Manufacturing lighthouses

Emitting powerful light that pierces fog and darkness,
lighthouses are key to maritime navigation.

 Manufacturing has experienced a decade
of productivity stagnation and demand
fragmentation; thus innovation is long overdue.
 Where Fourth Industrial Revolution innovation
has been taken to scale beyond the pilot
phase, unprecedented increases in efficiency have
occurred, with minimal displacement of workers.

3 megatrends for the factories of the future

 The lighthouses are the factories that have taken Fourth
Industrial Revolution technology from pilots to integration
at scale, thus realizing significant financial and operational
benefits.
 Qualification as a lighthouse requires meeting high
standards across four categories:
 1 - Significant impact achieved,
 2 - Successful integration of several use cases,
 3 - A scalable technology platform,
 4 - and Strong performance on critical enablers such as
change management, capability building, and collaboration
with a Fourth Industrial Revolution community.
Identifying lighthouses

 The future is here
 But it’s not evenly distributed
 Lighthouses are designed to scale
 Lighthouses Commit to Structural Change
 Lighthouses are Agile
 Investing in Technologies Means Investing In People
 Sustainable (Green) Manufacturing is Good for the Bottom-
Line
 Encourage collaboration
 Data creates transparency throughout an entire organization
 It’s Going to Take All of Us to Spread the Revolution
Things every manufacturer can learn from
lighthouses

 The agile working mode is comprised of two
engines: a flexible, flat organizational structure
and a technology platform that allows for
scalable organizational learning.
 Network of empowered teams
 Software-enabled rapid decision and learning
cycles
Agile working mode

 Ensure technology solutions can scale and evolve
 For example, Fast Radius in the US created an
analytics platform that captures data in the
manufacturing process using sensors and applies
machine learning to provide feedback, allowing
workers to more quickly improve design and
address any issues. This has led to a 36% inventory
reduction and a 90% reduction in the time it takes
to get products to market.
How manufacturing can thrive in a digital
world and lead a sustainable revolution

 Optimize efficiency to drive sustainability
 Unilever has reduced its material waste by more
than 40% in their Dubai, UAE, factory by digitally
enabling end-to-end quality management.
Manufacturing represents 54% of the world’s
energy consumption and is responsible for 20% of
global emissions. Increases in efficiency driven by
technology can help reduce materials consumption
and CO2 emissions.

 Focus on reskilling and enabling workers
 Schneider Electric runs “Digital Weeks” consisting
of a hackathon used to generate new ideas and
include workers in leading the company’s digital
transformation. Phoenix Contact in Germany has
built an application that guides operators through
their jobs and tracks accomplishment, giving them
more time for managing and trouble-shooting and
helping them demonstrate their success.

 Create a shared learning journey
 The manufacturing sector can only realize the full benefits
of the 4IR if there is a complete transformation across value
chains and production systems. Leaders in this space
should support the diffusion of technology through their
entire production networks, lifting up SMEs to improve
overall results. This shared learning journey can lead to not
only a return on investment but also a more inclusive
distribution of knowledge, which can accelerate innovation
across the industry.
 Bringing companies together to share best practices and
develop new approaches to future success is a key goal of
the Global Lighthouse Network.

 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.
 Additive Mfg
1- Fast Radius/UPS (Chicago, US)

From Idea to 3-D in a Day: UPS and
Fast Radius

The factory has used IoT technology to
create digital twins of physical assets for
advanced machine insights, lower
operating costs, and machine downtime
reductions.
It used the IoT to “make old machines
talk to one another.”
2-Johnson & Johnson DePuy Synthes (Cork, Ireland)

 Orthopaedic products and services for joint
replacement, trauma, spine, sports medicine,
cranio-maxillofacial, power tools and biomaterials
to advance patient care while delivering clinical
and economic value to health care systems
worldwide.
 Global innovation center focused on material
science and technology
innovation, with
in-house technical capability
and knowledge development

 ‘Smart and integrated factory’ -
Empowering operators to have
increased visibility into operations,
maintenance, and energy use and
sharing these best practices across
sites, has helped maximize energy
and operational efficiencies,
reducing energy costs by 10% and
maintenance costs by 30%
3- Schneider Electric (Le Vaudreuil, France)

 50 year old plant that recognized
the need to stay price competitive
for the next 50 years through
deployment of digital tools
 3D virtual reality model of the
entire factory to use in testing and
validating innovative ideas. This is
then used to engage operators so
they can see how their day-to-day
work will change.
Workforce engagement

