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DIGITALISATION AND INDUSTRY 4.0


Dr. Igor Kalinic

Head of Sector –Competitiveness and Internationalisation, EASME, European Commission


Joseba Bilbatua

Senior Manager Advanced Manufacturing at MONDRAGON Corporation

Joseba BilbatuaMONDRAGON CorporationBrussels – EREK Conference 25th September 2019

Digitalisation and Industry 4.0and their application to resources efficiency

Application examples from MONDRAGON Corporation

80.816 employees

Waste Management Services & Solutions

Remanufacture/ Retrofitting & New Uses

Project Development, O& M

Systems & Equipment

Sustainable Mobility

Business activities in Mondragon around Circular Economy activity

Digitalisation and Industry 4.0 applied to resource efficiency

Currentsituationanalysis

Areas to improve

Project contrast

Roadmap

Feasible objectives and strategic projects

Evaluation – 3 DIMENSIONS

1. Technology: Process & Product DigitalisationSmart Factory/ Smart Products

2. StrategyOrganisation and 4.0 Strategy

3. PeopleCulture and 4.0 skills

DIAGNOSIS OBJECTIVES

® Industry4.0 strategy

With the cooperative

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> 30 cooperatives> 250 projects and transformation plans

1Str

ateg

yStrategy and Organisation: To what extent is Industry 4.0 established and implemented in your company’s strategy??

We examine the current openness toward and the cultural interaction with Industry 4.0 using the following criteria:

§ Implementation status of Industry 4.0 strategy§ Operationalization and review of strategy through a system of indicators§ Investment activity relating to Industry 4.0

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2 Pe

ople

People:Our people, teams and organisations are ready to make the key decisions to make the most of Industry 4.0?

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It is about identifying those competences that will be characteristics of perfectly adaptedteams and in fluid coexistence with the industry4.0 and the new context in constant change.

4.0 COMPETENCES & SKILLS

WITH MYSELF

Consciousness

Proactivity

Emotions management

WITH THE OTHERS

Leadership

Communication

Flexibility

CONTRIBUTING VALUE

Multidisciplinary

Open Innovation

Problem solving

DIGITAL DOMAIN MASTERY

Digital Knowledge

Information Management

Digital Communication

REVISION

3 Di

gita

lisat

ion

Proc

esse

s y P

rodu

cts

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§ Support our businesses on their digital transformation strategy

§ Assessment according to Industry4.0 standards

§ New perspective and expert vision on their journey to become a “Factory of the Future”

BSH @ Industry 4.0 Page 10

Enabling Technologies

Autonomous Robots

Cost effective and flexible automation

Internet of Things

Remote monitoringand management of factories

Additive Manufacturing

Manufacturing of complex parts

Simulation

Plant simulationSupport to other fields

Cybersecurity

Safety on data management

Augmented Reality

Support for complex manipulations

System integration

Integration of new technologies with MES

Cloud Computing

Support to data exchange and storage

Data AnalyticsPrediction of undesired situationsSupport to decision making

ü ü

ü ü

ü

Context Dataand Communications

Workers Manufacturing Systems

Knowledge

Collaboration

Smart

PRODUCT

SMART

Adaptive Systems

Maintenance (preventive, predictive, …)

Energy management. Environment

Materials management (RFID, AGV, …)

KNOWLEDGE

Context information

Support to decision making

Visualization

Data analytics

COLLABORATION

Ergonomics and physical fatigue reduction (Cobots, …)

Mental fatigue reduction (on-lineinformation, augmented reality, …)

Occupational safety

PRODUCT

Customized / Individualized

Fully traceable

Higher quality / reliability

Optimized cost

Main application areas

Some recommendations – Project examplesIndustry 4.0 & Resource efficiency

1. FAGOR ARRASATE Optimum OEE through extensive monitoring and digital twin technologies (CAPITAL GOODS)Objective Recommendations in real-time about the condition of

machinery, to improve its availability, OEE and maintenance.Link Machine Alert Platform: Big data solution for advanced analytics and maintenance


2. SORALUCE complete monitoring of big production lines (MACHINE TOOL) Objective Achieve a complete

Condition Based Maintenance

• Improves reliability by discovering failures before they happen.

