Enterprise World 2014 - Manufacturing Industry Breakout Session
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Transcript of Enterprise World 2014 - Manufacturing Industry Breakout Session
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Digital Disruption Across Tomorrow’s
Manufacturing Supply Chains
Mark Morley, Industry Marketing Director
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Manufacturing 2.0, Rebooting Today’s
Global Supply Chains…
Global recession, wage strikes, natural disasters and increasing
regulatory compliance are leading to manufacturers having to
restructure their global supply chains
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Today’s Manufacturing Industry
North America, UK, Germany, China and
Japan lead global figures for production
output
Manufacturers continue to globalize
production facilities and de-centralize
design and engineering departments
Automotive and high tech industries are
increasingly consumer-driven, which is
leading to many new supply chain
transformation projects
New technologies such as the Internet of
Things will drive the ‘4th industrial
revolution’
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Today’s Manufacturing Value Chain Distributed Operations in Multiple Countries
Near-Shoring
2010 Onwards
China Globalization
2014 Onwards
Regional Marketing & Sales
Manufacturing
Distribution
Sales
Manufacturing
Research & Design
Manufacturing
Shared Services
Sales Distribution
Global HQ
Sales Shared
Services
Sales
‘BRIC’ Markets Expansion
2000 Onwards(BRIC = Brazil, Russia, India, China)
‘MINT’ Markets Expansion
2014 Onwards(MINT = Mexico, Indonesia, Nigeria, Turkey)
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From BRICs to MINTs
After significant growth,
BRICs starting to
experience difficult market
conditions
Inward investment to the
BRICs is reducing due to
an increasing interest to
invest in new low cost
markets
Fastest growing new
markets collectively known
as the MINTs
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Introducing the MINT Countries
MINT is term coined
by former Goldman
Sachs economist, Jim
O’Neill, who also
introduced the BRIC
term ten years ago
Analysts estimate that
the MINT countries
could enjoy similar
double digit growth as
China saw between
2003 and 2008
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Evolution of the Digital
Manufacturing Business
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Traditional Manufacturing Value Chain
Information resided in multiple departmental silos
Difficult to find and navigate through information
relating to a particular product
Lack of inter-departmental information exchange
and collaboration
Business expansion led to information replication
and multiple instances of key business systems
such as ERP
Product design department traditionally led
process automation initiatives and IT adoption
Product Design & Engineering
Manufacturing
Supply Chain Management
Marketing, Sales & Service
Traditional Value
Chain
Source: Cap Gemini Consulting Analysis
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Level
of
Dig
ital
Perv
as
ive
nes
s
High
Low
DesignProduction
DesignProductionPurchasing
Marketing
DesignProduction
Purchasing
Field Support
Logistics
Marketing
Design
Production
Purchasing
Sales
Field Support
Logistics
Marketing
Design
Production
Purchasing
1980 - 1990 1990 - 2000 2010 - 2020
Design & Production Automation
Computer Aided Design & Manufacture
Digital Mockups & Collaborative Design
Collaborative PLM & Cloud Connected Digital
Business
1970 1980 1990 2000 2010 2020
Evolution of the Digital
Manufacturing Business
Increased digitization of information over the decades has allowed more departments across the extended enterprise to access & utilise this information
Electronic Product Definition
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Digital Information Powers the
Integrated Value Chain
The Integrated Value Chain relies
on digital information to automate
and accelerate internal operations
A centralized digital information
hub:
Drives product innovation
Improves production efficiencies
Provides global agility
Increases customer satisfaction
Source: Cap Gemini Consulting Analysis
“Digital Transformation is not a quick-fix solution within rigid manufacturing processes and resources, but a long-term commitment and imperative”
Digital Product
Design
Digital Shop
Floor
Digital
Customization
Digital
Supply Chain
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Enterprise Information Management (EIM)
Information
governance,
security and a
single source of
truth
Enterprise
Content
Management
Process velocity,
flexibility, quality,
efficiency
Business
Process
Management
Rich experiences
across channels
and devices,
personalized to
the user
Customer
Experience
Management
Secure transfer of
information within
and between
organizations
Information
Exchange
Find the right
information at the
right time
Discovery
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How EIM Supports the Lifecycle of a
Manufactured Product
Market / Customer Requirements
A
Product Design & Engineering
B
PrototypeTesting & Compliance
C
Procurement / Supplier Onboarding
D
Manufacturing Engineering
E
ProductProduction
F
ProductQA & Certification
G
Plant Maintenance & Asset Management
H
Ship to Distributor or Retail Network
I
Online / Store Customer Experience
J
Aftermarket Service & Support
K
Recalls & Warranty Repairs
L
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Managing Information Across the
Lifecycle of a Manufactured Product
Market/Customer Requirements
Product marketing department to undertake
information gathering about market or customer specific requirements to
understand specifications for new product/equipment
design
Product Design & Engineering
Any information associated with the design of a
product, eg CAD files or specifications will need to
be stored via a LOTAR initiative, may also need to be exchanged internally or externally with contractors
Prototype Testing & Compliance
All product test data including materials testing,
stress analysis results, performance tests and
environmental test information should be
retained and archived as part of LOTAR initiative
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Managing Information Across the
Lifecycle of a Manufactured Product
Procurement / Supplier Onboarding
Suppliers will need to be identified & onboarded, procurement contracts drawn up and archived.
