digital manufacturing lab - economia.unipd.it · organization at the geographical level...
TRANSCRIPT
Digital Manufacturing Lab
Second Report Industry 4.0 in Italian SMEs
Survey 2017 (Released April 2018)
Research goals
• Fully supported by DSEA funds, the first research promoted by Digital Manufacturing Lab aims at: – carrying out a first map of degree of Industry 4.0
technological investments– understanding advantages and results achieved in the
introduction of such technologies– exploring reasons preventing firms in the adoption of
those technologies– deepening analysis on impacts concerning manufacturing
organization at the geographical level (internationalization) as well as in terms of environmental sustainability
2
Methodology
• Research on a sample of 7,293 manufacturing firms selected as follows (source AIDA database):– Made in Italy industries (Home furnishing, Mechanics, Fashion)– Geographical location: Northern Italy (Piedmont, Lombardy,
Veneto, Trentino-Alto Adige, Friuli Venezia Giulia, Emilia-Romagna)– Firms with 2015 turnover > 1 Ml € (firms with 2015 turnover < 1Ml € in industries characterized by industrial districts)
• Mixed method: CAWI addressing entrepreneurs and Chief Operations Officers (survey) and case studies
• Interviewed firms: 1,020 firms (14% response rate) (May - December 2017)
3
Profile of adopters
Average turnover (2016) 14.8 Ml EuroEmployees (average 2016) 58 total
35.6 in operation 4.6 in R&D
2.5 in marketing% Export (average 2016) 47% (first market 28.4%)R&D expenditure (% on turnover) 6%Main activity 40% B2C – 60% B2B
(average weight 1° client on turnover: 28.3%)
Production output 47.7% bespoke products18.9% customized products33.4% standard products
Location of manufacturing (value) 63.0% Region29.0% Italy 8.0% Abroad
Location of suppliers (% on total suppliers)
35.6% Region47.1% Italy17.3% Abroad
6
7
Quality
Flexibility in production
Customer service
Product innovation
Design
Efficiency
Other
0% 15% 30% 45% 60%
1,2%
6,0%
6,0%
10,7%
12,5%
22,6%
41,1%
Adopters: first source of competitive advantage
Digital Manufacturing Lab - Survey 2017
8Digital Manufacturing Lab - Survey 2017
Adoption Industry 4.0 by turnover
Micro firms (< 2 mil €), small firm (2-10 mil €), medium firm (10-50 mil €), large (> 50 mil €)
16,8%
11,1%
9,5%
15,8%
9,5%
5,8%
1,6%7,4%9
14,2%
8,4%
Digital Manufacturing Lab - Survey 2017
Adopters by industries
Robotics
Laser cutting
Big Data – cloud
Additive Manufacturing
IoT
3d Scanner
Augmented Reality
0% 15% 30% 45% 60%
14,2%
15,3%
24,2%
34,7%
41,6%
44,2%
44,7%
10Digital Manufacturing Lab - Survey 2017
Adopters: Industry 4.0 investments
0%
18%
35%
53%
70%
< 1mln Micro Small Medium Large
RoboticsLaser cuttingAdditive ManufacturingBig data/CloudIoT3D scannerAugmented Reality
Digital Manufacturing Lab - Survey 2017
Industry 4.0 by firm size
0%
25%
50%
75%
100%
Rubber - PlasticsElectrical equipmentLighting
Automotive
Furniture
JewelrySport equipmentEyewear
Apparel
Textile
RoboticsLaser cuttingAdditive ManufacturingBig data/CloudIoT3D scannerAugmented Reality
12Digital Manufacturing Lab - Survey 2017
Industry 4.0 by industries
0%
10%
20%
30%
40%
One technology Two technologies Three technologies More than three
16,9%
12,1%
36,2%38,4%
13Digital Manufacturing Lab - Survey 2017
Number of adopted technologies
14
Laser cutting Robotics
2008
Augmented reality
2011
Big data cloud
2012
Additive Manufacturing
2014
IoT 3d scanner
Digital Manufacturing Lab - Survey 2017
Industry 4.0 by year of adoption
15
0
20
40
60
80
Before 2000 2000-2007 2008-2013 From 2014
RoboticsLaser cuttingAdditive ManufacturingBig data/CloudIoT3D scannerAugmented Reality
Digital Manufacturing Lab - Survey 2017
Industry 4.0 by year of adoption (2)
Not of interest for our business
Other
Low knowledge about the topic
Under evaluation
Lack of adequate internal technological infrastructure
Lack of economic resources
Lack/low internal competences
Uncertainty about return on investment
0% 18% 35% 53% 70%
5,3%
5,4%
7,7%
10,2%
10,2%
15,3%
21,7%
65,9%
Artisan or small firm
17Digital Manufacturing Lab - Survey 2017
Reasons for not investing in Industry 4.0
Spare parts/post-sales
Marketing/sales
Logistics and SCM
Operations management
Operations