• Decreases maintenance costs by making sure parts are not replaced before the end of their useful life

• Reductions in errors as fewer maintenance activities are performed

• Eliminates unplanned downtimeresulting from equipment failure

• Prevents major failures that lead to health, safety and environmental risks

• Improves the management of spare parts

WorkpieceDisplacement monitoringduring machining operation

Spindle headBearings and gearscondition

Chatter vibrationsmonitoringThermal behaviuormonitoring

Rack-pinion systemPinion-rack conditionMotor condition

Hydraulic unitPerformance monitoringGearbox

Bearings and gearscondition

Motor condition

Ball screwsBall screw and nut condition

Bearing condition

Belt condition

MagazineTool life control


3. ULMA Forklift Systems: new business model based on Services (LOGISTICS)Objective Achieve a complete Condition Based

Maintenance. Diversify business towards servitization (Product-Service System)Renting per hours (pay-per-use)

• ULMA Fleet Manager• On-Line Assistance Service• Predictive Maintenance• Daily Reports (ULMA & Customer)• Customer loyalty


4. MOTORLAN: Refurbishment of Industrial Engine (

Objective Full Service Electric Motor/ Rotary machines Repair and Maintenance (and their electronic servo system)

Energy efficiency:• Real analysis of the

performance of electrical motors (new and repaired)

• Text protocol under regulation• Efficiency and savings

comparisons• Report on energy

management recommendations

• 20 Employees• > 1.500 Electric Motors Managed/ year• Service focused• First repair company with Quality

certification & Warranty

Company details Revenue Evolution (M€) – Crisis years

• Repair & Maintenance (little)• Refurbish (as new) & Remanufacture

(even better than new)• Reuse/ Recycle – Second hand – Spares

(P2P Web page)

Business Lines

Refurbishing

Remanufacturing


5. LKS: Eco-efficient Construction through BIM (CONSTRUCTION)

Objective Optimization of construction projects through BIM

• Information is generated during the construction phase, which will be very useful in the future.

• The BIM incorporates information about installations, safety, preventive & predictive maintenance,

Building Information Modeling (BIM) is an intelligent 3D model-based process that gives architecture, engineering, and construction (AEC) professionals the insight and tools to more efficiently plan, design, construct, and manage buildings and infrastructure.

Source: theBIMhub


6. SARE TEKNIKA: White Goods Reuse, new jobs and social integrationObjective Setting up of re-using and refurbishment centres for white goods, as well as technology and equipment

for testing, disassembly and data managemetn.

Source: theBIMhub

RESULTSCross cutting needs and priority areas

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§ Cibersecurity§ Systems integration§ Supply chain management§ Data analytics – big data - AI§ Iot connectivity§ Digital platforms§ Asset management§ Servitisation§ HMI (Human Machine Interfaces)§ Artificial vision

Thank you !!

Joseba BilbatuaSenior Manager Innovation & [email protected]

Contact for MONDRAGON DIAGNOSYS 4.0:Mrs Naiara [email protected]

mailto:[email protected]

mailto:[email protected]


Marek Wasilewski

Board member of the PolishCleaner Production MovementSociety

The Polish Cleaner Production MovementSociety – 30 years of action and experience

Cleaner Production in Poland - for prevention of pollution, circular economy

and the better climate

Michał Jan CichyMarek Wasilewski

www.cp.org.pl

1997 – financial support for the CP Programmefrom National Fund for Environmental Protection

Key milestonesat the beginning of the programme

1996 – first „Cleaner Production Certificates” issued for Polish companies

1993 – Polish Cleaner Production Centre in Katowice First, Polish Declaration on CP to be signed by Polish companies, local authorities and other institutions

1990 – support from Norwegian engineering association (NIF)

1999 - „UNEP International Declaration on CP” signed by the Polish Minister of Environment, UNEP seminar in Nairobi in 1999.

The Polish Cleaner Production Movement Society – www.cp.org.pl

2002 – inauguation of the Polish Register of Cleaner Production and Responsible Entrepreneurship

Key milestonesat the beginning of the programme

Conference „Cleaner Production = Responsible Entrepreneurship”,at the Chancellery of the Prime Minister of Poland, Warsaw,

with representative of UNEP (Jacqueline Aloisi de Larderel) and the Marshal of the Polish Parliament(photo by.: The Polish CP Movement Society)


Who we are today?

Association promotingCleaner Production,Circular Economy

environmental protection, environmental management

and sustainable development


Who we are today?