 The factory has implemented the latest digital tools
such as EcoStruxureTM Augmented Operator Advisor,
which enables operators to use augmented reality to
speed up operation and maintenance, delivering
between 2% and 7% gain in productivity.
 Its first implementation of EcoStruxureTM Resource
Advisor delivers up to 30% energy savings and
contributes to continuous improvement
over the years.
EcoStruxure™ Augmented Operator Advisor

 ‘Fully integrated technology platform for
flexible production’ - Delivers ability to take
customer orders and immediately allocate
resources and schedule production time on a
single, automated platform leading to 100%
quality compliance and 100% traceability,
while ensuring security and agility
 If a robot is soldering an assembly onto a PCB,
the systems first check whether the part works
properly before it is taken any further
4- Siemens Industrial Automation Products
(Chengdu, China)

 In addition to the Chengdu facility’s high levels of
automation and quality control, all production
processes are digitally recorded on the Simatic IT
manufacturing execution system . Software is fed with
about 10 million pieces of data every day, most of it
being process information. This is used to manage
production processes and ensure quality.
 Smart Manufacturing Center of Excellence,
 Smart Manufacturing Professional Lab,
 Industry Solution Research Center,
 and Talent Training Platform.
Siemens Smart Manufacturing Innovation
Center Chengdu

 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.
5- Procter & Gamble (Rakona, Czech Republic)

 Procter & Gamble’s plant in Rakona in the Czech Republic
which has historically produced about 4 million cases/day of
dishwashing liquids, powder and fabric enhancers.
 Faced with shifting customer demands and increasing
market pressure, management at the plant decided to engage
100% of the organization in digital innovation.
 And all staff were given the necessary skills to embrace new
technology such as analytics, smart robotics and additive
manufacturing.
 These new skills led to digital direction-setting, in-process
quality control, a universal packing system and end-to-end
supply chain synchronization.
 The results were impressive. In just three years, productivity
at the firm increased by 160% while customer satisfaction
rose by 116%. At the same time, plant costs were reduced by
20%.
The power of AI

 The fully integrated sensor, camera, scanner and wrapper
system detects and verifies the current status of each zone.
Along with automatic line clearance instead of paper-based
data records, UPack enables each zone of the packaging line
to be in a different phase (e.g. start-up, production, empty or
changeover).
 It also features automatic setup of machines based on
system-stored recipe data and in-process quality inspection.
 UPack, in addition to reducing the number of unpleasant
changeover tasks for operators, has cut changeover duration
by 50%, enabling a 40% reduction of minimum order
quantity.
universal packing system

 Plastic injection molding equipment is used to
produce complex parts that need to be ready in
ever shorter time frames due to the increasingly
customized nature of the end products.
 ‘Customer-driven digital twinning’ has involved
creating digital copies of each customer’s
specifications, cutting production times by 30
percent.
 Lot-size-one production at cost of mass
production, connected to web-based configurator
 Systems and solutions in the area of electrical
engineering, electronics and automation.
6- Phoenix Contact (Blomberg, Germany)

 Phoenix Contact in Germany has built an application that guides operators
through their jobs and tracks accomplishment, giving them more time for
managing and trouble-shooting and helping them demonstrate their success.
 Intelligent mechatronic systems communicate across different locations and
companywide using network infrastructures.
 Only standardized and open interfaces are used for this Ethernet and
Internet-based communication network. It provides the basis for flexible, self-
optimizing production processes.
 As soon as the material is on the workpiece carrier, a connection is established
to the higher-level system via an RFID tag, the circulation system, which can
be extended as desired, enables the flexible networking of all conceivable
production resources to form a single manufacturing system.
 The workstations, assembly machines and test cells required for the
manufacturing process can be easily connected. This requires uniform
interfaces, as well as autonomous control of the basic processes. It enables the
simultaneous production of different variants.
 Innovative connection technologies and plug-in installation systems reduce
costs and assembly times through quick and error-free wiring. To address
this, they developed push-in connection technology. Solid conductors or
conductors with ferrules can be directly contacted without any tools.
Axioline input-output

 It is the world’s first manufacturer-independent
Industry 4.0 production plant, acting as an
exhibition of the power of high quality and flexible
manufacturing and how it can be efficiently
implemented.
 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.
7 - Haier (Qingdao, China)

 Digitally integrates the entire factory process and supply
chain, leveraging big data, cloud computing, and IoT. It
connects suppliers and consumers, enabling customers to
communicate their preferences directly to the factory.
 Not only does this make customers participants in the
transparent design and production process, but it also
allows for product customisation according to consumer
demands and even different or unique requests.
 15 sub-platforms for different industries, with 12
demonstration bases across six regions. The model has been
further implemented in 20 countries, transforming clothing,
food, housing, travel, health, education, and other industries
so that global users can enjoy the enhanced lifestyle
experience opened up by mass customization.
5G-Empowered COSMOPlat

