ATS Industry 4€¦ · Smart Automation, Quality and IT Excellence Solutions •Double digit growth year on year •900+ people (>75% Consultants + Technical) •4000+ customers worldwide

The Independent Solution Provider for Smart Digital Transformation

Good, Bad & Ugly of Industry 4.0Understanding what is possible with Industry 4.0, today, tomorrow and in the future

ATS Global Headquarter

Hofmanweg 5A, 2031 BH

Haarlem, Netherlands

Michele Sciuto

Chief Commercial Officer

www.ats-global.com

ATS North America

1055 East South Boulevard

Rochester Hills, MI 48307, USA

http://www.ats-global.com/


ATS Global Business

• 30 Years leadership in Smart Automation, Quality and IT Excellence Solutions

• Double digit growth year on year

• 900+ people (>75% Consultants + Technical)

• 4000+ customers worldwide

• Selected by Gartner as Global MES/MOM consulting provider with system integration services

(2018 Gartner Market Guide for MES/MOM Implementation)

ATS Canada

ATS USA

ATS Australia

ATS UK

ATS Spain

ATS Belgium

ATS GermanyATS Netherlands

ATS Austria

ATS Czech Republic

ATS Mexico

ATS South Africa

ATS Singapore

ATS Turkey

ATS Italy

ATS IrelandATS China

ATS Hong-Kong

ATS India

ATS Indonesia

ATS Macedonia

Automation & IT MES / MOM PLM Quality ManagementSupply Chain

Management

Smart Manufacturing

Industry 4.0


Agenda

Practical steps to implement

an I4.0 strategy

An outlook on the factory of

near future

How do we see Industry 4.0?

Good, Bad and Ugly of it


Industry 4.0: Strategy to Raise Maturity

Computerization Connectivity Visibility Transparency

Predictive

Capacity Adaptability

Digitalization Industry 4.0

Valu

e

Seeing

Understanding

Being Prepared

Self-Optimizing

FIR e. V. at RWTH Aachen University: Stages in the industrie 4.0 development path

What happened

What is

happening?

What will

happen?

How can an autonomous

response be achieved?


The Good

It is a Strategy, delivering strong financial benefit

Triggers innovation and looking for new business opportunities

Generate competition in the manufacturing market

Industrial Standards are still very much valid (e.g. ISA-95, 88, 99)


The Bad

A lot of Buzz-wording

Technology for technology?

What’s the risk not to take that road?


The Ugly

Business Case can be extremely challenging

New Technologies are still under finalization

Need to complete the digitalization phase first

It is a long journey…


Need a Solid Strategy

Digital transformation is about business transformation

De

fin

e t

he A

mb

itio

n

Strategy Raising the Maturity Level Industry 4.0

Exce

llen

ce

Ad-H

oc

Pla

nnin

g &

Contr

ol

Sta

ndard

ized

Pro

cesses

Pre

dic

table

Perf

orm

ance

Continuous Im

pro

vem

ent

Business

Benefit

Processes

Structure

Technology

People

New Business Models

Internet of Services

Virtual to Physical

World

Individualization of

Mass Production

Self-Organized Smart

Factories

Cyber Physical

Systems

„Most people overestimate what they can do in one year and underestimate what they can do in ten years.“

Business

Benefit

Business

Benefit

Business

Benefit


Manufacturing Technology Landscape

Reduce Total Cost of

Ownership

Break data silos

Effectively collect data from

OT and IT systems

Enable and foster innovation

Enable collaboration among

the different systems


Bridging the IT/OT Gap

ERP

MESPLM

01001001001010100010

Leverage on IT and OT investments already in

place

Enable machine to machine and business to

machine collaboration

Acquire all the relevant data to create digital

product and process representations – Digital

Threads

Create a secure environment for data exchange

Break data silos and unleash untapped potential


Process VisibilityCollect, Calculate and Visualize KPIs

Use the ISO 22400 KPIs to find opportunities for

improvement in manufacturing operations

Process real time data stream to take decision

when process or product deviations happen

Make critical factory information accessible from

anywhere and any devices

Compare KPIs across multiple plants and find

what make a certain plant successful

Build and configure reports and dashboards to

fit your business needsSolution powered by Microsoft PowerBI


Process Transparency and Prediction

Reduce maintenance costs and improve asset

health and performance

Explore asset performance data to learn the

cause of failure

Provide optimized maintenance

recommendations to technicians

Calculate asset health scores and predict life

spans

match existing defect image and flag product

as defective

Solution powered by IBM Watson


Dynamic Planning and Scheduling

Support major decisions of production capacity:

