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© STAUFEN.
Keys to Successful
Manufacturing in China
Intelligent Factory
Concept
Austria Connect Greater China
2014
October 24th, 2014
David Mueller
General Manager
Email: [email protected]
Phone: +86 189 1810 2217
© STAUFEN.
Industry 4.0 – what is it?
2
Industry 1.0
Mechanized
End of 18th century
First mechanical loom
in 1784
Industry 4.0
Networked
Today
Connected,
virtual,
augmented
Mechanical equipment with the help of water and steam
Industry 3.0
Automated
Begin of 70th century
First programmable
logical controller
(PLC), Modicon 084
in 1969
Electronics and IT
Industry 2.0
Electrified
Begin of 20th century
First production line at
Cincinnati
slaughterhouses in
1870
Mass production with the help of electric power
Source: Umsetzungsempfehlungen für das Zukunftsprojekt Industrie 4.0, April 2013
© STAUFEN.
Overview
3
Concept elements Building blocks
Processes, methods,
competencies
Intelligent Factory
+ 7.
People &
organization
1.
Plant
concept
3.
Supply
Chain
6.
IT System
2.
Product
Design
4.
Production
system
5. Facilities,
Layout &
Automation
8.
Project
management
Lean
LELean
Enterprise
High
Tech
Modular
Leadership
© STAUFEN.
The context How the pieces fit together
4
Shopfloor
Management
Go-See-Understand
Train Perfection
Lean HighTech Modular
Continuous
Improve-
ment & Creativity
Efficient Processes
& Services
Connected
Virtual
Augmented
Modular & Standardized
Interchangeable & Scalable
LELean
Enterprise
Leadership
© STAUFEN.
The concept element “High Tech” consist of three characteristics
5
Connected
Characteristics
Self-guided trolley
Virtual
Digital factory
Augmented
area Aarea B
worker
robot
Human-machine
cooperation
High
Tech
Materials/
Products/
Machines/
Services/People
© STAUFEN.
8 building blocks make the intelligent factory
6
7.
People &
organization
1.
Plant
concept
3.
Supply
Chain
6.
IT System
2.
Product
Design
4.
Production
system
5. Facilities,
Layout &
Automation
8.
Project
management
© STAUFEN.
8. Project
management
5. Facilities,
layout & autom.
6. IT
system
4. Production
system
3. Supply
chain
7. People &
organization
The plant concept is intelligent because it takes into account all
elements necessary to make a factory work
7
Building block
1.
Plant
concept
Intelligent
element
Comprehensive approach
Staufen client
2. Product
design
Lean
LELean
Enterprise
High
Tech
Modular
Leadership
© STAUFEN.
2.
Product
design
The product design is intelligent if it is modular and reduces
complexity
8
Intelligent
element
Examples of smart solutions
Modular product family Scalable parts
Modular product family
Lean
LELean
Enterprise
High
Tech
Modular
Leadership
Building block
© STAUFEN.
The supply chain is intelligent if it optimizes the value stream across
factory boundaries in cooperation with suppliers
9
Intelligent
element
Examples of smart solutions
Early supplier integration in the
product development process
Intelligent replenishment systems
(e.g. eKanban) Supplier park and JIT deliveries
System and module suppliers
and business partner network 3.
Supply
Chain
Lean
LELean
Enterprise
High
Tech
Modular
Leadership
Building block
Supplier nomination SOP
Sampling
Planning
and
conception
RFQ and
assignment
Part-
develop-
ment
Process
Design
(Tools and
machines)
Part-
optimi-
zation
Series
production
RFQ
Price & Cost Technology Quality
Production Logistics a. Supply Chain
Pre Sourcing
Assessment
Supplier
Benchmarking
Requirement of International Customers
Staufen WPS Audit
Business Potentials
Supplier Self
Audit
APQP Readiness
Management
Project Management Support
Trial Run /
Process
validation/
Ramp Up
Tooling Production Process Machines
Parts Sub Supplier Management
Ramp Up Problem
Soliving
Trouble Shooting
Interims Management
Training
Sub Supplier Management
Speeding Up Machine Delivery
Speeding Up Sample Approval
Speeding Up On Site organization
Supplier Cockpit
KPI Definition Designing Monitoring
System
Data validation process Measurement Catelog
Operating Supplier
Cockpit
Regular Monitoring
Rugular Communication
Escalation
Operational
Problem Solving Q-Improvements
Delivery Task Force
Process Audit
Cost Calculation
Staufen Supplier Database
Supplier Questionnaire
© STAUFEN.
The production system is intelligent if it makes use of lean
principles and smart elements
10
4.
Production
system
Intelligent
element
Examples of smart solutions
Paperless work instructions Self-guided trolley
Lean
LELean
Enterprise
High
Tech
Modular
Leadership
Building block
© STAUFEN.
5. Facilities,
layout and
automation
Automation is intelligent if it optimizes the interaction between
worker and machine
11
Intelligent
element
Examples of smart solutions
Automation
Flow oriented layout Automatic lighting
control
Construction of energy saving and
environmentally friendly plant
Lean
LELean
Enterprise
High
Tech
Modular
Leadership
Building block
© STAUFEN.
The IT is intelligent if it connects, virtualizes, and augments
materials, products, machines, services, people
6.
IT-System
Intelligent
element
Examples of smart solutions
12
Real-time data Factory simulation
area Aarea B
worker
robot
Human-machine cooperation
Lean
LELean
Enterprise
High
Tech
Modular
Leadership
Building block
© STAUFEN.
The organization is intelligent if it supports communication and
problem solving.
13
Intelligent
element
Examples of smart solutions
Digital SFM Board
XX
xx xx xx
Value Stream Organization
7.
People &
organization
Training
Training
CIP
Lean
LELean
Enterprise
High
Tech
Modular
Leadership
Building block
© STAUFEN.
The project management is intelligent if it ensures the success of
the project
14
Intelligent
element
Examples of smart solutions
Project in stages
Project steering committee
8.
Project
management
Training
Project room
Lean
LELean
Enterprise
High
Tech
Modular
Leadership
Building block
Steering Committee
Mr. XYZ
Mr. Hu
Project Leader
Mr. Adrovic & Mr. Yu Mr. Voelker
Strategy
Objectives
Approaches
Project leading
Expertise input
Escalation
Conception
process/organization
Qualification
Implementation plan
Pilot implementation
Project core team
Supply Chain RSP
Mr. XX
2-3 days per
week
Mr. Fang
Order Fulfillment RSP
4-6 Project team members
Supply Chain RSP
On demand
Purchase Strategy
4-6 Project team members
Purchase Strategy
On demand
Ms. Jin Mr. Ma
Contribution in
project work
Rollout &
Implementation
4-6 Project team members
Order Fulfillment RSP
On demand
Mr. XX
2-3 days per
week
Mr. XX
2-3 days per
week
© STAUFEN.
Overview
15
Concept elements Building blocks
Processes, methods,
competencies
Intelligent Factory
+ 7.
People &
organization
1.
Plant
concept
3.
Supply
Chain
6.
IT System
2.
Product
Design
4.
Production
system
5. Facilities,
Layout &
Automation
8.
Project
management
Lean
LELean
Enterprise
High
Tech
Modular
Leadership
© STAUFEN. 16
David Mueller STAUFEN.Shanghai
Consulting Academy Ltd.
22H Cross Region Plaza
899 Ling Ling Road
200030 Shanghai P.R.China
+86 21 64417112/15/16
+86 21 64417105
www.staufen.cn [email protected]
General Manager
+86 189 1810 2217
- Thank You -