 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”.
 Bosch Nexeed PPM (Production Performance
Manager) can be rolled out plant wide as a standard
industrial i4.0 platform for predictive maintenance
or real-time process and machine condition
monitoring.
8 -Bosch Automotive (Wuxi, China)

 The Nexeed Production Performance Manager shows the current state
of production in the plant. The software offers a complete overview,
both of the current state of individual machines and the complete
production system. The simple control configuration allows
maintenance personnel to be proactive in their maintenance tasks with
as little downtime as possible. Product quality can also be improved due
to continuous monitoring and logging of process data.
Big data decision-making

 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.
 Top quartile pharma site reduced quality
deviations by 80% and increased OEE by
40%
 Augmented reality (AR) devices to
reduce changeover times when switching
product lines
9 - Bayer Pharmaceuticals Division
(Garbagnate, Italy)

 AR, is helping significantly reduce the time it
usually takes to change from producing one
product to another, increasing the utilization of
factory machines. Not only was the production
time reduced but employees no longer have to
follow lengthy, complicated paper-based
instructions.

 BMW’s digital manufacturing strategy is based on three
pillars: focus on effectiveness, the right mind-set and easy
access. All digital use-cases deployed must serve to further
improve its production processes in terms of quality, cost and
productivity, benefitting from easy access to technology while
adhering to a culture of cooperation.
 By using the custom BMW Internet of Things (IoT) platform,
the Regensburg plant cut the time needed to deploy all new
applications by 80 percent. That led to a significant reduction
in logistics costs and a 5 percent reduction in quality issues.
10- BMW Group (Regensburg Plant,
Germany)

 Rather than replacing operators with
machines, lighthouse factories are
transforming work to make it less
repetitive, more interesting, diversified
and productive. Beyond local pilots,
lighthouses create value and resilience
through the supply chain, and agility and
responsiveness for customers.

 This factory makes compressors for
refrigerators, air conditioning units and
other products.
 By using its full digital traceability
system and digital tools such as smart
sensors, visual inspection, auto
monitoring system etc. to improve
quality control, it has improved labour
productivity by 30% and decreased
customer complaints by 57% within two
years.
11- Danfoss (Tianjin, China)

 Automatically-guided vehicles drive up
and down the aisles and supply workers
with components.
 The same workers use intelligent
Bluetooth connected tools that
automatically tell if an assembly process
is incorrectly performed.
 They also have access to step-by-step
electronic work descriptions – no matter
where in the factory they work on a given
day.
Ultimate end-to-end digital experience

 This factory, which specializes in
components for smartphones and
other electrical equipment, boasts a
fully automated manufacturing
process with machine learning and
AI driving auto optimization of
equipment, smart self-maintenance
and real-time status monitoring in
smart production.
12 - Foxconn (Shenzhen, China

 A lights-off factory is not an un-
manned factory, as human workers
are still necessary in the front end,
to make decisions.
 Computer-controlled autonomous
manufacturing in the dark,
basically without assembly line
workers.
 Efficiency gains of 30% and
lowered its stock cycle by 15%.
“Lights off factory”

People Flow (人員流),
Cash Flow (資金流),
Tech Flow (技術流),
Info Flow (信息流),
Process Flow (過程流)
and Things Flow (物品流).

 The only SME in the Lighthouse network, its
use of Fourth Industrial Revolution
technologies such as smart watches, rapid
prototyping and digital dashboards has
helped improve turnover by between 7% and
8%.
 SmartFab was created by the collaboration
of the R&D teams of ROLD and Samsung
and now is also available with Microsoft's
Cloud Computing technologies - Digital
Twin in Real time
13 - Rold (Cerro Maggiore, Italy)

 Producer of cutting tools and solutions has
created a digital thread through its production
processes that has significantly raised labour
productivity. One example is its ‘touchless
changeover’ which allows design patterns to
be changed automatically, even during
unmanned shifts.
 Invest in smart automation with ultra-flexible
robots, machines, tools and fixtures which
together were able to perform complex
touchless changeover without the need for any
human oversight.
14 - Sandvik Coromant (Gimo, Sweden)

 A design program creates a computer-aided design (CAD)
model for each specific order, and this process is fully
autonomous.
 In similar fashion, process planning, machine programs,
production parameters, drawings, etc. are created
autonomously for each order.
 All of this happens within a few minutes of an order being
created and allows for customised products to be ordered
and handled the same way any standard order is done.

