio of high-value services around a member-defined set of Critical Issues that are shaping the future of manufacturing.

6 ML Council Membership Portfolio Global Business Network 7,000+ ML Website Global Members 2,200+ ML Linked In Group Members 10,000+ ML Viewpoint Subscribers 22,000+ ML Twitter Followers Live Council Plant Tours Industry Innovation Awards Independently-judged annual awards honoring industry leadership, innovation, and achievement: Exclusive M4.0 Research Senior-level collaborative business leadership network. Member-driven agenda, M4.0-focused programs, Industry-wide Council Members & Associate Members Hyatt Regency, Huntington Beach, CA. Executive Summit: June 11-13, 2018 Join senior-level executives making a disruptive difference with M4.0. Bold Ideas for a Better Future: Thought-Leadership Journal The Harvard Business Review of Manufacturing Written for the industry, by the industry.

7 Extensive Cross-Industry Membership

8 The Transformative Journey to Manufacturing 4.0 MANUFACTURING 4.0 IN CONTEXT

9 Industrial Revolutions Over the Centuries Production Power and Complexity 1.0 Mechanization, Line Production, Steam, Water 2.0 Mass Production, Electricity, Assembly Lines, Division of Labor 3.0 Computer Control, Semiconductors, IT, Automation, Miniaturization M4.0 Sensors, Connectivity, Data Analytics, Cyber- Physical Systems, Collaborative Robotics, Predictive Maintenance, 3D Printing, Augmented Reality 1780s 1870s 1960s M4.0: The Next Industrial Opportunity 2000s Digitization s Cognitive MFG

10 The Next Industrial Revolution: What s Driving M4.0?

11 M4.0: A 3 Dimensional Undertaking Technology M4.0 Leadership Organization Manufacturing 4.0 is the next stage of industrial progress, enabling mass customization on a global scale by factories and plants that are extensively networked, software-driven, intelligent, autonomous, and information-intensive. M4.0 will disrupt existing business models and enable the creation of new ones, requiring manufacturing companies to rethink the fundamentals of their business, and adopt new IT and automation technologies, organizational models, and leadership approaches in an orchestrated manner. M4.0: Driving Fundamental Business Model Change In Manufacturing

12 The Transformative Journey to Manufacturing 4.0 MOMENTUM IS BUILDING Technology M4.0 Organization Leadership

13 Technology Momentum: Digitization Will Surge Extensive Increase in Digital Platforms Over 5 Years Digital Production/Assembly * completely/largely digitized Networked Plant Equipment * extensively/partially networked Predictive Analytics * extensively/partially implemented Electronic Integration with Suppliers/Customers * extensively/partially integrated Now 5 Years 10% 64% 41% 87% 50% 80% 39% 78% Technology Organization M4.0 Leadership 2017 ML Council Research Surveys

14 Organizational Momentum: Integration Over 50% of companies regard Cross-Functional Integration as a formal goal for the future Key Reasons for Integration 53% #1 Cut costs, waste, and increase efficiency #2 Improve communications, reduce errors, leverage skills #3 Achieve greater speed and agility Technology Organization M4.0 Leadership 70% see Data Analytics as significant in driving functional integration Over one third have already adopted a Digital Thread approach 2017 ML Council Research Surveys

15 Organizational Momentum: Collaboration Command and Control Structures Giving Way to Collaboration Collaborative: employees, customers, suppliers involved Somewhat Decentralized: hybrid structures Highly Decentralized: managers have significant autonomy Highly Centralized: hierarchical, command & control structure Now 5 Years 9% 39% 38% 29% 24% 11% 25% 13% Technology Organization M4.0 Leadership 2017 ML Council Research Surveys

16 Organizational Momentum: Innovation 90% The Importance of Competitive Innovation Will Rise Dramatically with M4.0 Increasing in importance Key Innovation Goals Over Next 5 Years #1 New Products #2 Manufacturing Processes #3 New Services #4 New Business Models #5 Supply Chain Technology Organization M4.0 Leadership Customers, Business Partners, Suppliers, and Technology Vendors Will Be Main Innovation Collaborators Over Next Two Years 2017 ML Council Research Surveys

17 Leadership Momentum: New Skills Overwhelming Majority Say M4.0 Needs Different Leadership Approaches and Skills 99% fully or partially agree What Does M4.0 Leadership Mean? #1 Having a vision for the future and a strategy to get there #2 Inspiring and engaging everyone around me, every day 2017 ML Council Research Surveys What New Skills Are Needed in an M4.0 World? How to use Analytics to help make decisions How to integrate processes & functions How to manage accelerating market change How to lead collaborative organizations How to create open, virtual working cultures Technology Organization M4.0 Leadership

18 Leadership Momentum: New Roles Technology M4.0 Organization Leadership Source: 2017 August Manufacturing Leadership Journal

19 The Transformative Journey to Manufacturing 4.0 M4.0 CHALLENGES Technology M4.0 Organization Leadership

20 M4.0 Technology Challenges * Cost and Complexity of Upgrading Legacy Systems * Only One Third Have a Formal Technology Strategy in Place - 34% * Mixed Responses on Readiness of Technology Vendors * Over Half Think Cybersecurity Will Restrict or Hinder M4.0 Adoption - 54% * Hard to Keep Pace with M4.0 Technology Developments - 56% * Confusion Around Lack of Available M4.0 Standards * Understanding How to Manage and Maximize the Tsunami of Data 2017 ML Council Research Surveys

