“It’s all about the data”Smart Manufacturing: Playing with Data & Moving to Industry 4.0 – 24th February, 2016

Part 1: Playing with Data● “What is the Value of Data?”● World Exclusive : Awesome data-based game● Case Studies

Part 2: Moving to Industry 4.0● “What is Industry 4.0 anyway?”● SMEs: benefits & what to do next● Quiztime: How Industry 4.0 are you?

Welcome

What is the value of the data?

You can’t manage what you can’t measure!Shop floor data capture: Enabling continuous improvement!On paper vs Digital collectionReal time vs Historical data

Real time DataI had better take anumbrella with me!

Weather forecastHistorical DataIt has been cold this weekeveryday so it’s likely thattomorrow will be cold too

Your production planReal time DataRapid decisions to avoid wasteand improve efficiency

Historical DataInformed decisions on whatyour production plan will be in 3weeks’ time

Capture data to make betterbusiness decisions!

Part 1: Playing with data

The beer game - a game about (lack of) data

• Classical Lean Management exercise• Show the effect of delay on a Supply Chain• Whimsical customer ⬅ ⬅�ŇĂŝůŝŶŐ�ĚŝƐƚƌŝďƵƟŽŶ� despairing brewery

Now, let’s run it again with a bit moreinformation

Rules:1. Decide how much to order from your supplier (yellow box)2. You will receive an order from the customer3. At each turn, it costs you £100pi for over and £50pi for under stocking

• Small pieces of information– simple sensors, manual actions ➡ easy to collect– Time and duration, temperature, position, presence, open/close, number, job number

• Can be combined in a simple way in a single processe.g. duration vs number ➡ average cycle time, costing, production planning

• Can be combined in complex ways across processes ➡ not stealing Scott’s thunder

What is data? What data? Why?

Wickens Engineering• Cutter/puncher machine - production bottleneck

Machine underperforming? Do we need another machine?• Simple sensor - position versus time• System analyses patterns to determine if the machine is doing anything useful• Measure ➡ Analyse ➡ Change ➡Measure again

Case Study - Machine Efficiency

• The company has identified quality issues with some of their vacuum formed parts• Possible problem:

– Misuse of the oven (oven not at temperature, part removed too early)• Solution:

– Combine simple sensors (temperature, oven opened, part number)– Feedback to the user (stack light)

• The sensor monitors the temperature of the oven• Operator is notified through the stack light

– oven at temperature– part ready– open sensors to monitor compliance (six-sigma)

Case Study - Oven monitoring

Part 2: The road to Industry 4.0

Fourth Industrial revolution● It’s new: Term first used in 2012● Small SME involvement and uptake to date● 6 design principles

German Government initiative● Industrie 4.0● “implementation still in its infancy”● http://www.plattform-i40.de/

What is Industry 4.0 anyway?

6 design principles

1. Interoperability (internal integrations, IIoT sensors)

2. Virtualization (factory simulation, data display, augmented reality)

3. Decentralization (connected machines and mobile computing)

4. Real-Time Capability (Big data, The Cloud, data analysis)

5. Service Orientation (external integrations, cybersecurity)

6. Modularity (production line flexibility, robotics, additive layer manufacturing)

2 views from Germany

faster response timesimproved productivityincreased flexibilityincreased revenuemore jobs (NB: skills)

+ eventually your clients mightask you to integrate into theirIndustry 4.0 supply chain…!

… but all still uncertain!

5 benefits of Industry 4.0 for SMEs

(You’re on a journey here… it’s about evolution, not revolution)

What do SMEs need to consider?

what internal facing datado you have/need?

• machines• products• production• human

what external facing datado you have/need?

• quotes• orders• supply times• stock levels

how digital is yourorganisation?

• infrastructure• documents• machine setting• humans ?!?

Do you have theadequate IT skillsand support neededto take an Industry4.0 journey?

Nearly there...

Real time factory performance data in 3D

Even if you don’t believe Industry 4.0 is the next revolution, you should stilllook to digitise as it helps reduce wasted time in your business processes.

Our View

How Industry 4.0ready are you?

Quiz Time!

Q1/10: Email

How digital is your communication?

0 105

Office 365 onsmartphones

Office 365OutlookNo email !

Q2/10: Documents

What do you use to work on documents?

0 105

Collaborativecloud docs!

Office 365 /Google Docs

WordPaper only!

Q3/10: Internet connectivity

How modern is your infrastructure?

0 105

3G/4G roamingconnectivity

WifiCabled internetto PCs

No internet !

Q4/10: IT Support

How do you maintain your business tech?

0 105

Proactive ITsupport

Dedicated ITmaintenance

Part time role“my mate John”

Q5/10: Production Planning

How do you plan for making things?

0 105

Integrated /Cloud software

Specific planningsoftware

Use ExcelNo planning !

Q6/10: Machine performance

How do you track how your machines are running?

0 105

Real time datacapture

Historical datareports

Paper loggingNone logging !

Q7/10: Assets/Logistics

How well do you track your goods and assets?

0 105

RFIDbarcode systemPaper loggingNo tracking

Q8/10: Stock/Inventory

How well do you monitor stock levels?

0 105

Integrated /Cloud software

Computer logsPaper logging“Had a look”

Q9/10: Costings

How do you calculate how much to charge?

0 105

Using actualmanuf. costs

based on pastproduction data

based on pastcostings

“Finger in the air”

Q10/10: Quotes/Billing

How do you manage financial flow?

0 105

Integrated Cloudsoftware

“We use Sage”pdf and emailverbal / phone

Case Studies

Mobile based cask traceability system

Smarter Factories

Assets can be searchable on the mapReal time delivery and signature -

Invoicing is under 24 hoursWeb based - accessible from

everywhere and all devices● Incredibly easy to use● Data exported to a Cloud

Spreadsheet for easy reporting

QR Code based tracking for company’s fridges

● Lost/misplaced assets● Invoicing can take up to 5 days

and paperwork can be lostsometimes

● Too much paperwork and admin overhead

● Everything is manual - No digital capture

Before After

Thankyou

And remember,the future is digital !