Industrial Revolution 4.0 Digitilization to Production

Transcription

1 Industrial Revolution 4.0 Digitilization to Production 2016/11/16, Taichung/Taiwan Christian Decker General Management The Company DESMA Location Bremen/Germany Machines, Automation and Molds founded 1946 for the industrial footwear produktion 225 Employees 47 mio USD Global sales (average 5 years) Exportrate over 92 % 34% Asia 31% Europe (incl. Germany) 15% USA/Canada/Mexico/Caribbean 9% South America 5 % GUS 6 % Oceania, Japan, Afrika, near East Seite 2 1

2 Trends and Key Facts in the Footwear Market Development of the Footwear Industry over 60 years Seite 4 Order lot Size Warehouse Inventory Product Variation Customer Influence

3 Trends Developments - Keywords Sustainability Decentralisation Reshoring Self Adapting Production Lead Time Mass Customization Urban Production Design for Manufacturing Fair Production Taylormade Smart Factories Industrial Revolution 4.0 Internet of the things Seite 5 Trends in Production Principles principle advantages disadvantages trend traditional footwear making relatively flexible human compensates quality deviation automated manufacturing high quality flexible model mix in production reduced manual work many manual processes quality deviation high VOC cost related to labour cost trend last cost higher equipment invest direct attach soling high quality flexible model mix in production low number of manual work mould cost higher equipment invest 3D printing - additive manufacturing fast from design to production flexibility in design slow process limited material selection high cost Seite 6 3

4 Year 2000: The DesFLEX Technology Target was order production just in time vision is lot size 1 pair economic production mix of large variety in small orders Seite 7 Upper Production Knitting a booming trend 2D Knitting 3D Knitting Warp Knitting Seite 8 4

5 Coming Technologies 3 dimensional upper generation weaving - knitting 3D printing most / additive of these production technologies are plotting waiting printing for their breakthrough since glueing decades - weldingbut the development is automatic currently assembly rapidly going forward and taylored textiles - multilayer production 3 dimensional sole everything generation is going additive manufactured moulds additive manufactured parts and total soles automatic assembly and multilayer production Seite 9 3D Printing Additive Manufacturing 3D printing / AM is a general trend but not used in massproduction Limitations by material + surface time cost Seite 10 5

6 DESMA Wrap Trainer Concept Shoes individual light efficient slip resistant robust recycable waterproof flexibel performance automatic production multicolor washable Seite 11 Upper Design to Production - Technology Level Stages production design 2D sketching 3D sketching 3D last design 3D single layer design flattening 3D to 2D 2D nesting 2D cutting 2D stitching 3D closing upper flat -2D 3D ideal process Seite 12 6

7 DESMA Wrap Shoes Workminutes per Pair Traditional saving > 90% Quadwrap Seite 13 Comparison Today production with DESMA Wrap Today Production Future Desma Wrap Flexibility of delivery ++ Possibility of customization + + lead time ++ inventory + requirement of labour ++ Carbon Footprint ++ Recycability + product performance ++ + efforts to generate the upper ++ economics of urban production ++ Seite 14 7

8 Business of Tomorrow Supply Chain 2015 distribution design retail shipping manufacturing design order Seite 16 8

9 Businessmodel: Mass-Production Brand A Start Brand B Order push - principle S u p p l y Supply Manufacturer Supply Material Retail A Retail C End Retail B Retail D Supply Seite 17 Information Material schematic sketch of the information and material flow Supply Chain 2025 shipping shipping design order design order shipping shipping design order design shipping order design order shipping design order Seite 18 9

10 Businessmodel: Urban Manufacturing Brand A Brand B pull - principle Product Data Supply Material Retail A Retail B Manufacturer Retail C Retail D Order Supply Start End Seite 19 Information Material schematic sketch of the information and material flow DESMA Example for Shop-Production Individual-Shoe Shop Production Preprocess A outsole + last placing curing curing curing lasting + delasting curing curing activation product handover Postprocess B Postprocess A injection Seite 20 10

11 DESMA Example for Mass-Production Example production line of 1000 to 1500 pairs in 8h/shift for stockfitting and assembling of 3D knitted sports footwear Seite 21 Software: smart shopfloor solutions more software for collection of data and business intelligence Seite 22 11

12 Next Generation Footwear Production - Scan to Individual Insole or Shoe Seite 24 12

13 - Overview Personal Data Biometric Analysis Consumer Shoe Configurator Production Seite 25 - Consumer Profile Dynamic Walking Profile Scan Automated Analysis 3D Geometry Scan 3D Geometry adaption Seite 26 13

14 - Product Configurator Seite 27 Individualization: color, name, logo Upper Spots Midsole Frame Sock Seite 28 14

15 Individual Produced Polyurethane sole Section 1 Section 2 Section 3 Seite 30 WrapNX Exploded assembly drawing Seite 31 15

16 DESMA Quadwrap Score 81% GOOD Sensory Card - DESMA Quadwrap DESMA Quadwrap: Upper DESMA Quadwrap: Sole DESMA Waertest Results (no labtest) Forefoot loose tight Heel cushion hard soft Toe-box shallow high Forefoot cushion hard soft Fit runs ½ size smaller larger Stability: heel wobbly stable Mid-foot loose tight Stability: front wobbly stable Arch support poor great Arch support poor great Tongue slide yes no Outsole grip poor great Collar loose snug Flexibility low high Achilles dip stiff soft Responsive No yes Ventilation warm airy Transition poor great Materials minimal plush Durability low high Seite 32 we like to support you on the way into the future Desmastrasse 3/5 D Achim Germany Phone Fax Mail info@desma.de Web 16