 The use of drones to inspect pipelines and
machinery (cutting inspection times by 90%) and
wearable technologies such as digital helmets that
help workers cut the time it takes to make
inspections and repairs.
15- Saudi Aramco Uthmaniyah Gas Plant

Saudi Aramco Fourth Industrial Revolution
Center,

 This plant of 9,000 employees is putting its
people first, creating an Advanced Analytics
Academy to help workers come up with
solutions to reduce waste, and improve the
quality and reliability of production processes.
This work has resulted in a significant
improvement in financial results.
 End-to-end at scale transformation with clear
digital roadmap
16 - Tata Steel (IJmuiden, The Netherlands)

 Smart factory – from concept to realization
 Fully automated inbound logistics
 Digitized in-line QC with computer visioning
 In-process connectivity and traceability
 Smart matching of human
 Since coming into existence, automation of
low-value tasks has reduced operational costs
by 11%.
17 - Arçelik (Ulmi, Romania)

 Digital manufacturing manager (DMM) at
Arçelik, reports directly to the chief digital
officer in the interest of better support from
general management. This makes for a direct
link between production and IT.
 The company created agile teams with
members from production, maintenance,
engineering and quality as needed
Implementing new ways of working: agile
and increased transparency

 A research, training and experience center dedicated to
the digital transformation of the human resource
through Industry 4.0 enablers.
 Provide 30 different industrial level technical trainings
related to Industry 4.0, automation and robotics.
 Following the state-of-the-art technology together with
technology developers
 Turn-key automation projects for 18 different
production plants in 7 countries.
 Hardware and software development
'Atölye 4.0 Arçelik Advanced
Robotics Lab'

 Ford Otosan has the biggest and most capable
R&D organisation for heavy commercial
vehicles and related powertrains and also
global spoke for light commercial vehicle
development and diesel powertrain
engineering.
 Leverages digital manufacturing and
advanced automation to move beyond lean,
increasing its output by 6% and employee
engagement by 45% without additional capital
expenditure investment.
18- Ford Otosan (Kocaeli, Turkey):

 A custom-designed mobile app
contains numerous functions,
including a dashboard that
provides visibility of all KPIs,
allows supervisors to make and
approve investment requests, and
submit and manage ideas.
Ford Otosan: ConnecTruck Mobile
Application

 Fully digitalized 5G factory focuses on bringing together
design and production to introduce new products.
Implementing a range of 4IR solutions, connected by a
private wireless network, this site improved productivity
by 30%, and now brings products to market 50% faster
than before.
 No-touch internal logistics automation via connected
mobile robots
 Flexible robotics to ensure high productivity and agility
for continuous new ramp-ups
 Virtualization of new product introduction (NPI)
 4.9G/LTE Private wireless network to speed up NPI line re-
layout
 Cloud-based digital data control, enabling real-time process
management
19 - Nokia (Oulu, Finland)

Nokia, Telenor and Telia create the world’s
most advanced shared wireless network in
Denmark

 Challenged by its remote location, this mining service
provider deployed multiple Fourth Industrial Revolution
use cases (e.g. optimized truck dispatch, real-time
monitoring, drone surveys) that transformed the mine from
a loss-making entity into a profitable one in just six months.
 Drones took to the skies to plan mines, conduct mine
surveys and monitor road conditions, and an app was
specifically developed to control operational activities and
enable supervisors to make decisions and action plans to
increase productivity.
 Remote location – reaching the Tabang mine requires
around seven hours of travel by car and a further three
hours by boat – a stable network connection proved to be a
huge barrier, particularly when using, sharing and
integrating big data.
20 - Petrosea (Tabang, Indonesia)

 Digital dispatch (brain of the mine)
 Real-time crew management app
 Digital maintenance system using predictive
 analytics
 Digital operational mine planning
 Digital control tower
 Re-Skilling Workers in Remote Location
Petrosea: overcoming a shortage
of skilled labour

 This plant leverages artificial intelligence to drive
productivity and quality improvements in the steel
industry. It is building its own smart-factory platform
through a collaboration with a local ecosystem of academia,
SMEs and start-ups.
 Machine vision and deep learning
 Visualization and digitalization
 Al-based BOF temperature control
 Machine learning for rolling force
 Al-based automatic control
21 - Posco (Pohang, Republic of Korea)

 Cobots, virtual reality) to support operators,
eliminate waste, reduce energy consumption and
automate repetitive tasks.
 Digital-enabled service training
 Connected workforce for performance driving
 Process optimization through digital
 Automated inplant truck flow
 Digital and IOT energy management system
22 - Groupe Renault (Cléon, France)

REAL-TIME SUPPLY
MANAGEMENT
As soon as a customer
orders a vehicle,
suppliers are
informed, raw
materials are prepared
and logistics flows are
established.
SIMPLER
PROCESSES WITH
CONNECTED
TOOLS
digital technology
helps employees to
be more mobile and
proactive and to
share information. It
also contributes to
easier decision-
making on the
production line.
CONTINUOUS
TRACEABILITY
Vehicle parts,
assembly and
packaging are
tracked in real time,
so customers can
follow the progress
of their order.
DATA FOR
PLANNING
Data are sent and
analyzed
continuously to
conduct remote
operations and
simulations as well
as to optimize
maintenance

#01 PEOPLE AND ROBOTS, HAND IN HAND

#02 VIRTUAL REALITY, REAL PROGRESS!