21 M4.0 Organizational Challenges Top 3 Integration Challenges Changing What We Are Doing While Still Running the Business 77% Cultural Change / Behavior Change 73% Putting in Place New Metrics, Reward Systems, to Reinforce Integration 38% Resistance to Change 30% 25% 20% 14% 11% Middle-Level Managers Senior Executives Business Unit Leaders Supervisors & Managers Line Workers 2017 ML Council Research Surveys

22 M4.0 Leadership Challenges Manufacturing Leadership s Top M4.0 Concerns Understanding the Benefits/Challenges Corporate Culture Leadership Readiness 2017 ML Council Research Surveys

23 M4.0 Leadership Challenges Manufacturing Leaders NOT READY for M4.0 VERY FEW Understand M4.0 Impact 92% Not at all, or only somewhat prepared 13% Of leaders say M4.0 is well understood today 4 OUT OF 5 Feel Vulnerable About M4.0 Success 82% 2017 ML Council Research Surveys Very, moderately, or slightly vulnerable

24 M4.0 In Action PROGRESS IS BEING MADE Technology M4.0 Organization Leadership

25 M4.0 In Action Project: Advanced Logic Planning Support Description: Created a tool based on a sophisticated data-driven optimization model and smart algorithm that allows the company to dramatically reduce the time it takes to switch production lines from one product to another. The system, which replaces manual processes, allows Merck to optimize turnaround plans in near-real-time, enabling it to respond much more nimbly to market changes. Outcome: Shorter lead times, lower inventory levels, smaller batch sizes and higher equipment utilization at plants in the network.

26 M4.0 In Action Project: Cisco s Digital Design and Manufacturing (DDM) Platform Description: This initiative created a series of digital production data, visibility, and manufacturing applications that together, transformed how Cisco shares design and production data with its contract manufacturers. By getting the right data to the right people at the right time, Cisco effectively meshed its development and fulfillment supply chains, allowing it to get new products to market faster and more efficiently. Outcome: Millions saved in reuse of parts, reduced part and tooling costs, and much faster prototype and tooling cycle times.

27 M4.0 In Action Project: Lexmark s Predictive Service Description: Combines thousands of smart, connected printers in the field with predictive algorithms and models, allowing the company to predict and proactively fix service issues. Outcome: Millions of dollars in savings for Lexmark and better service for customers.

28 M4.0 In Action Project: Operations Talent Development Initiative Description: Enabled Dow to develop an engaged workforce for the M4.0 era. Innovative programs use unconventional methods to uncover latent skills, motivations, and ambitions, and provide clarity of purpose through a guided process of self-discovery. Outcome: Better developed employee capability and value, lower retention costs, increased morale and stability, improved engagement and effectiveness.

29 M4.0 In Action Project: iwarehouse Description: Telematics tracking and data analysis system that reports on utilization and maintenance data of fork lift trucks and lift truck operator efficiency. Outcome: Raymond s customers can now optimize labor and equipment productivity, fleet utilization, industrial battery management and warehouse operations.

30 The Transformative Journey to Manufacturing 4.0 THE WAY FORWARD Technology M4.0 Organization Leadership

31 The Way Forward What You Can Do Now Start Your Journey Now Identify Areas of Maximum Competitive and Operational Opportunity Launch Pilot Projects to Prove Concepts and Measure Gains Embrace New Insights from M4.0 Technologies and Analytics Create Collaborative Cross-Functional Teams to Share Ideas Partner with Key Customers and Suppliers to Drive Innovation Educate and Engage Your Workforce to be M4.0-Ready

32 M4.0: The Way Forward Think Big! Nothing will be Gained by Inaction Align Your M4.0 Initiatives with Future Business Strategy Learn, Experiment, and Embrace Risk Explore New Business Models that Harness Market Disruption Orchestrate Change Across the 3 M4.0 Dimensions Develop New Leadership Skills and Digital Industry Acumen Create a Culture of M4.0 Innovation & Success

33 Join the Journey to Manufacturing 4.0 Nominate Your Innovative Projects for a 2018 ML Award Join Industry Thought-Leaders at the 2018 ML Summit Join the World s Foremost Industry Leadership Network

34 2018 Manufacturing Leadership Awards Celebrate Your Success! Prestigious Annual Industry-wide Awards Program 10 Innovative M4.0 Project Categories Individual Category for Visionary Leadership Independently-judged Nominations Additional High Achievers & Manufacturers of the Year Awards 2018 ML Awards Gala Dinner, June ML Awards Deadline: December 15, 2017 Download Your Nomination Form Now

35 2018 Manufacturing Leadership Summit Accelerating the Journey to M4.0 June 11-13, 2018 Hyatt Regency Huntington Beach, Huntington Beach, CA Manufacturing 4.0 Early Adopters Thought-Leading Industry Speakers Award-Winning Innovative Projects Expert Panels M4.0 Think Tanks 2018 Critical Issues Annual Council Meeting 2018 ML Awards & Gala Dinner

36 Imagine a Better Future for Manufacturing

37 BOLD IDEAS - POWERFUL CONNECTIONS - WINNING STRATEGIES For questions regarding membership, please contact: Jeff Moad jeffrey.moad@frost.com About the Manufacturing Leadership Council The Manufacturing Leadership Council, part of Frost & Sullivan, offers an integrated portfolio of leadership networking, information and professional development products, programs, and services for industrial executives worldwide. MLC s mission is to help senior executives define and shape a better future for themselves, their organizations and the industry at large. MLC s portfolio consists of the Manufacturing Leadership website, an online global business network; the Manufacturing Leadership Council, an invitation-only executive organization; the annual Manufacturing Leadership Summit conference; the Manufacturing Leadership Awards program; and the Manufacturing Leadership Journal. For more information, visit

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