B2B solutions will need to be deployed and supplier
contact information centrally managed
Product Production
Assembly instructions, bill of materials, video
tutorials, essentially any information used in the
assembly of a product or piece of equipment could be made available on the
shop floor
Manufacturing Engineering
Product related engineering information could be used
to help design jigs and fixtures or develop tool paths for machining of
castings. Plant maintenance schedules will need to be
drawn up
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Plant Maintenance & Asset Management
All equipment on the shop floor will need to be
maintained and tested to a high standard, for example robots, milling machines,
lathes and any other equipment used to
manufacture products
Managing Information Across the
Lifecycle of a Manufactured Product
ProductQA & Certification
Each product needs to be tested to ensure
performance compliance and all results need to be
archived for future use, QA & performance certificates
will need to be archived
Ship to Distributor or Retail Network
Logistics and Shipping information needs to be sent to OEM or Service
Centre. Contact & contract information for logistics
providers needs to be maintained and archived in
a central location
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Aftermarket Service & Support
Aftermarket service centres and remote field service
engineers need access to all information associated with
a product or piece of equipment, eg drawings, 3D CAD Models, dis-assembly
instructions and videos
Managing Information Across the
Lifecycle of a Manufactured Product
Online / Store Customer Experience
Customer experience needs to be consistent across main website and any
support related sites as well as across mobile devices. All downloadable media
needs to be presented and managed effectively
Recall & Warranty Repairs
Any future product recall process or warranty repair
situation will need to be managed effectively. Any safety related issues will
require getting access to all archived information for
fault traceability purposes
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How EIM Supports the Lifecycle of a
Manufactured ProductMarket / Customer
Requirements
A
Product Design & Engineering
B
PrototypeTesting & Compliance
C
Procurement / Supplier Onboarding
D
Manufacturing Engineering
E
ProductProduction
F
ProductQA & Certification
G
Plant Maintenance & Asset Management
H
Ship to Distributor or Retail Network
I
Online / Store Customer Experience
J
Aftermarket Service & Support
K
Recalls & Warranty Repairs
L
Enterprise Content Management Customer Experience Management Business Process Management Information Exchange Discovery Appworks
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Managing Digital Information Across a
Manufacturing BusinessMarket / Customer
Requirements
A
Product Design & Engineering
B
PrototypeTesting & Compliance
C
Procurement / Supplier Onboarding
D
Manufacturing Engineering
E
ProductProduction
F
ProductQA & Certification
G
Plant Maintenance & Asset Management
H
Ship to Distributor or Retail Network
I
Online / Store Customer Experience
J
Aftermarket Service & Support
K
Recalls & Warranty Repairs
L
Enterprise Content Management Customer Experience Management Business Process Management Information Exchange Discovery Appworks
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Managing Digital Information –Product Design & Engineering
Any information associated with the design of a product will need to be centrally managed
Government regulations may require CAD data to be archived under a Long Term Archival and Retrieval (LOTAR) policy
Design information may need to be exchanged with external design partners and suppliers
Compliments an existing PLM archival system
• 3D CAD/CAM Models• 3D Printing Files• 3D Visualization Models• 2D Drawings• Production Information• Product Bill of Materials• Stress Analysis Test Reports• Environmental Test Reports• Materials Testing Reports• Materials Specifications• Product Specifications• Videos/Animations/Renderings
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Managing Digital Information –Procurement / Supplier Onboarding
Suppliers will need to be identified, on-boarded and managed on an ongoing basis
Contract and Contact information for every supplier will need to be centrally managed
Each supplier will need to be contacted to identify existing B2B and ICT capabilities
Appropriate B2B technologies, either software or web-based portals, will need to be setup
Adherence to regulatory compliance initiatives
• Supplier Contract Information• Supplier Contact Information• Protocol/Document Mediation• B2B Connectivity Testing• B2B Document Mapping• Implementing Appropriate B2B
Software/Web Portal Solutions• Backend Systems Integration• Adhere to GRC Initiatives, e.g
Electronic Invoicing• Community Management• 24/7 Helpdesk Support
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Managing Digital Information –Plant / Asset Management
All production-related equipment will need to be proactively maintained, including assembly & handling equipment, machining centres and utilities equipment
Maintenance teams will normally follow some form of standard process or procedure
Maintenance teams will need mobile access to a centralized repository of information for all plant equipment
• Maintenance & Test Procedures• Equipment Monitoring• Assembly & Disassembly Videos• 3D Plant Design Models• 3D CAD Equipment Animations• 2D Equipment Drawings• 2D Utilities Diagrams• Equipment Test Procedures• Equipment Test Certificates• Sub-contractor Information• Regulatory & Compliance Info.