extend workforce, resource capacity and

factories

Predict effects of change in production and

react in real time to lack of resources

match existing defect image and flag product

as defective

Solution powered by Siemens Preactor

Import production orders from ERP and create

the optimal detailed schedule for the plant


Production Management

Show electronic work instructions to operators

Dispatch the jobs to the right work centers

Deliver part programs and recipes to shop-floor

machines

If any, plug your MES system into the

ecosystem


Quality ManagementATS CM4D - Dimensional Quality (Discrete Manufacturing)

Validate accuracy of supplied parts

Create the Digital Twin and compare product to

Original Design

Predict Assembly Problems and avoid

production issues


Quality Management ATS Inspect, Visual Quality for Discrete Manufacturing

Improve Right First Time KPI and Prevent

Defective Products from Leaving the Plant

Create a dynamic inspection process with the

support of 3D models

Eliminate Paper Checklists

Minimize Costs of Rework and Scrap


Quality Management Cognitive Visual Quality for the Discrete Manufacturing

Employ cognitive and human expertise to attain

the highest confidence levels of defect detection

Reduce Inspection cost and time while

improving throughput

Increase consistency of defect detection and

classification

Images captured

Defects compared

Real-time monitoring

existing defect image and flag product as defective

Store

Machine Learning system

Match

Solution powered by IBM Watson


LIMS Laboratory Management for the Process Industry

Improved lab efficiency through reduced

administration, errors, scrap and rework

Automatic data capture and centralized data

consolidation for fast and easy quality data

retrieval and reporting

Full traceability of quality data resulting in

improved regulatory compliance

Improved lab efficiency through reduced

administration, errors, scrap and rework


Realize the Factory of the Future

Predictive Maintenance

Planning and Scheduling

Cognitive QualityQuality Management

Manage Production

Process Visibility

Laboratory Management


What to do then?

• Create a step-by-step business case reflected in your Digital Roadmap and focus on gradual measurable improvements

• Leverage on IT and OT investments already in place

• Complete the digitalization phase first, the 4th

Industrial Revolution can only come later

• Start as soon as possible, it will be a long learning journey…


Industry 4.0Let’s start the journey

Computerization Connectivity Visibility Transparency

Predictive

Capacity Adaptability

Digitalization Industry 4.0

Valu

e

Seeing

Understanding

Being Prepared

Self-Optimizing

FIR e. V. at RWTH Aachen University: Stages in the industrie 4.0 development path

What happened

What is

happening?

What will

happen?

How can an autonomous

response be achieved?


Thank You

ATS North America

1055 East South BoulevardRochester Hills, MI 48307, USA

Michele Sciuto

ATS Global CCO

http://www.ats-global.com

mobile: +31 6 46764766

email: [email protected]

ATS Global Headquarters

A. Hofmanweg 5a, 2031 BHHaarlem, The Netherlands



Thank You

Michele Sciuto

CCO

ATS Global B.V.A. Hofmanweg 5a

NL-2031 BH Haarlem

http://www.ats-global.com

mobile: +31 6 46764766

email: [email protected]

Discover more


http://www.ats-ados.com/




TraditionalTraditional BronzeBronze SilverSilver

MaturityModel

Reactive...Reactive... Monitor...Monitor... Vision...Vision...Control...Control...