We address our activities mainly for companies, local authorities and other institutions

We act for all types of comapnies, all branches, but majority of our beneficiaries are SMEs

Our members are people engaged in environemtnal protection and management because of their jobs or hobbies

… the core of our activities :• educational programme in CP/CE for companies

called Cleaner Production Academy,

• the Polish Environmental Voluntary Agreements Scheme in the Polish CP Programme (CP EVA) …


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We co-operate with many organisations, among them of coruse with EREK

Katowice

Who we are today?

We provide information by various means

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Many conferences, seminars, debates, events a.s.o.

Źródło: http://csr.parp.gov.pl/index/more/32652

Fot. Anna Bąk

Numerous patronages

Źródło: https://www.facebook.com/events/1207646472704079/

Educational programme of the Polish CP Movement(„how to achieve this goals?”)

Cleaner Production AcademyAbout 10-months-long educational programme,

with design/implementation componentCapacity building for environmental management system, implementation of a pilot environmental

improvement in trained organisations

First meeting of the 46. edition of CP Academy. Warsaw, 19.09.2017

Cleaner Production Academy

CP Academy includes:Ø CP strategy concept and approachØ Principles and methodology - conducting an effective initial review / CP AuditØ Case-studies: good environmental practice, the concept of Eco-innovation and Cleaner

Production Project (CP Project)Ø Basics of the concept of a Circular EconomyØ Building management system in line with the Cleaner Production strategyØ Creation and functioning of the Environmental Team in companiesØ Formal and legal assessment: basic obligations of entrepreneurs Ø Financial and economic analysis of pro-ecological projects, calculation of economic

effectiveness of CP ProjectsØ Sources of financing for pro-ecological projects in PolandØ Ecological and social reporting in the CP ProgrammeØ Presentations of the results of the project work so far, discussionØOpportunities for further improvement: CP and formalised environmental management

systems according to ISO 14001 and EMASØOpportunities for further improvement: selected environmental management tools -

product life cycle assessment (LCA), eco-design (eco-design)Ø Basics of Corporate Social Responsibility (CSR)

Public defence of CP Projects carried out during the Academy's duration Graduation from the Academy and ceremonial awarding ofinternational diplomas of Cleaner Production Experts

• 46 completed editions since 1990(+ 3 planned editions co-funded by the Polish Enviromental National Fund)

• 749 Cleaner Production Projects implemented

• 1064 trained institutions

• 1483 Cleaner Production Experts

Alumni of the 46th edition of the CP Academy, with their consultants; handing Diplomas of CP Experts to participants from Popharma company.

Educational programme of the Polish CP Movement

• Register of Cleaner Production Certificates

• The Polish Register of Cleaner Production and ResponsibleEntrepreneurship

The Polish CP Voluntary Environmental Agreements Scheme (CP EVA)


CP Environmental Voluntary Agreements’ procedure

248 laureates of the CP Certificate

Register82 laureates of the

Polish Register of CP and RE


www.prcpiop.pl

Exemplary synthetic „Report card”

Conference ”Cleaner Production and Circular Economy”, Ministry of Environment, 26th of April 2018Photos by Ministry of Environment

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Yearly meetings of laureates -- the Polish Register of CP and RE

Next conference: „30 years of CP – on the pathway to Corcular Economy”7.10.2019., Warsaw, Poland


Planned postgraduate studies

„Circular Economy and Cleaner Production in practice”including the whole educatinal program of the CP Academy

In close co-operation with the Silesian University of Technology


Education campaign on Circular Economy

„Kampania edukacyjna na temat zapobiegania zanieczyszczeniom oraz Gospodarkio Obiegu Zamkniętym, z wykorzystaniemdoświadczeń Czystszej Produkcji i EMAS”

Education campaign on pollution prevention and Circular Economy, based on Cleaner Production and EMAS experience

Project activities: Ø Conferences Ø Cleaner Production Academies (3 editions: Upper Silesia, Mazovia and Lower Silesia) Ø Workshop "Life Cycle Assessment (LCA), carbon footprint, eco-design - new tools, methods

and applications of environmental analysis in the CE". (8 workshops in Katowice, Wrocław, Warszawa, Gdynia, Zielona Góra, Kraków, Lublin, Opole)