#03 TOTAL TRACEABILITY, NOTHING IS WASTED!

 A challenging market environment drove this site
to implement a new model for mass
customization. Digitalizing the value chain end-to-
end, from customers to suppliers, through an
integrated digital thread resulted in improved
sales and reduced costs.
 Digital quality management
 Digital twin in production
 Digital supply chain
 Intelligent engineering
23 - SAIC Maxus (Nanjing, China)

 Electrification – With "hydrogen fuel technology" as one of the final
solutions for new energy sources as the core, and taking the lead in
realizing the industrialization of fuel cell vehicles, we take the lead in the
industry and gradually realize a comprehensive clean power.
 Intelligence – In the intelligent development especially intelligent driving
technology, it has reached the leading domestic level in the fields of
environmental perception, control algorithm, simulation and testing
technology, which made the car experience more humane, caring, relaxed
and smart.
 Connection – With Internet technology as its foundation, the platform
will demonstrate the vertical ecosystem of vehicles, people, applications
and living platforms and create an online travel platform for the bus eco-
cycle of "MAXUS Interactive Platform" and "RV Life Home".
 Sharing – integration of leasing, sales, car life, to reduce the use of shared
costs, enrich the life of cars, change the way travel.
Electrification, intelligence, connection and
sharing

Customization, Intellectualization,
Internationalization, Younger

 A self-owned platform, c2b.saicmaxus.com,
which is capable of communicating with more
than 1 million users simultaneously and has
collected data from more than 200,000 users.
 In the age of Internet and big data, C2B
represents the global trends of
personalization and diversification in car
making.
C2B mass customization

 One of Schneider Electric’s nine smart factories, this
location developed a full spectrum of Fourth
Industrial Revolution solutions (e.g., IIoT platform)
that were then shared with the wider Schneider
Electric community, including customers and
partners, thereby improving the operations of the
entire ecosystem.
 Maintenance 4.0
 Digital performance management tools
 Quality 4.0 for defect reduction
 Quality 4.0 for traceability
 Integrated supply chain
24 - Schneider Electric (Batam, Indonesia)

 Deployed a wide range of Industrial Internet of Things (IIoT)
technologies including smart sensors, alarm prediction management,
site benchmarking, and augmented reality to create an empowered
workforce that has visibility into operations, maintenance, and energy
use. With the goal to reduce maintenance costs while increasing overall
equipment efficiency, the factory is so far reporting a 44 percent
reduction in machine downtime in one year.
 In addition, the factory leverages IT/OT convergence by implementing
digital tools like planning and scheduling management that provide an
end-to-end view of demand, aligns all partners, and engages all workers,
resulting in a 40 percent improvement in on-time delivery.
 It is also a testbed for machine learning, AI, predictive and digital
maintenance, and connected machines and processes. With the
integration of big data, cloud, and IIoT technologies, the Batam factory is
paving the way for organisations in Asia to work towards their own
digital transformation to become more energy efficient and sustainable
in the long term.

 This greenfield steel plant is helping to set a new standard
for the speed at which a factory can achieve full capacity
from complete nascency. It also improved time-to-market by
50% thanks to significant investments in digital and analytics
solutions, as well as capability-building to develop the digital
skills of a relatively junior and inexperienced team.
 Visualization of shape of cohesive zone in furnace
 Al model to predict and control silicon
 AA-driven dynamic process control model
 Control system to plan and schedule manufacturing
processes from raw material to customer
 Predictive maintenance deployment
25 - Tata Steel (Kalinganagar, India)

 Connected workforce: will improve the productivity of the workforce and pre-
empt unsafe incidents.
 Video analytics: In process video analytics is being used to identify surface defects
on cold rolled products and predict ferrous content in the ore while being
transported via conveyors.
 Maintenance technology roadmap: improve the overall equipment effectiveness.
 Advanced analytics: Deployed in the pellet plant to reduce bottlenecks and
achieve higher consistency in raw material quality to enhance its throughput,
resulting in savings worth 100 crore a year.
 Operations research based optimisation: cost reduction of ~40 crore.
 Plant shutdown optimisation tool: Helps schedule the optimal sequence and
combinations of shutdowns by grouping upstream and downstream plants or sub-
processes together to avoid losses or hot metal dumping.
 AI-powered chatbots: Deployed in the domains of HR and procurement to
provide information and perform basic tasks.
 Robotic process automation: Being deployed across support functions like finance
and accounts and human resource management to bring intelligence and agility
into business processes.
 Digital platforms: Tata Steel has built Compass, DigECA & Aashiyana, catering to
B2B, B2SMEs & B2C customer segments. They aid the customer’s decision journey
and provide better visibility of products and services.
4IR deployments

