Industry 4.0 is the next Industrial Revolution. It involves integrating data from many kinds of sensors to gain the necessary visibility to predict issues and self-diagnose as problems occur. To some manufacturers, the coming age of cyber-physical systems is the inevitable next step. For most, however, these concepts feel quite distant from today’s reality where many plants have yet to adopt the automation technologies of Industry 3.0, and are decades away from mass adoption of Industry 4.0. While today Industry 4.0 is an aspiration, every company can benefit from greater visibility throughout the production process. This slide deck explores how the manufacturing plant is evolving from recording the past to controlling the present to predicting the future. What You'll Learn From this Presentation: -Where your company ranks among the four Industrial Revolutions -How to get to the next stage -How increased visibility can have a positive and resounding impact throughout the manufacturing process -What it takes to embrace Industry 4.0

1. Visibility in Manufacturing:
The Path to Industry 4.0
Hosted by Adrian Jennings, CTO - Americas, Ubisense

2. The Path to
Industry 4.0
Adopting
Industry 3.0
What the
Survey
Revealed
What is
Industry
4.0?
Introduction
Webinar Agenda

3. Recovering
Rocket Scientist
Expert in
Location Technology
Dot-Connector-in-Chief
at Ubisense
Published
Photographer
Ex-pat Brit,
Living in Alabama
Dog
Lover
Adrian Jennings

4. What is Industry 4.0?
X
X
X
X

5. How many hours a day do you spend searching
73%
19%
5%
3%
½ – 1 hour
1 – 2 hours
3 – 4 hours
More than 4 hours
for equipment and products?

6. How much visibility do you have into the real-time status of your
company’s manufacturing process? (select all that apply)
13.9%
26.5%
43.7%
29.4%
50.0%
45.0%
40.0%
35.0%
30.0%
25.0%
20.0%
15.0%
10.0%
5.0%
0.0%
No visibility Visibility limited to plant
Andon board
Visibility limited to personal
operational dashboard
Have access to instant real-time
status of every product

7. SOURCE: Gartner (August 2014)

8. How is your company leveraging its visibility data?
73.4%
To monitor current
performance against plan
68.7%
To identify areas for
improvement
56.2%
To identify problems
as they occur
40.3%
To identify problems
before they occur
(select all that apply)

9. What data do you have to support process improvement initiatives?
4.9%
31.7%
82.1%
59.3%
16.3%
(select all that apply)
My Team
Observations
My Personal
Observations
Independent
Analysis
Sensors that
Measure Process Flow
Other

10. What is your biggest cause of quality issues?
51% 33% 9% 7%
Workers not adhering
to designed process
Inexperience of
new line workers
Insufficient
process time
Inability to tie quality
records to specific products

11. An important milestone
is missing…
Introduction of
Mass Customization
Introduction of
Mass Production

12. Process Complexity Versus Process Variability
Complexity Variability

13. Where do you see the biggest opportunity
for decreasing the cost of quality?
2%
8%
35% 55%
Better worker training
Fault tolerant process design
More process time
Online repair

14. 80%
70%
60%
50%
40%
30%
20%
10%
0%
What percentage of wireless tools are currently in your plant
and what percentage do you estimate in 5 years?
Now 5 years
0-10% 11-20% 21-50% 51% and up

15. Adopting Industry 3.0
Measure Control React

16. Asset
Visibility
Process
Visibility
Error
Proofing
Reactive
Controls
Industry 3.0 Technologies

17. Asset Visibility

18. Process Visibility

19. Error Proofing

20. Reactive Controls

21. The Path to 4.0
How do you get there from here?
Industry 3.0 Industry 4.0

22. Be Selfish
Start small and local: that’s the only way to quickly
justify, deploy, and prove visibility solutions.

23. Be Forward Thinking
Understand both your next step and your ultimate goal,
and invest in the right infrastructure from the outset.

24. Be Cooperative
Pay it forward: there are significant benefits when the entire
organization invests in visibility solutions.

25. Be Supportive
Guide other plants through the process to help the
organization prepare for the final step.

26. The Path to 4.0
How do you get there from here?
Industry 3.0 Industry 4.0

27. Be Collaborative
Get a seat at the table, and trust them:
they really are here to help.

28. The Path to 4.0
Layers of Value
Process Department Plant Division Company
Industry 3.0 Industry 4.0

29. Don’t get lost in the hype
Focus on Industry 3.0 and introduce tools that are already available

30. Questions?

31. Connect with me
LinkedIn
Adrian Jennings
Twitter
@Adrian_Jennings
Email
Adrian.Jennings@ubisense.net

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