Ø Webinars (6 thematically different webinars) Ø Computer animationsØ Examples of CP Projects. Good practices and investments from the Cleaner Production

MovementØ Various Publications

2019-2022


CP and Industry 4.0

Questionnaire how CP companies implement I4.0

the questionnaire covered 28 CP companies, the return on 12

I4.0 survey questions:

• knowledge about I4.0 • what I4.0 operations were implemented• planned implementation of I4.0 solutions• inhibiting factors • challenges and risks• need to conduct a series of I4.0 seminars

and thematic workshops


CP and Industry 4.0


CP and Industry 4.0

planned implementation of I.4.0 solutions• full digitisation• optimize logistics and supply chains• robotisation• automation of packaging of finished

products• autonomous equipment and vehicles• Big Data• automated manufacturing systems• Smart Information Systems

inhibiting factors• insufficient information on I.4.0• low awareness of the benefits of I.4.0• lack of adequately qualified/ educated staff• concern about I4.0 technologies implementation• high investment costs

challenges and risks• loss of jobs – employment reduction• lack of qualified personnel• lack of full control over the data• cybercrimes

need to conduct a series of I4.0 seminars and thematic workshops• 31% YES; 69% maybe YES• Workhops issues: IoT, Augmented Reality, Big Data, Intelligent Factory,

Robotics and Networks


CP and Industry 4.0MCD Electronics

digitisation - e-documentsSMT line (autonomous machines)

castomisation, concerns panel colours, prints in different language versions - the decision could be made just before start of production

access control and logging (person/time/zone/activity/ etc.)

3D printer on the production lineIntelligent control systems

for buildings, gardens a.s.o.


Thank you for your attention!

Marek Wasilewski, Phd Eng.Member of the Board, The Polish CP Movement Society

Tel. +48 601 51 70 81E-mail: [email protected]

EREK INTERNATIONAL CONFERENCE “Make it happen with

RESOURCE EFFICIENCY!”25-26/09/2019 BRUSSELS

CP measuers and eco-solutions

Example solution from Famed

Photos by.: Famed Zywiec sp. z o.o.


CP measuers and eco-solutionsBWiK Biała Podlaska

8 heat pumps(over 240 MWh of energy per year)

New Waste Management Plantfor the region of Biała Podlaska

Production of energyfrom biogas


Heat recovery installation in BOLIX S.A.


Heat recovery installation in BOLIX S.A.

Example solution from Kegar …



Sigrid Linher

Director – Energy, Climate and Environment at Orgalim Europe’s Technology Industries.


Sigrid Linher

Director – Energy, Climate and Environment at Orgalim Europe’s Technology Industries.

Digital4Planet:

Innovating at the crossroad of the climate and digital transitions

Sigrid LinherEREK Conference, Brussels, 25 September 2019

European technology industries at a glance

The transformative change of digitalisation

The battle for technology leadership

…and further challenges

Global

resource useDemographic

changeTrade tensions –

future of the WTO

Global rule based order

Global climate neutrality by

2050

Three strategic imperatives for Europe’s technology industries

61 Europe’s opportunity is clear

Creating a Win-Win: Digital4Planet

Sustainability hand in hand with renewed growth and global competitiveness

IoT, big data solutions at hand

More green energy and less waste through the use of sensors and data analytics

Innovating and generating resource savings through the digital twin

Further examples of digitally enabled solutions

Data analytics for reducing environment burden of waste collection & transport in cities

Digitally enabled industrial symbiosis platforms

• Active collaboration with re-use organisations• Spare parts online purchasing possibility• I4R platform

..and best practices

Compressed air as a service

Life extension and service support

Energy efficiency first

Remanufacturing, refurbishment

We can not do it alone

Recommendations & conclusions

• Impactful investment in digital, clean energy and waste management infrastructures for bringing the benefits of the ongoing transition to consumers

• Building trust and credibility for enabling new partnerships and value chain cooperation

• Dynamic and consistent regulation fit for the systemic change (policy objectives, consistently applied and coupled with incentives; e.g.: public procurement, tax incentives, sandboxing)

• Humans are the most important capital in the digital age: we must invest in skills!

Thank you for your attention!

#ResourceEfficiency

QUESTION TIME

#ResourceEfficiency

COCKTAIL

Discussion corner 3 - Digital transformation: how to combine it with resource efficiency

and circular economy?

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