 A digital native, this bio-engineering site is using
robotics and artificial intelligence on processes that
have traditionally been highly manual, resulting in the
doubling of its innovation rate.
 Sensor network and data architecture
 Reconfigurable modularity
 Dynamic, digital work instructions
 Real-time process monitoring and control
 Dynamic simulations-based scheduling
 Zymergen is a science & material innovation company
rethinking biology & reimagining the world. They
partner with nature to create never-before imagined
products.
26 - Zymergen (Emeryville, USA)

 This 40-year-old factory adopted digitization early. Its
extensive implementation of artificial intelligence and
advanced analytics has allowed it to maintain its
industrial competitiveness in the digital era, creating
value of $50 million.
 Production planning powered by advanced analytics
 Advanced IIoT applied to process optimization
 Predictive maintenance aggregating equipment and
process data
 Visual inspection powered by artificial intelligence
 Logistics powered by real-time tracking, unmanned
operations and automatic planning
27 - Baoshan Iron & Steel (Shanghai,
China)

 Uses intelligent technologies like remote maintenance
operations, big data, and artificial intelligence
 The two 200-meter-long major production lines in Baoshan
are fully unmanned, and each line needs just two to three
workers for inspections.
 During working hours, the four to five operators sit away
from each other in the more than 100-square-meter control
room. They use an intelligent remote control system to
maintain high efficiency.
 The smart logistics system with only four operators
effectively moves the steel products from production line to
the warehouse, and then to the dock for shipments.
 The Baoshan base ships 100,000 metric tons of steel rolls to
destinations globally on a daily basis
Smart manufacturing, logistics

 Foton Cummins has self-deployed internet of things
and artificial intelligence throughout its end-to-end
product life cycle in its design, production and after
service. By doing so, it has improved product
quality and customer satisfaction by 40%.
 Internet of vehicles-enabled fleet performance
management
 Digital operation platform
 Visual inspection powered by artificial intelligence
 IoT-enabled manufacturing quality management
 Quality warranty reduced by advanced analytics
28 - Foton Cummins (Beijing, China)

A solar array on one building generates about
15% of its power needs.

 The Beijing Foton Cummins Engine Company (BFCEC) is
so wired with high-tech tools it can almost identify defects
in certain tasks and bottlenecks in production before they
happen.
 Oil leaks caused by the faulty sealing of metal pans can be a
major headache for manufacturers and customers, alike. By
bringing together artificial intelligence, special cameras and
information technology, a system at the Foton-Cummins
plant automatically determines the quality of a pan’s sealing
and can reject it for further use if it doesn’t pass inspection.
Claims regarding the faulty sealing of pans have been
reduced to zero.
A plant that’s ahead of its time

 This GE factory, with more than 30 years’ experience of lean
manufacturing, used Fourth Industrial Revolution
technologies to transform into digital lean manufacturing.
This has resulted in achieving the next level of performance,
for example, cutting costs by 30% and reducing cycle times by
46%.
 App-based eAndon on production lines
 Biometric authentication for operators
 Real-time production performance monitoring and
visualization
 RFID-enabled material pull system (eKanban)
 eSpaghetti diagram for walking route optimization
29 - GE Healthcare (Hino, Japan)

Edison™ Intelligence to enable better patient care
Deployed via Cloud, Edison HealthLink or smart
device

 The Haier Shenyang refrigerator factory is an
example of a user-centric mass customization model.
Achieved by deploying a scalable digital platform
that connects end-to-end with suppliers and users, it
has improved direct labour productivity by 28%.
 Mass customization and B2C online ordering
 3D digital twin for product development and testing
 Supplier-connected digital platform
 Digital pull system and shop-floor automation
 Digital quality management
30 - Haier (Shenyang, China)

