The4StagesofIndustrialEvolu8on
4.Industrialrevolu1onBasedoncyber-physical-systems
3.Industrialrevolu1onThroughtheuseofelectronicsandITfurtherprogressioninautonomousproduc8on
2.Industrialrevolu1onIntroducingmassproduc8onlinespoweredbyelectricenergy
1.Industrialrevolu1onIntroducingmechanicalproduc8onmachinespoweredbywaterandsteam
Endofthe18thcentury.
Beginningofthe70th
Industry1.0 Industry3.0Industry2.0 Industry4.0
Levelofcom
plexity
Today
Manufacturing-MegaTrendsMegatrends have considerable impact and drive structural changes in nearly all manufacturing sectors
Changing demographics (growing world population, aging societies, increasing urbanization)
Globalization & future markets (ongoing globalization, BRIC, beyond BRIC)
Scarcity of resources (energy, water, other commodities)
The challenge of climate change (increasing CO2, global warming, ecosystem at risk)
Dynamic technology & innovation (technology diffusion, power of innovation, the age of life science, ubiquitous connectivity)
Global knowledge society (know-how base, gender gap, war for talent, multiplication of data and information)
Sharing global responsibility (shift to global cooperation, growing power of NGO´s, increasing philanthropy
SmartSupplyChain
CurrentState
MegaTrendsaredrivingthefuturefaceofManufacturingIndustrythroughrapidtransforma1ons
CapacityandEfficiency
DisparatePlantSystems
MaketoStock
Supplychain
CapabilityandFlexibility
ConvergenceofOTandIT
MaketoIndividual
SupplyCircle
FutureState
HistoricalDataMonitoring
RealTimeDashboards
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2
3
4
5
FactoryoftheFuture–Summary
Objec1ve:• Sustainablemanufacturing• ICT-enabledintelligentmanufacturing• Highperformancemanufacturing• HigherAutoma8on
ATransforma1onFrameworkleveraging§ OTandITconvergence§ IndustrialEthernet§ MobileApplica8ons§ Automa8on§ BigMDataAnaly8cs§ DigitalModelingandSimula8on
Visio
nFram
ework
DesiredStage
FactoryoftheFuture–Defini8on&Vision
ConnectedshopfloortoTopFloorSystems(BusinessSystems2WayIntegra1on)
Ver1callyandHorizontallyIntegratedsystems,instruments&informa1on
Supporttheinternalcustomer(paradigmshi\withdemonstrableandsustainablebenefits)
Real-1memonitoringofmachines,inventoriesandmanualprocesses
Fullshopfloorvisibility/transparency(allplantsandprocesses)
RFID/Barcode’s/QR-Codesetc.
SmartSupplyChainNetwork
FactoryoftheFutureisparadigmshi\sfromdisconnectedshopfloortoconnectedmanufacturingfacili1esbyautoma1ngtheflowofinforma1onthroughver1calintegra1on“ShopFloortotheTopFloor”andhorizontalintegra1onacrosstheplantsite,loca1onsetc….
WhatdowemeanbySmartSupplyChain,anddoweall
meanthesamething?v Visibilityof:
v Productstatusv Real8medemandanddemandplansv Supplyplansv Inventorylevelsbyloca8onv Orders
v Andvisibilityofassetse.g.:v Vehicles,condi8onandcapacityv Produc8on&Packagingequipmentv Loading-&Unloadingsystemv Peopleandcapabili8es
Ifyoucan’tmeasureit,youcan’tmanageit!
Howcanitbesoverydifficultwhenwehavetheabilitytousealltheseassets:
Sta8cSupplyChain
Func8onalExcellence
HorizontalProcessIntegra8on
ExternalCollabora8on&Integra8on
SmartSupplyChain
Instrumented
Interconnected
Intelligent
IntegratedTransac8ons(ERPtoERP)
Balancingriskandperformance
Effec8velydrivingprofitablegrowth
Managingcomplexity
NetworkedPlanning,
Execu8on&DecisionAnalysis
Op8mizedFlows
Flexibility&stability
Future
CSCO
AutomatedTransac8ons
(Sensors&Actuators)
OurPointofViewontheProgressionofSupplyChainManagementtoaSmarterFuture
SmarterSupplyChainTheSupplyChainoftheFuturemustbeSMARTER...ItwillbeInstrumented,Interconnected&Intelligent
Instrumented
Interconnected
Intelligent
AutomatedTransac8ons&SmartDevices
Op8mizedFlows
NetworkedPlanning,Execu8on&DecisionAnalysis
• Useofsensors,actuators,RFID,&smartdevicestoautomatetransac,ons:inventoryloca8on,shelf-levelreplenishmentdetec8on,transporta8onloca8ons&boalenecks
• Supportsreal-,medatacollec,on&transparencyfromPOStomanufacturingtorawmaterial
• Sense-and-responddemand/supplysignalsallow“predictandact”
• Mul8-Tiersystemintegra,onacrossthenetwork.Standardizeddataandprocesses.
