Combinate l'eccellenza operativa alle possibilità offerte dall'Industria 4.0 per una maggiore agilità, flessibilità e, in definitiva, una maggiore efficienza. Una soluzione concreta per ridurre di circa un terzo i tempi di produzione e fino all'80% il tempo dedicato all'amministrazione. Scegliete l'Industria 4.0 per liberare il vostro potenziale.
Tutte le industrie dovranno abbrcciare la trasformazione digitale (alcune hanno già iniziato a farlo), anche se con modalità e ritmi diversi. L'obiettivo della fabbrica del futuro è la creazione di sistemi migliori per le operazioni e la loro gestione.
L'Industria 4.0 rappresenta il quarto stadio della rivoluzione industriale o, più esattamente, della sua evoluzione. Si tratta del connubio tra elementi fisici e tecnologie avanzate che comunicano, analizzano ed elaborano dati e informazioni.
La connettività che la contraddistingue sta trasformando radicalmente i processi di fabbricazione e di approvvigionamento. Il ricorso a tecnologie innovative come l'intelligenza artificiale (IA) e l'Internet delle cose (IoT) migliora l'automazione, la comunicazione e l'utilizzo di dati in tempo reale. In questo modo le organizzazioni sono più flessibili e reattive e possono prendere decisioni più oculate in funzione dei dati disponibili.
L'applicazione di queste tecnologie e principi permette di accrescere l'efficacia, la qualità e la sicurezza dei processi industriali. Le aziende possono creare nuovi prodotti, servizi e modelli di business grazie al funzionamento in tempo reale della supply chain.
L'Industria 4.0 libera quindi ulteriormente le potenzialità di miglioramento e amplia le opportunità di crescita generando redditività
Integriamo la dinamica operativa, digitale e umana per amplificare e accelerare progressi tangibili, assicurando fin da subito il radicamento e la sostenibilità dei risultati ottenuti.
L'Industria 4.0 è la soluzione che fa per voi.
Il team di EFESO Consulting può accompagnarvi nella transizione permettendovi di cogliere le grandi opportunità che offre.
Le nostre soluzioni digitali sono completamente integrate e affrontano le vostre sfide in modo olistico, dando la priorità all'aspetto umano, che è spesso l'elemento più importante, se non addirittura critico.
Scegliete EFESO per:
Il punto di partenza di una strategia sostenibile per l'Industria 4.0 è una visione completa e obiettiva delle opportunità e degli ostacoli all'attuazione presenti nella vostra azienda. Saremo lieti di aiutarvi a realizzare questa analisi e implementare le azioni.
In quanto partner di grande esperienza, EFESO Consulting vi aiuta a sfruttare il vostro potenziale perché la vostra azienda sia a prova di futuro, da un punto di vista operativo e organizzativo.
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Smart Factory: making a factory future-proof
In just four weeks, a pharmaceutical & life sciences company wants to plan the main focus for the Smart Factory Transformation of four plants.
Workflows and key performance indicators varied by line and plant, with various digitization needs and priorities. Therefore, at beginning of the project, it was necessary to get a clear picture of the actual maturity and requirements for each location. To this end, the project team developed a scalable approach for lean transformation of the plant.
Challenge
After starting in individual pilot areas of assembly, it transferred the improvements to the current line and finally, with further lessons learned, to the ramp-up of the two new models.
After assessing the digital maturity level of the existing production system, the project team held a joint workshop with the plant management to determine the main directions for each site.
The result was a big picture that ensured a common understanding among the workshop participants as to where the journey should take them. The commitment for the joint next steps was correspondingly high.
Solution
Besides that, the participants also determined the different directions of digitization of the respective locations including topics such as data transfer, advanced analytics, digital twins or autonomous transport systems (AGVs).
So-called “deep dives” were then made to explore the technological and economic details of the defined directions identifying for example areas with high potential for driverless transport systems, the size of the investment needed and the economic benefits.
From this, it was possible to derive very precise statements regarding profitability / pay back of individual business cases.
At the end of the project, the project team for each location arranged approx. 40 key topics and initiatives from the previous weeks into a portfolio with three structure criteria:
Result
Among other things, three key topics were identified, that fulfil three requirements: quickly realizable, low deployment cost and great benefits.
