Keys to Successful Manufacturing in China Intelligent Factory Concept Austria Connect Greater China 2014 October 24 th, 2014 David Mueller General Manager Email: d.mueller@staufen.cn Phone: +86 189 1810 2217
Industry 4.0 what is it? Industry 1.0 Mechanized Industry 2.0 Electrified Industry 3.0 Automated Industry 4.0 Networked End of 18 th century First mechanical loom in 1784 Begin of 20 th century First production line at Cincinnati slaughterhouses in 1870 Begin of 70 th century First programmable logical controller (PLC), Modicon 084 in 1969 Electronics and IT Today Connected, virtual, augmented Mass production with the help of electric power Mechanical equipment with the help of water and steam Source: Umsetzungsempfehlungen für das Zukunftsprojekt Industrie 4.0, April 2013 2
Overview Concept elements + 7. Building blocks Processes, methods, competencies 8. Project management People & organization 6. IT System 1. Plant concept 5. Facilities, Layout & Automation 2. Product Design 3. Supply Chain 4. Production system Intelligent Factory 3
The context How the pieces fit together Efficient Processes & Services Continuous Improvement & Creativity Connected Virtual Augmented & Standardized Interchangeable & Scalable Shopfloor Management Go-See-Understand Train Perfection 4
The concept element consist of three characteristics Characteristics Connected Virtual Augmented area A robot area B Materials/ Products/ Machines/ Services/People Self-guided trolley Digital factory worker Human-machine cooperation 5
8 building blocks make the intelligent factory 8. Project management 1. Plant concept 2. Product Design 7. People & organization 3. Supply Chain 6. IT System 5. Facilities, Layout & Automation 4. Production system 6
The plant concept is intelligent because it takes into account all elements necessary to make a factory work Building block 1. Plant concept Intelligent element Comprehensive approach 2. Product design 3. Supply chain 4. Production system 5. Facilities, layout & autom. 6. IT system 7. People & organization 8. Project management Staufen client 7
The product design is intelligent if it is modular and reduces complexity Building block Examples of smart solutions 2. Product design Intelligent element product family Scalable parts product family 8
The supply chain is intelligent if it optimizes the value stream across factory boundaries in cooperation with suppliers Building block Examples of smart solutions 3. Supply Chain Early supplier integration in the product development process Supplier Self Audit Requirement of International Customers Staufen WPS Audit Business Potentials Planning and conception Supplier nomination RFQ and assignment RFQ Pre Sourcing Assessment Price & Cost nology Quality Production Logistics a. Supply Chain Partdevelopment Partoptimization APQP Readiness Management Tooling Production Process Machines Parts Sub Supplier Management Sampling Process Design (Tools and machines) Ramp Up Problem Soliving Trouble Shooting Interims Management Training Sub Supplier Management SOP Trial Run / Process validation/ Ramp Up Series production Supplier Cockpit KPI Definition Designing Monitoring System Data validation process Measurement Catelog System and module suppliers and business partner network Supplier Benchmarking Cost Calculation Staufen Supplier Database Supplier Questionnaire Project Management Support Speeding Up Machine Delivery Speeding Up Sample Approval Speeding Up On Site organization Operating Supplier Cockpit Regular Monitoring Rugular Communication Escalation Intelligent element Operational Problem Solving Q-Improvements Delivery Task Force Process Audit Supplier park and JIT deliveries Intelligent replenishment systems (e.g. ekanban) 9
The production system is intelligent if it makes use of lean principles and smart elements Building block Examples of smart solutions 4. Production system Intelligent element Self-guided trolley Paperless work instructions 10
Automation is intelligent if it optimizes the interaction between worker and machine Building block Examples of smart solutions 5. Facilities, layout and automation Flow oriented layout Automatic lighting control Intelligent element Automation Construction of energy saving and environmentally friendly plant 11
The IT is intelligent if it connects, virtualizes, and augments materials, products, machines, services, people Building block Examples of smart solutions 6. IT-System Factory simulation Real-time data Intelligent element area A robot area B Human-machine cooperation 12
The organization is intelligent if it supports communication and problem solving. Building block 7. People & organization Examples of smart solutions XX xx xx xx Intelligent element Value Stream Organization Training Digital SFM Board CIP Training 13
The project management is intelligent if it ensures the success of the project Building block Examples of smart solutions 8. Project management Project core team Supply Chain RSP Mr. XX Mr. Fang 2-3 days per Steering Committee Mr. XYZ Mr. Hu Project Leader Mr. Adrovic & Mr. Yu Mr. Voelker Order Fulfillment RSP Mr. XX Ms. Jin 2-3 days per Purchase Strategy Mr. XX Mr. Ma 2-3 days per Strategy Objectives Approaches Project leading Expertise input Escalation Conception process/organization Qualification Implementation plan week week week Pilot implementation 4-6 Project team members Supply Chain RSP On demand 4-6 Project team members Order Fulfillment RSP On demand 4-6 Project team members Purchase Strategy On demand Contribution in project work Rollout & Implementation Intelligent element Project steering committee Training Project in stages Project room 14
Overview Concept elements + 7. Building blocks Processes, methods, competencies 8. Project management People & organization 6. IT System 1. Plant concept 5. Facilities, Layout & Automation 2. Product Design 3. Supply Chain 4. Production system Intelligent Factory 15
David Mueller General Manager www.staufen.cn STAUFEN.Shanghai Consulting Academy Ltd. 22H Cross Region Plaza 899 Ling Ling Road 200030 Shanghai P.R.China +86 21 64417112/15/16 +86 21 64417105 +86 189 1810 2217 d.mueller@staufen.cn - Thank You - 16