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Managing Digital Information –Online / Store Customer Experience
OEMs need a fast and secure way to manage and exchange media files across retail networks
Any type of retailer, whether car, motorbike, consumer goods or high tech will need to exchange information with their HQ location
All aspects of the customer experience must be consistent across online and in-store platforms
Centralized access to customer-related information brings significant business benefits
• Product Brochures• Promotional Videos & Adverts• High Resolution Images• 3D Computer Graphic Animations• Product Training Videos• Technical Bulletins• Advertising Agency Collaboration• In Store Graphics/Designs/Layouts• Website Design & Management• Mobile Platforms & Social Media • Online Product Catalogues• Online Product Configurators
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Managing Digital Information –Aftermarket Service & Support
Aftermarket service centres and remote field service engineers need access to all information associated with a product
Information must be accessible remotely via ruggedized mobile devices
Replacement parts may need to be ordered/despatched from central warehouse
Product repairs may be part of a recall or warranty related process
• Repair & Test Procedures• Assembly & Disassembly Videos• 3D Visualization Models• 2D Product Drawings• Product Specifications• Warranty & Recall Procedures• Regulatory & Compliance Info.• Product Test Certificates• Fault Diagnosis Routines• Spare Parts Ordering Portals• Technical Service Bulletins
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Managing Digital Information Across a
Manufacturing BusinessMarket / Customer
Requirements
A
Product Design & Engineering
B
PrototypeTesting & Compliance
C
Procurement / Supplier Onboarding
D
Manufacturing Engineering
E
ProductProduction
F
ProductQA & Certification
G
Plant Maintenance & Asset Management
H
Ship to Distributor or Retail Network
I
Online / Store Customer Experience
J
Aftermarket Service & Support
K
Recalls & Warranty Repairs
L
Enterprise Content Management Customer Experience Management Business Process Management Information Exchange Discovery Appworks
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The Future of the Digital
Manufacturing Business
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How will Information Technology Impact
Your Company in the Year 2020?
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Data
Cloud
Mobile
Apps
Security
Social
Governance
SaaS
Disruptive Innovation
We are living in a time
of massive disruption
where information and
the way we use it is
changing the rules
of business
Information is at the
heart of the disruption
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The Digital Age
Information drives innovation
and growth
Information leads to greater insight,
higher customer satisfaction,
accelerates time to market, helps to
open new opportunities, and
enables you to remain competitive
Information is a key strategycomponent for every organization
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Gartner Technology Trends - 2015
By 2018, the total cost of
ownership for business
operations will be
reduced by 30 percent
through the adoption of
smart machines and
industrialized services.....
Gartner, October 2014
1. Computing Everywhere
2. The Internet of Things (IoT)
3. 3D Printing
4. Advanced, Pervasive, Invisible Analytics
5. Context Rich Systems
6. Smart Machines
7. Cloud/Client Architecture
8. Software Defined Infrastructure
9. Web Scale IT
10.Risk Based Security & Self Protection
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Cloud Deployments in Manufacturing
Simplifies the deployment and management of global IT infrastructures
Allows manufacturers to quickly scale up or scale down production
Design information is now accessible by anyone across the enterprise
ERP B2B PLM
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Today’s Manufacturing Operations are
Entering a Period of Significant…..