• Collabora,vedecisionmakingthroughdecisionsupportandbusinessintelligence–star8ngwiththecustomer
• Networkedriskmanagementprogramsforintegratedfinancialcontrolswithopera8onalperformance–monitoredandmeasured
• Simula,onmodelstoevaluatetrade-offsofcost,8me,quality,serviceandcarbonandothercriteria
• Probability-basedriskassessment&predic,veanalysis
• Networkedplanning/execu8onwithop,mizedforecasts&decisionsupport
CaseStudyCementProducerKeyChallengesinCementSupplyChain
v Anend-to-endsolu8onthataddressesallaspectsoftheCementSupplyChainManagement
v AutomatedOrderManagement
v Real8mestockmeasurement
v Rou8ng
v Completemonitoringoftheprocesses--fromloadingofcementintothetrucktodeliveryatcustomersiteandreturnofthetrucktotheplant
v TheOrbitLogVMI-solu1onprovidesreal8mestock&distribu8oninforma8onandintegratesitwithintheERPsolu8on
v TheServiceorientedLOGis8cSystemSoLOGS®forautomatedselfserviceloading
v Noreflec8onoftherealinventorysitua8on
v Providingrightinforma8ontotheclientabouteverydispatch
v FleetUnderu8liza8on
v HighDistribu8onCostduefrequentorderchangesorcancela8ons
v Wai8ng8metounloadtrucksdueunavailablesilos
v Manualorderentry
Solu1on Benefitsv ReducedInventoryCost
v ReducedDeliveryCycleTime
v Elimina8onoftruckwai8ng8mes
v ImprovedPlantProduc8onPlanning
v Op8mizingrou8ngandtransporta8on8mes
v Reducedadministra8on
v Costreduc8onbyapprox.20%
Solu8on
TanksWebportal Customer
SAP
Automatedconsignmentcalcula1on
Webportal
Real-1meInventory
Forecast&Deliverystatus
PODTerminalsBargesTruck Railcar
Supplier
Customer
SoLOGS®ServiceorientedLOGis8csSystem
3e_Automate(English).mp4
CaseStudyOilProducerKeyChallengesinOil/GasSupplyChain
v Integra8onbetweenschedulingcenters,terminals,trucksand
customersassuredrobustplanningandcollabora8on
v AutomatedOrderManagement
v Real8mestockmeasurement
v Rou8ng
v TheOrbitLogVMI-solu1onprovidesreal8mestock&distribu8oninforma8onandintegratesitwithintheERPsolu8on
v Noreflec8onoftherealinventorysitua8onatpetrolsta8ons
v Unstructuredorder8ming
v Ordervolumescausingtankerstogoouthalffull
v Peaks&troughsduringtheweakdueconsumerdemandandpricechanges
Solu1on Benefits
v Petrolsta8onManagerknowwhendeliverywillarrive
v Elimina8onoftruckwai8ng8mes
v Op8mizingrou8ngandtransporta8on8mes
v Schedulerscanmaximizethedeliveriesinashij
v Reducedadministra8on
Solu8on
Tanks
Automated consignment calculation
Webportal
Real-time Inventory
Forecast & Delivery status
POD Terminal
Supplier
Customer
FleetOp1mizing&Schedulingsystem
PODTimestamp
3PL/4PL
Thevision:Real8mecollabora8veplanning&
forecas8ngCollabora8venetwork(customer/supplier/carrier)
DemandCloud
Real-8me:orders+forecast+inventory+consump8on+loading+movements
Orderautoma1on
Customerorderportal
ProofofdeliveryExcep1onhandling
CompanyborderFirewall
Alwaysexternalconnec1ons
internal
RALOGSupplyChainEngagementMethodology
v Product/CustomerPorlolioanalysisv Sales&Opera8onsPlanningv MetricsDefini8on
v OrderToCashCycleTimev ReturnonAssets
v ForecastAccuracyv TotalSupplyChainCostas%of
Revenue
v HighLevelRoadMapv To-BeProcessDesignv Timeline
v Resource/Staffingv Cost/Benefit
v Iden8fica8onofpossiblesolu8ons
v Quickwinsv Exis8ngProcessstandardiza8on
androllout,ifneeded
v Implementa8onv SCMStrategy
v Organiza8onalchangev Solu8ons
v Projectmanagement
v ChangeManagementv Training
v UnderstandAs-Isprocess&capturecurrentperformance.
v Qualita8veAnalysis:PainpointsandIssuesiden8fica8on.
v Quan8ta8veDataAnalysis:(e.g.ProductABCbasedonrevenue/grossmargin/inventory)
v ProcessandPerformanceAnalysis
v ProcessandPerformanceGapAnalysis
v Iden8fyopportunityareasandQuickwins
v ValueIden8fica8onandes8ma8on
DiscoverConductAs-IsAnalyzes
DeepDiveDefini,onTo-BeSitua,on
DeploymentDefini,onTo-BeSitua,on
MarkusLanzManagingPartner/SeniorConsultantRALOGEngineeringAGAarburgerstrasse21CH-4800SwitzerlandPhone:+41763954521Mailto:[email protected]:www.ralog.ch
Thankyou