High Productivity Through Smart Factories - Industry 4.0 - Bulletin Board
2018
Lighthouse Smart Factories - WEF
WEF judged these nine factories as lighthouses for others to model their smart factory implementation. 7 more were added later making a list of 16 in total
Bayer Pharmaceuticals Division (Garbagnate, Italy): At a time of major volume growth for the site, the company has deployed a digital twin-based scheduling programme to drive improvements in its quality-control lab.
Bosch Automotive (Wuxi, China): Advanced data analytics are helping the company to “deeply understand and eliminate output losses, simulate and optimise process settings, and predict machine interruptions before they occur”.
Fast Radius/UPS (Chicago, US): Industrial-grade 3D printing is helping to tackle demand for fast-turnaround times and mass customisation of products, while a centralised, proprietary operating system drives real-time analytics and orchestrates design, production, and global fulfilment.
Haier (Qingdao, China): Artificial intelligence has been at the heart of work to create an ‘order-to-make’ mass customisation platform and a remote, AI-supported intelligent cloud platform for predictive maintenance.
Johnson & Johnson DePuy Synthes (Cork, Ireland): The factory has used IoT technology to create digital twins of physical assets for advanced machine insights, lower operating costs, and machine downtime reductions.
Phoenix Contact (Bad Pyrmont/Blomberg, Germany): ‘Customer-driven digital twinning’ has involved creating digital copies of each customer’s specifications, cutting production times by 30 percent.
Proctor & Gamble (Rakona, Czech Republic): The factory has developed a Web-based analytics model for supply chain improvements, speeding up time to market, and increasing inventory efficiency and customer satisfaction.
S
chneider Electric (Le Vaudreuil, France): Operators have increased visibility into operations, maintenance, and energy use, leading to energy cost reductions of 10 percent and maintenance cost reductions of 30 percent.
Siemens Industrial Automation Products (Chengdu, China): A new platform for flexible production takes customer orders and immediately allocates resources and schedules production time, leading to 100 percent compliance and 100 percent traceability.
https://internetofbusiness.com/nine-world-leading-smart-factories-identified-by-world-economic-forum/
BMW Regensburg - Smart Factory
1986 This plant began producing automobiles for world markets.
1990 A paintwork shop and facilities for manufacturing body components were completed
1997 The press shop was built.
2004 The Regensburg plant started producing the BMW 1 Series in addition to the 3 Series.
Current - bout 10,000 employees are taking care for the 880 BMW cars leaving the assembly lines daily.
In BMW factory digitization is happening constantly and in many places - and often the ideas come from the team itself.
The assembly has now anchored this innovative ability in the organization - in the InnoLab.
Team is composed of heads of different departments. They bundle the competence and the curiosity from the process improvement, the maintenance and of course the IT.
The InnoLab is supported by students from the region.
"PREDICTIVE ANALYTICS".
Press shop.
The beginning of every car is a tin roll. But no tin is like the other.
This is exactly where the project started: BMW systems sensory-adjusted so that they recognize the nature of the sheets, their individual properties - for example with regard to material strength, surface roughness or thickness of the oil film.
The data obtained in this way enable the plants to adjust themselves exactly to the delivered sheets - and to regulate themselves independently.
Cobots
Here company finds an expression of Industry 4.0, which allows the employee to work directly and without a protective fence with an industrial robot. This is possible because the robot were made so intelligent that it recognizes independently whether and how the colleague man gets in his way.
In practice, both man and machine can work hand in hand: the robot handles the arduous lifting and turning of the engine block. And the employee can - unlike in the old process - concentrate on putting the nut runner in the engine block. Industry 4.0 can not only make processes simpler and more efficient, but also more ergonomic.
RAPID PROTOTYPING CENTER
With development of technology, BMW have established a Rapid Prototyping Center, a competence center with seven 3D printers. Using this technology, they have now started to produce tools.
3D printers build objects in layers from a meltable plastic. Much of the work for their Rapid Prototyping Center comes from development. Because it often needs components for the prototypes of new vehicles. And as fast as possible. Whether they are bumpers, seat shells, rear axles, rear or front flaps: the parts do not have to be functional.
Assembly & Logistics
During assembly, the painted body becomes a finished BMW. Approximately 23,000 components must be installed in the vehicle. All vehicles go through several assembly lines. These are interconnected and have a total length of about 5.5 kilometers. The Regensburg plant produces several models in a mix on one and the same assembly line. These include models of the 1, 2, 4 and X series. Each car is assembled according to the individual wishes of customers from all over the world. A large number of parts assemble trained employees by hand. In order to relieve the employees of individual tasks, handling devices support the installation of large and heavy parts.
