China From Volume to Value with Intelligent Manufacturing

Transcription

1 Bitte decken Sie die schraffierte Fläche mit einem Bild ab. Please cover the shaded area with a picture. (24,4 x 13,2 cm) China From Volume to Value with Intelligent Manufacturing Hui Zhu 17 th Nov.,

2 Content Proposal 25min presentation Continental AG 1 slide 2 slide (Location map + China in Motion) China New Normal (Macro Economics + Automotive) 2/3 slides Industry 4.0 vs. Made in China slide Example textile/electronics production move out 1 slide Labor cost / sales examples 1 slide Our Solution lean automation examples 2 slides Executive Summary: localization / Stay in China / Productivity / Lean Automation - 1/2 slides 2

3 Continental Corporation Overview 2015 Since 1871 with headquarters in Hanover, Germany Sales of 39.2 billion 207,899 employees worldwide 430 locations in 55 countries Tires 26% ContiTech 14% Sales by division in % Chassis & Safety 21% Powertrain 18% #213 (Top 5 Automotive Supplier) Interior 21% Status: December 31,

4 Continental in China Locations Map Manufacturing Locations: 26 Sales Offices: 27 R&D Locations: 17 Joint Ventures: 13 Total Employees: >24,000 Chongqing Heihe Changchun Shenyang Beijin g Tianjin Jinan Baoding Yancheng Yanzhou Changzhi Qingdao Qufu Changzhou Lianyungang Zhangjiagang Nanjing Changshu Yangzhou Hefei Shanghai Wuhu Wuhan Ninghai Sanmen Headquarters Manufacturing Locations R&D Locations Sales Offices Joint Venture Liuzhou Guangzhou Taipei Status: Aug

5 In the Market for the Market Customized Solutions for Chinese Market ESC ABS Chassis & Safety Caliper Actuation Airbag Control Unit Short Range Lidar... Powertrain EMS(DI Injector, DI Pump) Transmission Management System Fuel Supply SCR Systems NOx Sensor 48 V Machine... Interior Body Control UnitsAccess & Start Systems Tire Pressure Monitoring Instrument Cluster Multimedia Systems Connectivity& Telematic Truck Instruments & Control Units... Passenger Car Tires Light Truck Tires Two-Wheel Tires Tire... ContiTech Hose Lines Engine Belt Engine Mount Air Spring Interior Foil Conveyor Belt Elastomer Coatings... 5

6 We are living China s New Normal 6

7 Automotive Industry in 2015 We experienced the auto Market Volatility Mio. units 2.5 Production Wholesales Dealer Sales % % Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Source: Production & Wholesales from CAAM, Dealer Sales from CPCA

8 Made by China 2025 : Chinese Industry 4.0 China moving towards more Innovation We will be an Innovative Country. Made in China 中国制造 & 中国创造 Made by China >2025 Opening The House of Manufacturing Largest Market of the World Innovation All pictures downloaded from open internet, copyrights restricted, not for distribution. 8

9 Is China not any more Attractive & Competitive? Textile, Electronics and more Industries are moving southi All pictures downloaded from open internet, copyrights restricted, not for distribution. 9

10 350, , , , , ,000 50, % 18.00% 16.00% 14.00% 12.00% 10.00% 8.00% 6.00% 4.00% 2.00% 0.00% Productivity Examples A Plant Sales (Mio CNY) +22% +14% B Plant Sales (Mio CNY) +10% +27% 3,341 4,432 4,993 5,707 2,952 3,588 3,540 4, Act 2013 Act 2014 Act 2015 Act 2012 Act 2013 Act 2014 Act 2015 Act Var. Labor Cost Fix Labor Cost Labor Cost of Sales % +28% +34% % 6.34% 6.99% 7.03% 2015 Act 2012 Act 2013 Act 2014 Act FC Act November 2016 Dr. Ralf Cramer, Continental AG 10

11 Smart Continental Our Focus is on the Improvement of Processes Continuous & Disruptive Innovations / Technologies / Trends Application Fields Advanced Robotics Execution Supply Chain Management Shop Floor Management Smart Sensors & Actuators Software & Services Augmented Reality Big Data Collection & Analytics 3D Printing Physical Process Smart Material Flow Process Smart Production Process RFID, GPS Continuous Cloud Storage & Applications Innovation Artificial Intelligence Disruptive Asset Management Facility Management Maintenance Process 11

12 Smart Continental Supply Chain Management RFID / GPS Big Data 3D Printing e.g. for packaging development 3D Printing: Technology for Packaging Planning. Lead time reduction and increase of packaging density. RFID/GPS: Transparencyand increase in efficiencymaterial flow supply chain Advanced Analytics Material Flow: inventory and transportation cost reduction Advanced AnalyticsDemand Planning: Efficiency increase and precision increase in forecast planning 12

13 Smart Continental Shop Floor Management: Wearables, Devices & Augmented Reality Digital Line Board Watches Tablets Glasses Manufacturing Execution System Efficiency increase: Digital Line Board: visualize real time data of deviations in the plant Watches: to inform real time breakdown of machines Tablets: reduction of downtimes by virtualization of complex working instructions Glasses: 7*24h remote support for operator MES: Backbone for Data Management 13

14 Smart Continental Smart Material Flow Process: Material Replenishment 2 1 Automatic Guided Vehicle Smart Handling Unit I am closest to the warehouse. I will take the refill order. I am below replenishment level. Please fill me up. 3 Automatic braking and sidestepping There is an obstacle. I ll look for another way. 4 Warehouse The parts can be picked up in three minutes. SMART HANDLING UNITS Intelligent supply and replenishment. OPTIMIZED SUPPLY Fast, optimized routes to production and warehouse. CONNECTIVITY Throughout all processes. Benefits: Productivity Improvement Improved safety and efficiency Easy tracking, monitoring & controlling 14

15 Smart Continental Smart Production Process: Advanced Robotics Cage Free (Collaborative) Robot Dual Arm (Collaborative) Robot Multiple Robots in Backend Cell New Backend Design for Robots Mobile Collaborative Robots I the end of separation of employees & robots by big fences I for parallel or more complex operations I scalability & flexibility with a varying number of robots in the backend I Robots will lead to new assembly stations with high robustness, low investment needed, less floor space demand and shorter lead time I the Collaborative Robot becomes mobile Competence in Application Engineering & Gripper & Tooling Technology is Key 15

16 Smart Continental Facility Management: Energy Data Management Vision: Energy Forecast We use production plans and weather forecast to optimize the energy consumption. Source: CEP Plant RBG MRSA 5 Pilot: Energy Data Management System System administrator, my energy consumption per piece is to high! Vision: Energy Maintenance kwh/m³ ventilation exceeded upper limit: please change air filters Vision: Smart Building Control System I am running in stand-by mode, please reduce the utility consumption (e. g. air handling units) 16

17 Smart Continental Maintenance Processes: 7 * 24h Service by Wearables 7 * 24h Service bywearables/ Realtime Video: Best support in real time (video streaming) Cost effective remote expert support Reduction of communication barriers 17

18 Thank you for your attention! 18