Prototyping
New product development (R&D)
0,0% 12,5% 25,0% 37,5% 50,0%
IoT Augmented reality 3D scanner Big data/cloud Additive Manufacturing Robotics
Digital Manufacturing Lab - Survey 2017
Value chain activity and industry 4.0
Big data for operations management and marketing
Robots for operations
Additive manufacturing for prototyping/NPD
ICT adoption
0%
25%
50%
75%
100%
Web site Social media CRM E-commerce CAD/CAM CNC ERP MRP SCM Other
7,3%10,7%
22,7%26,0%
44,7%
67,3%
24,7%24,7%
45,3%
95,8%
Web marketing ICT for operation and value chain
Digital Manufacturing Lab - Survey 2017
Number of ICT technologies adopted
0%
7%
14%
21%
28%
One Two Three Four 5 or more
22,5%
20,0%
17,5%
13,8%
26,3%
21
Positive relationship between ICT and 4.0 adoption
Digital Manufacturing Lab - Survey 2017
0
1,25
2,5
3,75
5
hardware software Integration
3,423,633,06
23Digital Manufacturing Lab - Survey 2017
Industry 4.0 projects
Investments in industry 4.0 projects (% on turnover): 10.5%
Customization Industry 4.0 Investments Domain of customization
(average value - 1 not at all/5 very high)
Machinery/Plant suppliers
Industry 4.0 technology suppliers
Consultants
system integrator
University/research centers
Technology transfer centers
Other
0% 18% 35% 53% 70%
2,8%
2,1%
8,5%
14,0%
31,9%
39,0%
64,5%
24Digital Manufacturing Lab - Survey 2017
Partners to select and develop Industry 4.0 projects
Machinery/Plant suppliers
Industry 4.0 technology suppliers
Consultants
system integrator
University/research centers
Technology transfer centers
Other
0% 18% 35% 53% 70%
2,8%
2,1%
8,5%
14,0%
31,9%
39,0%
64,5%
25
Robotics
Additive ManufacturingLaser cutting3D Scanner
Big data/Cloud
Augmented reality
Digital Manufacturing Lab - Survey 2017
Partners to select and develop Industry 4.0 projects
Better customer service
Internal efficiency seeking
Supporting international competitiveness
New market opportunities
Augmenting product variety
Maintaining manufacturing in Italy
Environmental sustainability
Client's request
Adapting to industry standards
Imitation of competitors
Reshoring
0% 20% 40% 60% 80%
5%
9%
23%
30%
32%
37%
44%
52%
58%
65%
75%
27Digital Manufacturing Lab - Survey 2017
Reasons investments in Industry 4.0
% firms with value 4-5 (high/very high)(relevance of motivation - scale 1 - 5)
Production cost reduction/Internal efficiency
Increase in productivity
Better customer service
Increase in turnover
Product diversification
Entrance in new markets
Maintenance in International competitiveness
Increase in customized product rate
Environmental sustainability
Reorganization activities Italy/abroad
Other0% 18% 35% 53% 70%
3%
7%
17%
20%
23%
23%
37%
39%
53%
54%
60%
28Digital Manufacturing Lab - Survey 2017
Impacts of investments in Industry 4.0
Robotics and laser cutting
Additive Manufacturing(big data)
Robotics (augmented reality)
Difficulties in finding appropriate professionals
Lack of broadband
Limited financial resources
Time of implementation
Lack of internal competences
Inadequate internal information systems
Difficulty in identifying the right partner/supplier
Other
0% 6,5% 13% 19,5% 26%
5,6%
17,8%
20,0%
22,0%
22,9%
23,1%
24,3%
25,4%
29Digital Manufacturing Lab - Survey 2017
Difficulties in adoption of Industry 4.0 technologies
% firms with value 4-5 (high/very high)(relevance of motivation - scale 1 - 5)
Higher role of customer in product development
Increased product performance with new added services
Higher control on product during its use
Higher role of customer in production
Different distribution system
0% 8% 16% 24% 32%
11,3%
12,5%
25,8%
27,1%
30,2%
30Digital Manufacturing Lab - Survey 2017
Impacts on the product
% firms with value 4-5 (high/very high)(relevance of motivation - scale 1 - 5)
Robotics, laser cutting
Additive manufacturing
Big data
IoT
Waste reduction
Lower inputs/material used
Lower envir. impacts of business processes
Traceability of consumption/use
Adoption of more sustainable inputs
(re)use waste of firm's processes
Change in supply chain organization
Use of inputs/waste from other sectors/firms
0 8 15 23 30
4,5
6,3
13,4
14,8
20,5
25,3
25,6
26,4
31Digital Manufacturing Lab - Survey 2017
Industry 4.0 and sustainability