Individual process steps are taken over by robots.
Assembly & Logistics
Individual components such as engine, gearbox, axles, doors or bumpers are pre-assembled in separate areas and then delivered to the final assembly area "just in sequence". Even important parts such as the exhaust system, the seats or the wheels are brought "just-in-sequence" from external suppliers directly to the assembly line. In the final assembly, the actual highlight of automobile production, the so-called welding, comes about: The drive train (engine, chassis, axles) is automatically connected to the body and bolted.
IoT System
BMW's own IoT platform currently connects over 3,000 machines, robots and autonomous transport systems and is built on Microsoft's Azure cloud computing service.
https://www.zdnet.com/article/microsoft-and-bmw-we-can-help-you-build-a-smart-factory-with-the-cloud-robots-and-iot/
Shubham Parikh 1904038
Shah Shubham Bholabhai 1902209
BOSCH AUTOMOTIVE, WUXI, CHINA
SURA BHARAT - 1902233
SMRITI MAURYA - 1901116
SURAVAJJULA V S ABHIRAM - 1902235
BIG DATA IN BOSCH
Before digitization for big data
Bosch began its journey towards big data analysis in 2015.
Operational data from shop floor such as machine cycle times or part failure modes
Data typically required a significant amount of manual collection and pre-processing.
Shop floor improvement activities were impacted due to this delayed data availability and suboptimal data quality
IMPACT OF BIG DATA IN BOSCH
Real time data and insights from its analysis would provide a path to better and faster decision making
Business agility, vital for competition in China
IOT IN BOSCH
Workforce management was carried so smoothly after the implementation along with smarter way to handle machines by employees
One device will be in a position to monitor all the machines in the factory from providing input raw materials into machines to the final end product
In case of inventory or storage RFIDs are implemented in the warehouse and factory where human errors can be reduced
Logistics is one of the major part of a factory where we implemented IOT. Also future might shift to driver less vehicles
Wuxi site set up an industrial IOT framework
100% Newly installed machine-condition sensors
100% Individual cutting tool information
100% data analysts Visualize the data and develop customizable reports with increasingly powerful analyses
Bosch implemented IOT in 2013 and provides IOT suite for other businesses
Ref: https://www.bosch-presse.de/pressportal/de/en/likeabosch-bosch-to-launch-iot-image-campaign-179328.html
Ref: https://www.bosch-connected-industry.com/en/connected-manufacturing/nexeed-production-performance/starter-kit/production-performance-starter-kit/
https://assets.bosch.com/media/en/global/products_and_solutions/connected_products_and_services/industy_40/produc
SOFTWARE-ENABLED RAPID DECISION AND LEARNING CYCLES (AGILE)
Bosch strives to complete the proof-of-concept (PoC) phase very rapidly.
Able to focus its resources and to maintain an innovation spped of approx. 10 PoCs per year.
To achieve this Bosch, Wuxi created Production Innovation Center with small assembly line for training and development purpose.
Fast Radius/UPS (Chicago, US) - Smart factory
The structure of a smart factory can include a combination of production, information, and communication technologies, with the potential for integration across the entire manufacturing supply chain.
Industrial-grade 3D printing is helping to tackle demand for fast-turnaround times and mass customisation of products, while a centralised, proprietary operating system drives real-time analytics and orchestrates design, production, and global fulfilment.
Rather than having a physical inventory of parts, manufacturers and users can have virtual inventory in the form 3D designs in digital form. They can digitize legacy items through 3D scanning. For new components, 3D-printable, virtual versions are developed. Then, when these items are requested by a customer, they can be pulled from a digital drawing inventory and be 3D printed on demand. Fast Radius has 3D printing centers located throughout the world and this part printing can be performed on demand at a hub that is as close to the end-use location of the users as possible and delivered to the user in 24 hours through UPS.
About Additive manufacturing
It is a technological advancement made possible by the transition from analog to digital processes. In recent decades, communications, imaging, architecture and engineering have all undergone their own digital revolutions. Now, AM can bring digital flexibility and efficiency to manufacturing operations.
Additive manufacturing uses data computer-aided-design (CAD) software or 3D object scanners to direct hardware to deposit material, layer upon layer, in precise geometric shapes. As its name implies, additive manufacturing adds material to create an object. Although the terms "3D printing" and "rapid prototyping" are casually used to discuss additive manufacturing, each is actually a subset of additive manufacturing. In the right applications, additive manufacturing delivers a perfect trifecta of improved performance, complex geometries and simplified fabrication. As a result, opportunities abound for adopting components produced by additive manufacturing.