 By leveraging a range of industrial internet of things technologies and
data analytics in engineering, production and maintenance operations,
Hitachi Omika Works has reduced the lead time of core products by
50% without undermining quality.
 Omika Works produces products for social infrastructure systems, such
as electricity, traffic, steel making, water supply/sewerage, and
industries.
 It has introduced the factory energy management system (FEMS) in
each building. By controlling power consumption in the building, the
system facilitates efficient use of energy.
 The factory has also installed a photovoltaic power generation system
(rated output: 940 kW), storage batteries (capacity: 4,200 kWh), and
about 900 power consumption sensors (smart meters) in the factory.
 In addition to management by building, power consumption by use (air
conditioning, lighting, OA, equipment, etc.) is "visualized". Careful
energy management has also been implemented for peak power
reduction, for example, by forecasting photovoltaic power production
and power demand and by planning storage battery
charging/discharging.
31 - Hitachi (Omika, Japan)

Lumada:
The name "Lumada" comes from the words "illuminate"
and "data".
This name reflects the mission to shed light on the
customers‘ extensive data and identify potential
correlations, to provide insights valuable to their
businesses.

 Digitally enabled operator performance
management
 Digitally enabled equipment performance
management
 IoT infrastructure for control systems
 Digital twin to simulate customer systems
 Energy management system
Disney Parks Is Using Hitachi Vantara's
Lumada To Improve Rides

 Enabled by a digital backbone and people development,
Infineon has used data, advanced analytics and
automation in its manufacturing plant and supply chain
network to reduce direct labour costs by 30% and improve
capital efficiency by 15%.
 IoT-enabled manufacturing system
 Automated material-handling and process automation
 Advanced analytics-enabled scheduling and dispatching
 Manufacturing control tower
 Real-time visibility on production network, including
contract manufacturers
32 - Infineon (Singapore)

 This site has scaled up standardized digital solutions
developed in other Johnson & Johnson sites to drive
performance improvements, including increasing
productivity by 15%.
 E2E supply-chain visibility platform
 Virtual reality-enabled training simulator
 Digital dashboard to monitor OEE performance
 Digital process recipe management
 Automated optical inspection
33 - Johnson & Johnson DePuy Synthes
(Suzhou, China)

 This semiconductor fabrication facility has integrated
big data infrastructure and industrial internet of
things to implement artificial intelligence and data
science solutions, raising product quality standards
and doubling the speed at which new products are
ramped.
 Automation of production and maintenance
 IIoT-enabled smart factory
 Advanced analytics with OEM for process
optimization
 Deep-learning optical defect detection
 Integrated deviation management platform
34 - Micron (Singapore)

Micron team members at the Remote Operations
Control (ROC) Room that is powered by data
analytics to display KPI, highlight potential issues,
and diagnostic tools. 90 team members in the ROC
monitor over 3,500 pieces of equipment in the facility.

Automated Guided Vehicles (AGV) at the probe floor loading and un-loading front
opening unified pods (FOUPs) from the smart rack and into the probe test tool. FOUPs
are specialised plastic enclosures designed to hold silicon wafers securely and safely in a
controlled environment.
Smart racks identify the lot numbers and location of FOUPs through RFID, and schedule
AGVs to pick them up for loading into the probe tester.

 The first lights-off operation in P&G Asia and
connect its E2E supply chain. It increased
productivity by 2.5x, boosted its production agility
enabling e-commerce growth and improved
employee satisfaction.
 E2E-synchronized supply chain planning
 E2E-integrated supply chain digital war room
 Light-off operations in making
 Machine learning 3D quality inspection
 Distribution security system
35 - Procter & Gamble (Taicang, China)

 Weichai digitally transformed its entire end-to-end
value chain to accurately understand customer
needs and reduce costs. Powered by artificial
intelligence and internet of vehicles, it shortened its
R&D cycle by 20% and improved operating costs
by 35%.
 Digitally enabled product development
 Customer-centric Internet of Vehicle
 Real-time asset performance monitoring
 Automated warehousing
 Digital supplier quality management
36 - Weichai (Weifang, China)

1. Big Data
2. Smart Factory
3. Cyber Physical Systems
4. Internet of Things (IoT)
5. Interoperability
Five Key Industry 4.0 Technologies

 First, an appbased car networking platform provides users with
efficient service solutions including repair orders, customer support
and satisfaction reports.
 Second, a customer member management system builds loyalty
through a membership system, articulates member rights and
privileges and implements a point mall (including dynamics for
collection and consumption of points).
 Third, remote maintenance guidance conducts online fault diagnosis,
assists on-site maintenance personnel, and saves time for customers.
Engine maintenance time is reduced by 15%, saving 20% of document
auditworkload.
 Finally, the generation of visual AR models for Weichai engines
supports pre-sale technical exchange, engine assembly and after-sales
maintenance guidance. Unrestricted by location or by the physical
exhibition machine, this AR method improves training and on-site
support while enhancing the company’s image. This end-to end
linkage shows the power of interconnectivity of functions throughout
the value chain, extending to the customer.
E2E product development