The other focal points from the portfolio were added to the “open items” list in order to implement them later. After a portfolio evaluation of all decision-making instances in the company, the implementation of the following actions was started:
With these digitization initiatives, the company has been optimally equipped for further Smart factory transformation at all locations. Already in the planning phase, it was thus possible to improve the quality of the process and operational excellence at the sites.
Realising true end-to-end digitization for better customer journeys
A global furniture manufacturer was offering a broad variety of different product lines ranging from luxury to discount furniture, each with its own specific sales channels.
In order to reshape this kind of segmentation ROI-EFESO created a unified and integrated ‘end-to-end’ process from the customer request to the delivered product that took into account all relevant stations of Value creation: from the customer experience via ordering to manufacturing and logistics.
Solution
In two workstreams ROI-EFESO took care of the back-end integration and thus everything that happens from the ERP system all the way to the production for one.
For another workstream the project team accelerated the development of the digital channel, starting with the customer experience at the point of sale, working through the ordering process and on to the factory itself.
Result
Parallel front-end and back-end teams ensured that product customization was working flawlessly from the point of sale, through production, to delivery of the product.
The solution created by ROI-EFESO is a highly innovative combination of a 3D visual space and experience and an intelligent configurator. The customer navigates between OLED screens and finds himself in a virtual, photorealistic, 3D animated room. There he is viewing his desired piece of furniture – rendered as a 3D model – from all perspectives.
Furthermore, an ‘intelligent’ configurator is used, comparable to the car configurators used in the automotive industry. During the customer’s ‘try out’ of his virtual product, the salesperson can configure different variants, e.g. the frame of a bed, material or backrests, and visualize them on the screens.
In the future, the salesperson can use several different room settings with plant arrangements, parquet or carpet. Ambient lighting effects, i.e. different lighting scenarios for day and night, will enhance the customer experience. This mix of digital and real world turns the purchase into a “wow factor” experience.
Once the customer has preconfigured his furniture, the order can be placed at the touch of a button. The process for this is automated. Product customization via the configurator at the point of sale naturally modifies the supply chain – more variants result in smaller batches.
Parallel to the developments in the front-end area, ROI-EFESO has therefore combined the ERP systems of the different brands so that the data of all production and logistics processes are now available in real time.
Predictive quality and production through digital process twins
A global automotive supplier was facing two major challenges in its dashboard panel production: on the one hand, risks in the process chain remain undetected due to a lack of transparency and poor supplier management.
On the other hand, the processing of highly sensitive materials means that even the smallest of errors in the production process can lead to the rejection of complete components. ROI-EFESO supported the customer by using a ‘digital twin’ to map the entire production process step by step.
This led to an IoT pilot project that pinpointed potential for improvement and triggers improvements in both production and value stream management at suppliers.
Challenge
As a first step, the project team defined process parameters that could affect both the performance of the plant and the quality result.
The derivation of these parameters was empirically based and included initially more than a hundred different parameters, which were reduced or supplemented in the further course of the analysis.
In the next step, the team verified that the existing process data had been correctly aggregated and processed and gathered data that had not been previously recorded. The team also used additional sensors to capture the new data required for the defined parameters.
Solution
The resulting database was then consolidated and analyzed in a cloud application. On this basis, the project team designed a model that reflects the process of improving the production line for dashboards as precisely as possible – in other words, all relevant parameters, their interactions and critical values.
Like the process itself, this model can go far beyond the company. In the case described, for example, it can be extended to the logistics company that transports the foam, or even to the foam manufacturer.
This is because the reasons behind problems in the foaming process – such as dangerous temperature fluctuations for the sensitive polyurethane – can appear at any point in the value chain.
Result
As a result, the company obtained a digital process map that tracks the entire physical process in real time and enables early intervention according to critical process parameters – a “digital process twin”.
With the help of this ‘digital twin’, the project team was not only able to significantly reduce the plant’s rejection rate, but also to make the correlations of relevant influencing factors on the quality result more transparent. The company also developed a prediction model of the result at the next quality gate.
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