Fast Radius
Fast Radius’ technology platform and team of engineers help clients unlock value from additive manufacturing across a product’s lifecycle. The platform supports clients in identifying potential applications, conducting engineering and economic evaluations, accelerating new product development, and ultimately manufacturing industrial-grade parts at scale with the latest additive technologies.
Fast Radius offers manufacturing solutions for an increasingly digital supply chain. The company couples additive manufacturing expertise, across metals and polymers, with traditional methods such as CNC machining and injection molding.
A key part of Fast Radius’ service is a strategic partnership with United Parcel Service (UPS) enabling a 24 hour turnaround for part manufacturing and shipping.
Whether you're looking to unlock new business opportunities through additive, or want to innovate your supply chain with Virtual Warehouse, they can help. Companies can get a price today and the part tomorrow. No matter the process - whether it's advanced additive, CNC, or rapid injection molding Fast Radius can get that critical part, fast.
With their additive manufacturing capabilities, you can redesign or reengineer a part. Or, you can discover and produce a new-to-the-world product - enabling you to launch a new business model powered by mass customization and global fulfilment. The company has one of the most advanced industrial-grade additive manufacturing (“3D printing”) facilities in North America. It also houses the largest Carbon production facility in the Western Hemisphere and extensive HP MultiJet Fusion technology.
To date, Fast Radius has raised over $17M in venture funding from top-tier investors including Drive Capital, United Parcel Service (UPS), Jump Capital, Skydeck Ventures, and Hyde Park Venture Partners.
Logistics Aspect
Fast Radius has a production facility onsite at UPS Worldport, the world’s largest automated packaging facility, located at Louisville International Airport in Kentucky. As of 2016, the company also has a 3D printing factory in Singapore aligned with UPS’s intra-Asia transportation network. The partnership with UPS puts Fast Radius in competition with other logistics companies, such as PostNord, FedEx and RSA Global, that have launched 3D printing on demand services around the globe.
Along with an expansion of production, the company is scaling up its software development teams and sales department.
Technological Aspects in Fast Radius factories
The firm has customized its array of systems for an automated distributed manufacturing environment. After a customer places an order, it will automatically find the proper printer and begin printing. Once finished, the machine resets for the next print. In turn, Fast Radius requires minimal print management. Though the company has systems that print with a wide range of materials from hard, engineering-grade thermoplastics to metals, it has begun reaching out to service bureaus in other locations, expanding both the types of orders it can perform and its distributed manufacturing network.
The contract manufacturer, succeeds at two things extremely well: speed and quality.
The WEF cited them for "Accelerating innovation and "meeting increasing demand for fast-turnaround and mass customization of products through distributed, industrial-grade 3D printing and proprietary operating system that drives real-time analytics and orchestrates, design, production and global fulfillment."
Fast Radius has its sister service bureau, ZYCI, a large CNC machining operation. At their Atlanta location, the firm will expand to include some industrial AM systems, and, likewise, the Fast Radius facility in Kentucky is in the process of expanding to include CNC machines.
To introduce its 3D printing services to potential OEMs, Fast Radius has partnered with about a dozen companies that are looking to make the shift to a virtual inventory. The companies that they are working with are identifying 1,000 or 1,500 parts that are excellent candidates for on demand production. As costs of additive manufacturing drop precipitously and quality continues to rise over time, a larger and larger percentage of physical inventory will be moved to a virtual inventory model.”
Some applications
Fast Radius created a virtual parts warehouse (parts exist only digitally until needed) comprising 3,000 items for a heavy equipment manufacturer, which really adds up over time.
Husqvarna Group, a Swedish global leading producer of outdoor power products for forest, park and garden care. The Fast Radius team has worked closely with Husqvarna Group over the past year to identify parts that could be made more efficiently and sustainably through additive manufacturing — driving a reduced carbon footprint, improved customer experience, and lower costs. The parts identified for production using AM, have to be validated for their performance and durability, and certify them for production and sale. This meant performing UV resistance tests, chemical resistance tests, days-long cycle tests, and then evaluating real-world performance in the field. All were done successfully. The ongoing transition to production-grade additive manufacturing is adding value to Husqvarna Group’s spare parts supply chain in three key ways:
- Reducing company carbon footprint through less material waste.
- Improving the customer experience with spare parts never being out of stock.
