Industry 4.0 Case Studies (curated)
Topic
General Industry 4.0
Subtopic
Industry 4.0 Overview
Cost: Free
Duration: 0.75 Hour(s)
Certification Available: No
Course Level: Introductory
Prerequisites: None
Administered By: Various
Description
Curated Set of Case Studies demonstrating problem, solution, and results of implementing Industry 4.0.
What You'll Learn
- Optimizing Overall Equipment Efficiency and Utilization (Avalign Technologies & machinemetrics)
- https://www.machinemetrics.com/avalign-case-study requires free login, 10 page pdf article download
- Who – Avalign Technologies medical device company utilized machinemetrics for machine and operational data
- Problem – Needed to decrease downtime and increase throughput.
- Solution – deployed measuring, monitoring, dashboards for equipment like grinding, and lathes across 132+ machines at 4 facilities
- Results – 40% increase in OEE, 9.9% increase in throughput, $4.5M capacity utilization increase, 14k hours saved, across 9 months
- BJC HealthCare adopts IoT for inventory and supply chain management
- Who - BJC healthcare, service provider that operates at multiple hospitals in Missouri and Illinois
- Problem - Inventory tracking is labor intensive and inefficient.
- Solution - RFID tagging to track and manage thousands of medical supplies. Reduced manual labor to maintain inventory.
- Results - Reduce onsite stock by 23% at facilities.
- Big Data decision-making at Bosch Automotive factory in China
- Who - Bosch Automotive Diesel System factory in Wuxi, China
- Problem - Bottlenecks and production efficiency problems
- Solution - Collect machine monitor sensors' data, combine data sources, and use machine learning analytics to predict equipment failures, thus schedule maintenance before failure.
- Results - Higher uptime durations, contributing to > 10% production output increase in some areas
- Fetch Robotics help DHL improve warehouse operations
- Who - Fetch Robotics (California) and DHL distribution center (Netherlands)
- Problem - Improve efficiencies for locating, tracking, and moving inventory in warehouse and logistics facilities
- Solution - Used collaborative Autonomous Mobile Robots (AMRs) to pick and place alongside the workers. AMRs autonomously learning and sharing most efficient travel routes.
- Results - Reduce order cycle time up to 50%, provide up to 2x picking productivity gain.
- Fast Radius’ digital additive manufacturing solutions to enable new business models
- Who - Fast Radius Chicago, contract manufacturer with multiple locations.
- Problem - Improve efficiencies for fast turnaround and mass customization of products.
- Solution - Collect data for every part design and identify applications suitable for 3D printing.
- Results - Reduce costs in storing parts through virtual inventory, decrease cycle time.
- Racing to win with digital twins
- Who - Siemens and American pro racing squad Team Penske
- Problem - Speed up the race car development process
- Solution - Create a digital twin, digital representation of a real-world product, machine, process, or system, that allows companies to better understand, analyze and optimize their processes through real-time simulation based on machine learning. Sensors were fitted to a real car and collected data real-time continuously, such as tire pressure, engine control and wind speed, which is then converted into a virtual car model. It’s this model that allows engineers to test different design configurations.
- Results - Reduce testing costs, and time, and ultimately a faster vehicle.
- AI visual insights drive manufacturing efficiency gains
- Who - IBM manufacturing of mainframes, servers, storage, and IT appliances, in Canada, Hungar, mExico and US.
- Problem - Increase efficiencies of visual inspection and product quality. Manual inspections lead to missed defects. Traditional automated inspections also provide too many false positive results.
- Solution - Used IBM Maximo Visual Inspection, an AI-powered computer vision solution to automatically detect quality defects in manufacturing. System was trained using deep learning.
- Results - Up to 5x efficiency gains, 20% reduction in false positives.
- Summer Garden Food Manufacturing Reduces Downtime and Improves Machine Performance
- Explained in 7 minute video and implementation of plex.
- Who - Summer Garden Food Manufacturing
- Problem - Not enough productivity and low OEE, no visibility.
- Best Maid food product provider 185% ROI in 0.5 years
- Who - Best Maid food product provider
- Problem - No ERP system - legacy database and excel spreadsheets. Difficulty managing inventory (5 manual audit days/month), Production planning (schedule written day before), challenging for Safe Quality Food Certification.
- Solution - Plex implementation - training, implementation, within 8 months.
- Results
- Inventory Management - reduction in raw material inventory of $0.5M, eliminate $50k mislabeled items, eliminate lost 1% due to spoilage.
- Streamline Order to Cash - deliver within 3 days window to avoid penalties (was 1% of orders delayed w/penalties and 50% of Best Maid's revenue)
- Financial management - financial close process now 25% of previously required - was 4 months behind, now closes within 4 weeks of month end.
- Industry 4.0 Examples
- Areas with videos, BBC mostly, Logistics, Construction, Public Transport, Manufacturing, Food production, Fieldwork