Inherited local operational rules base on local key performance

metrics

Making the hidden factory visible to enable informative

decisions

Taking control of manufacturing through standardisation

World class flexible and responsive manufacturing

operations

Us

Paper Based

Solution

Plant Scheduled

Weekly

LowEfficiencies Manual

Reliance

Push Philosophy

FirefightingMentality

WIPTracking

Production Scheduling

Manual Data Capture /

OEE

Electronic Work

Instructions

Visual Inspection

Standard Accurate Reporting

Quality Management

Auto Data Capture /

OEEChangeover

Management

Order Management Machine

Connectivity Resource Compliance

Advanced Production Scheduling

Supply Chain Management Predictive

Maintenance

Inventory Management

Product Lifecycle

ManagementIndustry 4.0

You GoldGold

ATS – Maturity Pathfinder


• Graphics from GKN presentation


Agenda

• What is Industry 4.0 about?• It is financial benefit / new business models

• Industry 4.0 VS digitalization

• Good• It is a Strategy

• It delivers Financial Benefit

• Triggers innovation and looking for new business opportunities

• Generate competition

• Industrial Standards are still valid (ISA-95)

• Bad:• Buzz Wording and confusions (Gartner hype

• Technology for technology

• What’s the risk not to take that road?

• Ugly:• Business Case extremely challenging

• New Technologies still under finalization

• Need to complete the digitalization phase first

• It is a long journey

• How do we approach it?• Need a strategy (VP slide)

• IT/OT convergence (Factory of Future)

• Next opportunities (Factory of the future)

• Food and Beverage and Pharma (Recipe Management and LIMS)

• SODA (innovation)

• 4:10 PM - 4:45 PM - Solution Spotlights

• Future Technologies & IoT

• Good, Bad & Ugly of Industry 4.0

• Understanding what is possible with Industry 4.0, today, tomorrow and in the future

• Michele Sciuto, Chief Commercial Officer, ATS Global


• How do we approach it?• Need a strategy (VP slide)• IT/OT convergence (Factory of Future)• Next opportunities (Factory of the future)• Food and Beverage and Pharma (Recipe Management and LIMS)• SODA (innovation)

• 3 Waves Process (???)1. Strategy2. Raise Maturity Level with gradual Benefit Realization 3. Implementations???


Success Stories


Automotive OEM Automated Self Correction Process

Problem

Need perfect robotic welding and painting processes with an automated self correction process

The Solution – ATS ADOS

Capture all the data generated, no matter the type or source

Automated validation for the quality of welding and painting processes

Enable manufacturing traceability for each component and validate vehicle variants at every gate

Business Case

2% improvement in overall quality of robotic operations

10% reduction in scrap rate due end-to-end traceability and root cause analysis

Checklist

Points

Automated Decision

OK NG


Automotive OEM Improve Product Quality and Reduce Warranty Claims

Problem

A carmaker knew that not all the defects found in the quality inspections made it to the reports due to

lost paper sheets and informal communication. They wanted to go paperless, provide KPI reporting to

the plant floor and send real-time alarms for critical issues to the production supervisors for immediate

containment to increase their FTR%.

The Solution – ATS Inspect

Business Case

Number of defects decreased 84% in 18 months at constant volume.

Paper removed from the plant

Real-Time Analysis

Inspection

Points

Rework

Points

Ship / No Ship Decision

Sites: 10 | Countries: 5 | Inspection Points: 100+ | Benefit: Quality Improvement | Savings: Millions


Quality defects behaviour


Problem

Easily integrate IT and OT layer

Send work order information between machines on shop floor and MES platform.

Track location of each part on the production line.

Collect all data through the production process

The Solution – ATS Bus

Business Case

Full process visibility and product traceability thanks to data contextualization

All data are securely transferred

Low TCO and ability to easily extend the architecture with new IT and OT components

Leading Aerospace OEM chooses ATS Global for Integrated Production Tracking and Order Handling

Representative

image


Problem

Simplified, system driven, Planning & Scheduling process

Ability to present various short-term schedule scenarios to the planning team(s)

Obtain medium-term forecasts to support internal forecasting requirements

The Solution – APS integrated in the application landscape

Business Case

25% reduction in customer complaints relating to deliveries.