- Eliminating inventory carry costs - including working capital, warehousing, and obsolescence.
The Need for Eliminating supply chain waste with virtual warehousing and on-demand production
Inventory comes at a high cost — nearly $550 billion is tied up in inventory in the manufacturing industry alone, according to a report from the National Institute of Standards and Technology (NIST).
Because the additive manufactured parts will be stored digitally and produced on demand in any quantity, transitioning to additive manufacturing eliminates the supply chain costs of traditional manufacturing, such as:
1.Warehousing costs.
2.High minimum order quantities.
3.Unnecessary material waste.
4.Part obsolescence.
5.Working capital tied up in tooling and inventory.
SIVARAM S (1902220) SOMYA JAIN(1902223)
https://www.fastradius.com/
https://www.fastradius.com/case-studies/
Interview: Fast Radius CEO on embracing additive manufacturing for production
25 April 2019 16:27
https://www.tctmagazine.com/3d-printing-news/fast-radius-ceo-additive-manufacturing-production/
30 September 2019
Fast Radius Puts Curtiss Motorcycles on a Manufacturing Fast Track
A hybrid manufacturing approach, including AM for complex parts, helped the firm meet an accelerated design and build cycle for its new Zeus 8 electric motorcycle.
The company had only three weeks to exhibit the motor cycle in a show and there was no chance for the traditional approach to manufacturing to do it. The company partnered with Fast Radius and used the hybrid manufacturing approach that leveraged CNC milling, hot tube bending and additive manufacturing. Instead of trying to force a single manufacturing process for Zeus, the team leveraged the strengths of the different methods when and where it made sense and delivered the model for the show.
https://www.digitalengineering247.com/article/fast-radius-puts-curtiss-motorcycles-on-a-manufacturing-fast-track/design
Fujitsu Smart Factory
Digitally Connected Plant using IoT
People, machines and processes are all digitally connected, causing free flow of information.
Using that information factories speed up the decision-making process, making it possible for people to move on to the next action appropriately and dynamically.
Predictive analysis with machine learning is an application of AI, which can alert plant managers and engineers to anomalies in the functioning of machines.
it can prolong the life of parts and reduce excess spare parts inventories that the plant needs to keep on hand
Customer validated benefits
Shreyash Ajit Pande 1902216 & Stutu Rajgarhia 1902227
Fujitsu Partners with KUKA to pioneer human-robot collaboration in mainboard handling and testing
Latest Newsby Sarah Mead, Web Editor, 12/04/2018
https://www.automationmagazine.co.uk/articles/fujitsu-partners-with-kuka-to-pioneer-human-robot-collaboration-in-mainboard-handling-and-testing/
Building a Factory of the Future with SAP Leonardo and Fujitsu
July 18, 2017
https://news.sap.com/2017/07/how-to-build-a-smart-factory/
P&G - Smart Factory
Proctor & Gamble (Rakona, Czech Republic)
Market shifts from dry to liquid washing products effected a significant drop in demand between 2010 and 2013. Facing this challenge, the site triggered a programme to cut costs significantly in order to attract new business.
SOLUTION PLAN
Two essential enablers have supported Rakona’s successful Fourth Industrial Revolution innovations
Exploit the external digital environment:
Improve people’s skill levels, shape the jobs of the future.
TOP USE CASES
DIGITAL DIRECTION-SETTING
The digital direction-setting tool shows live KPIs on touchscreens directly on the shop floor, which allows users to explore the data at multiple levels in order to understand performance drivers and identify the root causes of deviations.
Additionally, the system is used for operator task scheduling and tracking.
IN-PROCESS QUALITY CONTROL
Quality control is now based on real-time analytics applied on data collected by various sensors that monitor pH value, color, viscosity, active level, etc.
Enabled by IT/OT integration, it was first tested with a new production line and then rolled out to legacy systems.
Reworking & complaints have been cut by 50%, scrap is down & quality inspections have been reduced significantly.
UNIVERSAL PACKING SYSTEM
Allows for recipe change propagation through the packaging line while the line is running.
The fully integrated sensor, camera, scanner and wrapper system detects and verifies the current status of each zone.
UPack enables each zone of the packaging line to be in a different phase (e.g. start-up, production, empty or changeover
END-TO-END SUPPLY CHAIN SYNCHRONIZATION
Distributor Connect” connects P&G with distributors
Digitally enabled operational program, it allows the supply managers to track the status of the delivery
Incorporates “GDSN,” Global Data Synchronization Network with the operation with retailers. GDSN enables 100% automated commerce without human intervention
ACHIEVEMENTS
Rakona’s innovation experience showcases the kind of substantial impact that can be achieved by a lighthouse facility embracing Fourth Industrial Revolution approachesand technology. In three years:
Productivity has increased by 160%.