% firms with value 4-5 (high/very high)(relevance of motivation - scale 1 - 5)
33Digital Manufacturing Lab - Survey 2017
Investments in Industry 4.0: impacts on employment
No significant differences among firms by size
Industry 4.0 and changes in factory work
New knowledge to improve products
New knowledge to improve production process
Increased training support workers' competences
Increased collaboration between operations and other functions
Increased collaboration between operations and suppliers
Increased collaboration among workers in factory
More complex problems related to industry 4.0
Reduction interaction workers - machines
0% 12,5% 25% 37,5% 50%
8,9%
14,0%
16,5%
18,1%
28,4%
35,5%
47,2%
48,7%
34Digital Manufacturing Lab - Survey 2017
% firms with value 4-5 (high/very high)(relevance of motivation - scale 1 - 5)
Investimenti industria 4.0 e performance
• Positive impacts of industry 4.0 investments on business performance (analysis on average EBIDTA/sales and Sales growth 2014-2016 between adopters and non-adopters)
• In particular positive impact refers only to the adoption of 1 or 2 technologies (not significant for higher number of technologies)
36Digital Manufacturing Lab - Survey 2017
• Results on more than 1,000 imprese (including textile and apparel) confirm a process of adoption • still limited (about 19%)• that involve also small firms (more than 40% of adopters)• implemented for a long time (average years of adoption
between 2008 and 2014) • with industry variety (industry of specialization impacts
on this process)• market-driven (first reason: better customer service)
• Adopters are innovative firms, often with already implemented ICT investments
38Digital Manufacturing Lab - Survey 2017
Executive summary 1
• Technologies are applied differently within the firm: 3D printing mainly in prototyping and new product development, robots in operations, big data for operations management and marketing.
• Industry 4.0 technologies are adopted mainly to product customized products. 66.6% of adopters produce bespoke or customized products, while only 33.4% of them standard products.
• Investments in Industry 4.0 technologies/projects have increased firm’s innovation capabilities.
39Digital Manufacturing Lab - Survey 2017
Executive summary 2
• Impact-wise, firms mention three main results achieved: efficiency (60%), increase in productivity (54%),increase in quality of customer service (53%), with a different role played by different technologies.
• Increased value related to product in terms of customization (co-design), related services and traceability/control on product, and environmental sustainability
• Positive relation with employment (more than 61% of adopters have maintained stable employment, while 34% has increased it), with an impact on work within the factory mainly on knowledge management (new knowledge to improve products or processes or development of competences through training)
• Positive impacts on performance (EBIDTA/sales and sales growth) in particular with 1 or 2 technologies, where the selection of technologies is aligned with business strategy (quality more than quantity, selection based on business goals
40Digital Manufacturing Lab - Survey 2017
Executive summary 3
• Those technologies require ad hoc 4.0 projects of implementations (72% of adopters), they are not off-the-shelf technologies ready to be used immediately. Accompanying activities are essential and the primary partners are firm’s technological suppliers (even though a variety of partners emerges and it is linked to different technologies adopted)
• A positive relation with investments on ICT technologies • Three main difficulties in the adoption process: lack of internal/
external competences, broadband and time of implementation• The main motivation for not-adopting firms is linked to business
strategy and culture (more than 65% declare that those technologies are not of interest for their business) rather than financial motivation. This result is confirmed by the second motivation: being a small firm/artisan.
41Digital Manufacturing Lab - Survey 2017
Executive summary 4
Contact:
Prof. Eleonora Di Maria [email protected]
http://www.economia.unipd.it/en/DML/Digital-Manufacturing-Lab