D
I
G
I
T
A
L
D I S R U P T I O N
New Sources of Unstructured Information Will Need Managing Across the Enterprise
4G Networks
Cloud
B
Y
O
C
Internet of ThingsW
I
F
IPaaS
5G Networks
Smart Grids
Mesh Networks
Big Data
Social Networks
Remote Monitoring
Analytics
Mobile Apps
NFC Payments
SAAS
S
E
C
U
R
I
T
Y T
E
L
E
M
A
T
I
C
S
Sensors
RFID
Smart Phones
Tablets
B
Y
O
D
Connected Devices
3D PrintingDrones
Wearable DevicesMass Storage
M2M
Robots
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Tomorrow’s Supply Chains Will be Impacted
by a Nexus of Disruptive Technologies
Wearable
Devices
Devices, such as Google Glass, will
transform how digital information
is accessed & shared across the
enterprise allowing
3D
Printing
3D Printers will manufacture parts
on demand and contribute
towards the introduction of the
‘zero length’ supply chains
Drone
Logistics
Drone aircraft will transform the
delivery of parts/finished
goods to customers across short
distance logistics networks
Future EIM platforms will need to embrace these technologies….
Internet
of Things
Introduction of more connected IoT devices /equipment
will allow manufacturers to
develop more responsive supply
chain networks
Advanced
Robotics
Next generation advanced robotics will work side by side with human
operatives, helping to automate more
production processes
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1. Wearable Devices
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Devices, such as Google Glass, set to revolutionize
how employees interact with their work
environments
Many manual-focused jobs require hands to be free
at all times
Glass, for example, brings data-rich information to
the user in real-time
Wearable Devices
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Wearable Devices – Warehouse Picking
OK Glass,Trace ShipmentLocate Part in WarehouseScan BarcodeContact 3PL Provider
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2. 3D Printing
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3D Printing
Technology entering the enterprise and general
consumer markets
Products can be made using a variety of materials
including metal
Likely to revolutionize production, as machine costs
come down
HP is evaluating market as an extension of their printer
business
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Technology is not new, been around for over twenty
years, formerly rapid prototyping, stereolithography
Limited production area, restricts type of products
that can be made
Relies on having a 3D representation of a product,
either as a CAD model or a 3D scan based
representation
3D Printing
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HP Sprout PC & 3D Printer – 29th October 2014
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HP, a Leader in Multi-Colour 3D Printing
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3D Printing Examples
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Most Ambitious 3D Printing Project?
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Introduction of Zero Length Supply Chains?
Original OEM Part
3D Printed Part
3D printing could potentially revolutionize the service
sector
Certain replacement parts could be printed instantly at a
service location
Combined with IoT, parts could be manufactured before
existing parts experience wear or stress failure
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3. Advanced Robotics
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Advanced Robotics
Google acquired 8 robotics companies in 2013, looking
to develop Android-based robotics operating system
One goal of robotics division is to help high tech
companies automate manual-based assembly
processes
Contract manufacturer Foxconn seen as perfect test
environment, however will Google robots be
assembling iPhones?
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Foxconn Automation, Goal = 1M ‘Foxbots’
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Foxconn Automation, the Reality
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Say Hello to ‘Baxter’
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4. Drone-based Logistics
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Amazon Prime AIR
Amazon aims to offer a 30 minute delivery service via
fleet of drones
FAA is due to introduce regulations in 2015 for drone
operation/safety
Amazon likely to acquire drone manufacturing
companies, will then own part of their logistics
network
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The Future of Expedited Shipments?
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Rolls-Royce Drone Ships?
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5. Internet of Things
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The Internet of Things -What Exactly is it?
Internet of Things (IoT)
Internet of Everything (Cisco)
Industrial Internet (GE Software)
Industry 4.0 (Bosch)
Machine to Machine (M2M)
Connectivity Across the Internet
“Any machine or device connected (via
fixed wire or wireless communication) to
the internet & being able to transmit
information in one form or another”
IDC - 200Billion connected devices by 2020
Cisco - Estimates market size at $14.4Trillion
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Digital Information is now Feeding the
Fourth Industrial Revolution
Industrie 4.0
Source: Bosch
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Core IoT Building Blocks
Sensors
Dedicated
Processor
Internet /
Dedicated Network
Big Data
Storage
Analytics &
Reporting
Key Characteristics = Energy Efficient + Cost Effective+ Quality & Reliable + Secure
WiFi or 4G
Comms
Devices /
‘Things’
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Home Automation
Nest provides an internet-enabled range of devices for home automation applications, this example shows a thermostat
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Home Automation Communications
LG has developed a home hub to allow consumers to send text messages to remotely control household appliances
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Utilities Infrastructures
Utilities companies in Barcelona, Spain have installed internet-enabled refuse bins to help identify whether bins are full or empty
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Connected Vehicles
Tesla Motors offers one of the most advanced connected cars on the market today, the Model S sedan
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Remote e-Health Monitoring
E-Health is expected to be a major beneficiary of IoT based devices, for example this e-Pill has a built-in high definition video camera
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IoT Related ROI
Source: Cisco
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How Will IoT Impact Global Supply Chains?