Customer satisfaction has increased by 116%.
Customer complaints have been reduced by 63%.
Full plant cost has been reduced by 20%.
Inventory has been reduced by 43%.
Off-quality products have been reduced by 42%.
Time for changeover has been reduced by 36%.
Shivamkumar Pandey & Satyabh Kumar
November 14, 2019
Elisa rolls-out 5G for industrial IoT to 100 P&G factories, says ‘world will change’ with 5G
Finnish telecoms company Elisa is supporting the digital upgrade of around 100 factories owned by US consumer goods company Procter & Gamble, following an initial rollout of IoT monitoring and insights at 10 sites.
https://enterpriseiotinsights.com/20191114/channels/news/elisa-rolls-out-industrial-iot-to-pg-says-world-will-change-with-5g
Qualcomm
Qualcomm Incorporated founded in 1985 is an American multinational semiconductor and telecommunications equipment company that designs and markets wireless telecommunications products and services. It derives most of its revenue from chipmaking and the bulk of its profit from patent licensing businesses.[2] The company headquarter is located in San Diego, California, United States, and has 224 worldwide locations.
INDUSTRY 4.0 TECHNOLOGIES QUALCOMM IMPLEMENTING CURRENTLY
AI CLOUD (CURRENT PRCOJECT AI 100)
SIMULATION
AUGMENTED REALITY
IOT
AI solution that is designed to meet cloud AI inferencing needs for datacenter providers. The Qualcomm® Cloud AI 100 is built from the ground up to help accelerate AI experiences, providing a turn-key solution that addresses the most important aspects of cloud AI inferencing including
low power consumption
Scale
process node leadership
signal processing expertise
SIMULATION
SImulation softwares like VERDI(Visualize gridded netCDF data with this easy-to-use Java program) Automated Debug System is the centerpiece of the Verdi SoC Debug Platform and enables comprehensive debug for all design and verification flows.
IoT(Internet of Things)
Qualcomm Technologies and Bosch Announce Research Collaboration on 5G NR for Industrial IoT
Connectivity solutions that support a wide range of devices.
VIRTUAL REALITY (VR)
VR POWERING MOBILE DEVICES THAT DELIVER IMMERSIVE AUDIO, VISUALS, AND INTERACTION ACROSS ENTERTAINMENT, GAMING, EDUCATION, INDUSTRIAL APPLICATIONS, AND MORE
XR IS TRANSFORMING THE WAY WE DO BUSINESS. THIS NEW WORLD OF ENGAGEMENT CREATES MULTI-DIMENSIONAL EXPERIENCES UNMATCHED IN TRADITIONAL ARENAS
Suman Sekhar 1902229 Section G (2019-21)
Collaborating with industry leaders to expand 5G for Industry 4.0 [video]
DEC 17, 2019
https://www.qualcomm.com/news/onq/2019/12/17/collaborating-industry-leaders-expand-5g-industry-40
How Qualcomm develops its AI and machine learning workforce
MAY 14, 2018
https://www.qualcomm.com/news/onq/2018/05/14/how-qualcomm-develops-its-ai-and-machine-learning-workforce
ROLD - Cerro Maggiore, Milan.
LIGHTHOUSE OF THE Industry 4.0 REVOLUTION – ROLD MILAN
Located in Cerro Maggiore, Milan.
It implemented digital manufacturing technologies to drive financial and operational gains.
Of the 16 factories chosen from a shortlist of 1,000 factories to be highlighted as WEF’s ‘Factories of the Future’ Rold’s Cerro Maggiore factory stands out as the only
SME on the list.
Rold – has only 250 full-time employees. But it has demonstrated that SMEs can adopt Industry 4.0 with limited investment by using off-the-shelf technology and collaborating with technology providers and universities. Rold hired
only three programmers to implement industry 4.0.
Applications and Benefits
Comprehensive use of touch screens, smart phones and smart watches to drive notifications .
Result- Quick response time
Rapid design prototyping through 3D additive manufacturing has shortened the time to market for new product introductions.
Cost modelling to support make vs buy decisions using the data collected from sensors on machines.
Hemant Kumar Singh 1901114 and Sudarsha S
https://theaseanpost.com/article/rold-industry-40-italian-way