 By combining digital solutions with intelligent line
design, AGCO/Fendt can manufacture nine series of
tractors – ranging from 72 to 500 horsepower – on a
single assembly line with a batch size of one. This
has increased productivity by 24% and reduced cycle
time by 60%.
 Digitally enabled variable takt time
 Virtual build for design to manufacture and line
balancing
 Intelligent transportation management system
 Advanced analytics for quality monitoring
 Digital supplier performance management
37 - AGCO (Marktoberdorf, Germany)

 This pharmaceutical site has applied Fourth Industrial
Revolution technologies throughout its manufacturing
operation, exploiting advanced analytics and neural networks
to use existing datasets. It has improved line speed by 21%,
reduced downtime and increased yield, delivering an overall
equipment effectiveness improvement of 10%.
 Advanced analytics-based machine performance
improvement
 Deep learning image recognition to detect quality defects
 Artificial intelligence-guided machine throughput
optimization
 Digital twin planning
 Cycle time monitoring and visualization digital tool
38 - GSK (Ware, UK)

 Henkel has developed a cloud-based data platform
that connects more than 30 sites and more than 10
distribution centres in real time. This helps meet
growing customer and consumer expectations on
service and sustainability, while achieving double-
digit cost and inventory reductions.
 Digitally enabled real-time global OEE-boosting
platform
 Digitally integrated E2E demand sensing
 Digital twin of sustainability
 Digital E2E dispatching and GPS tracking
 Digitally steered lights-out warehouse
39 - Henkel (Düsseldorf, Germany)

Henkel
Laundry Digital
Backbone

 Renault Curitiba approached Fourth Industrial
Revolution technologies with a focus on improving
employee accountability and E2E connectivity,
engaging its workforce and developing a connected
ecosystem throughout value-chain players including
dealers, customers and workers. Results include
improving its productivity by 18%, without major
capital deployment.
 Customer connectivity: B2C e-commerce platform
 Connected workforce driving performance
 Flexible automation through AGVs and cobots
 E2E vehicle delivery tracking
 Digital recruitment platform tailored to shop floor
40 - Groupe Renault (Curitiba, Brazil)

 Leveraging advanced analytics for predictive
maintenance, a digital twin of its process plant, and a
proprietary data platform to accelerate development
and enable the exponential scale-up of new
algorithms across oil production vessels, this offshore
facility has reduced downtime by 65%.
 Digital twin
 Machine-learning predictive maintenance
 Artificial intelligence to accelerate scaling of digital
applications across fleet
 Digitally enabled people performance management
 Advanced analytics-enabled process monitoring
system
41 - MODEC (Rio de Janeiro, Brazil)

 An FPSO is a floating production system that receives fluids
(crude oil, water and a host of other things) from a subsea
reservoir through risers, which then separate fluids into crude
oil, natural gas, wataer and impurities within the topsides
production facilities onboard. Crude oil storeded in the
storage tanks of the FPSO is offloaded onto shuttle tankers to
go to market or for further refining onshore.
 The FPSO Cidade de Campos dos Goytacazes MV29,
recognized by World Economic Forum this time, is deployed
for operations in the Tartaruga Verde and Tartaruga Mestiça
fields in the Campos Basin offshore Brazil
FPSO Cidade de Campos dos
Goytacazes MV29

 This 35-year-old petrochemical facility embarked on a digital
journey to drive value creation. Self-developed artificial
intelligence algorithms optimize process and product pricing
by analysing billions of production scenarios, resulting in an
earnings before interest and taxes improvement of more than
20%.
 Yield and throughput improvement using IIOT and
advanced analytics
 Energy optimization by predictive analytics
 Quality improvement by predictive analytics
 Virtual reality-enabled HSE training
 Digital maintenance
42 - Petkim (Izmir, Turkey)

 In a drive to improve cost competitiveness, a local
entrepreneurial team established a factory data lake
and developed and deployed at scale Fourth
Industrial Revolution use cases. With limited
investment and in a short period of time it achieved
a cost reduction of more than 25%.
 Digital dashboard to monitor OEE performance
 Advanced analytics for quality prediction
 Digitally enabled E2E quality management
 Robotic process automation
 Smart device maintenance management system
43 - Unilever (Dubai, UAE)

 Vision Care has digitally connected its value chain
end-to-end from suppliers to consumers, as well as
implementing reconfigurable manufacturing, to
achieve double-digit cost reduction and sales growth.
 Digital customer collaboration
 Modular platform for rapid line reconfiguration
 IIoT-enabled advanced process automation
 E2E supply chain visibility platform
 Vision-guided robotics order fulfillment
44 - Johnson & Johnson Vision Care
(Jacksonville, USA)

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