>5% yield improvement through optimised scheduling

10% increase in on-time deliveries

Improved Forecasting Ability that enabled scenario planning

ATS Integrates Advanced Planning & Scheduling System at a Turbine Blade Manufacturer in the UK


Back Up


Electrical Vehicles OEM

Problem

Ensure production is in sequence, track vehicles and improve efficiency

The Solution – ATS Ignition Solution

• RFID tags are read at each work station and compared to the body sequence queue for vehicle tracking and process

instructions

• Vehicle body spec are communicated to the offline work cell operators, PLC, and robots thus insuring the offline

production is in sequence to the main line.

• Andon control: warnings or line stops are triggered if there is a quality problem (Pokayoke points). Automated conveyor is

controlled based on the production schedule

• OEE is calculated and displayed along the full assembly process

Business Case

Zero mistakes on production sequence, every vehicle is built according to the specs with no quality issues, world class OEE


Problem

Process innovation and built in quality with end-to-end traceability

Mind-set shift, introducing excellent process with robust gatekeeper and “zero outflow” management

The Solution – ATS ADOS (phase-wise rollout approach)

Phase 1 – Trim & Chassis and Vehicle Quality Assurance (VQA) – Using ATS Inspect and ATS Bus

Phase 2 to encompass all earlier manufacturing processes

Phase 3 to encompass all variable production data stored within ATS CM4D

Business Case

Unified European QMS

Major advances in data availability and process reporting

Reduction in re-work and production errors due to end-to-end traceability

Leading Car Manufacturer chooses ATS Global to improve Quality Assurance and Traceability

8Global plants where

solution is being used


The Digitalization Process

Digital transformation is about business transformation

De

fin

e t

he A

mb

itio

n

Strategy Raising the Maturity Level Industry 4.0

Exce

llen

ce

Ad-H

oc

Pla

nnin

g &

Contr

ol

Sta

ndard

ized

Pro

cesses

Pre

dic

table

Perf

orm

ance

Continuous Im

pro

vem

ent

Business

Benefit

Processes

Structure

Technology

People

New Business Models

Internet of Services

Virtual to Physical

World

Individualization of

Mass Production

Self-Organized Smart

Factories

Cyber Physical

Systems

„Most people overestimate what they can do in one year and underestimate what they can do in ten years.“

Business

Benefit

Business

Benefit

Business

Benefit



Step-by-Step Process to Manufacturing Excellence


Awareness and Strategy

Business Assessment

Business Case

Selection and Specification

Implementation and Integration

Support Packages

Benefits Realization and Consulting

WP1

WP2

WP3

WP4

WP5

WP6

WP7

A successfully proven process developed by ATS in

delivering Manufacturing IT and OT solutions to customers

Based on the ISA-95 standard model

It comes with a defined set of deliverables

It incorporates lessons learnt and best practices gained

from ATS and other implementations

It provides a guideline in implementing Manufacturing IT

and OT solutions but it can be tailored to our customer

needs

SUCCESSFULL

STANDARD

DEFINED

EXPERIENCED

FLEXIBLE


On Time parts delivery

Minimize Inventory Level

Receiving Area

Trace delivery of external

suppliers

Quality of supplied parts


Ensure visibility of work in

Progress (WIP)

Fabrication Area

Improve efficiency and

equipment availability

Optimize production

schedule and allocation of

resources

Ensure quality of produced

parts

Dispatch the right job to the

right work center at the right

time


Painting Area

Minimize setup and change

over times

Ensure quality of painted

part

Minimize consumption of

utilities


Synchronize sub-assemblies

with the main line

Assembly Area

Support customizations

(MTO/CTO/ETO)

Timely dispatch EWIs and

recipes to the line

Be ready for quality audits

Trace direct and indirect

material consumption


Feedback to engineering any

need of business

improvement

Shipping Area

Deliver a perfect product on

time

Minimize inventory of

finished goods


Quality ManagementATS CM4D - Dimensional Quality

Validate accuracy of supplied parts

Create the Digital Twin and compare product to

Original Design

Predict Assembly Problems and avoid

production issues


The Good

Documents

ATS Industry 4€¦ · Smart Automation, Quality and IT Excellence Solutions •Double digit growth year on year •900+ people (>75% Consultants + Technical) •4000+ customers worldwide