Exponential growth in data flow across future supply chains
IoT will impact future supply chains in many different ways:
Predictive
MaintenanceSelf diagnostics identify
failing components
resulting in automated
parts ordering
Pervasive
VisibilityEnd to end visibility of
shipments from point of
manufacture to point of
delivery
Proactive
ReplenishmentOptimization and
automated ordering of
inventory at the
ultimate point of sale
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1. Pervasive Visibility
Business Case - Visibility of
shipments from the factory
to the point of delivery
Example - Bosch developed
a virtual supply chain based
on inputs from an extended
network of RFID readers at
both their factories and
across their global network
of 3PL providers
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2. Proactive Replenishment
Business Case - Optimization
of inventory levels at the
ultimate point of sale
Example - SAP developed a
HANA based vending machine
which tracks consumption
trends, makes alternative
buying suggestions & places
automated orders for new
stock
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3. Predictive Maintenance
Business Case - Self
diagnostics identify failing
components resulting in
automated parts order
Example - RAC automotive
association in the UK offers a
retrofit module that can help
identify problems with a car
and notify driver before they
get too serious
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EDIFACT
XML
SWIFT
OFTP2
IDOCANSIAS3
Contract Mfg.
DistributorsCustomers
3PLs
Banks
Insurers
AS2
FTP
HTTPSSuppliers
B2B
HULFT
IDOCS
External Trading Partner Community
Managing Information Across Tomorrow’s
Digital Manufacturing Business
ERPPLM
Internal Enterprise Community
Procurement Production
Design
Marketing Sales
Service
HQ
EIM
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B2B & Supply Chain Related Benefits
Supply chains will become even more responsive
due to the sheer number of connected devices
monitoring the end to end movement of shipments
Cross enterprise connectivity and collaboration will
significantly improve business process and overall
operational efficiencies
Introduction of more closed loop, intelligent B2B
platforms and supply chains
Significant investment in new cloud based solutions
will improve functionality and usability of next
generation supply chain platforms
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Issues to Resolve
Address the inevitable security and privacy issues
relating to IoT networks (in-house and third party),
eg ensure virus protection for connected devices
Investment required to WiFi enable equipment,
deploy sensors, build out IP and cellular networks
Introduce appropriate global standards to support
future IoT related platforms, setting up relevant
industry bodies such as the Industrial Internet
Consortium (Cisco, GE, IBM, Intel, AT&T)
Avoid an IoT related ‘Dotcom’ style bubble of high
valuations on unproven companies or technologies
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‘Facebook for Machines’In the Future Every Connected Device Could Have an Online Profile
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Conclusions
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Manufacturing 2020
Enterprise Information Management helps to
embrace digital disruption in order to Simplify,
Transform and Accelerate tomorrow’s Digital
Manufacturing Business
Continued globalization will fuel the need for a simplified &
centralized digital information hub
Technology being introduced today is going to transform
tomorrow’s manufacturing operations
The Internet of Things is going to improve visibility across
supply chains, accelerating business decisions and allowing
companies to be more responsive to their customers
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Finally…….
New IDC Manufacturing Study!
Survey undertaken across 270 companies in the High Tech, Automotive and CPG sectors
Survey responses from companies located in 8 leading manufacturing countries including South Korea, Japan and China
Report discusses how B2B integration can help companies drive superior supply chain performance Session INX 422 @ 13:55
on Wednesday
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Review of IDC
Manufacturing
Study
Panasonic
Round Table
Conflict Minerals
Reporting
Michelin
Case Study
IDC Customer
Panel
Columbia
Case Study
Industry
Strategist
Meetings
Birds of a Feather
Breakfast
www.opentext.com/OTIndustryInsights