Whirlpool EMEA Industry 4.0 Athens public€¦ · Whirlpool Corporation -Confidential Smart Factory...
Transcript of Whirlpool EMEA Industry 4.0 Athens public€¦ · Whirlpool Corporation -Confidential Smart Factory...
Whirlpool Corporation - Confidential Smart Factory Conference 2019
Industry 4.0 transformation in Whirlpool EMEA
Pierluigi Petrali – Manufacturing R&D Manager
Whirlpool Corporation - Confidential Smart Factory Conference 2019
$11.7BSALES
26.000EMPLOYEES
NAR
$4.9 BSALES
22.000EMPLOYEES
EMEA
$3.4BSALES
24.000EMPLOYEES
LAR $1.5BSALES
20.000EMPLOYEES
ASIA
A GLOBAL COMPANY
Whirlpool Corporation - Confidential Smart Factory Conference 2019
A LEADERSHIP POSITION
WHIRLPOOL CORPORATION
72 million products sold in more
than 170 countries
in the world
World’s leadingmajor home appliance company (NYSE:WHR)
Approximately
$21 billion in sales in 2017
92 000 employees
70 manufacturing
and R&D centers
$1 billion investment in capital and R&D centers annually
Whirlpool Corporation - Confidential Smart Factory Conference 2019
OUR GLOBAL PORTFOLIO
*Whirlpool ownership of the Hotpoint brand in EMEA and Asia Pacific regions in not affiliated with the Hotpoint brand in the Americas
*
Whirlpool Corporation - Confidential Smart Factory Conference 2019
TODAY
EUROPE, MIDDLE EAST AND AFRICA (EMEA)
14 industrial sites
in 7 countries
Over 14 000 manufacturing jobs
22 000 employees $5 billion in annual sales
*in 2017
Whirlpool Corporation - Confidential Smart Factory Conference 2019
EMEA
MelanoItaly
Comunanza Italy
CassinettaItaly
SienaItaly
NaplesItaly
IsithebeSouth Africa
YateUK
WroclawPoland
ŁódźPoland
RadomskoPoland
Lipetsk Russia
Poprad Slovakia
ManisaTurkey
Carinaro Italy
INDUSTRIAL FOOTPRINT
Whirlpool Corporation - Confidential Smart Factory Conference 2019
WE SHIP AROUND 23 MILLION PRODUCTS IN 140 COUNTRIES
EMEA
DISHWASHERS DRYERS HOODS OVENS
REFRIGERATORS WASHING MACHINES WASHER/DRYER
v
AIRCONS
v
FREEZERS
v
SDA
v
HOBSFS COOKERS MICROWAVE OVENS
*in 2017
Whirlpool Corporation - Confidential Smart Factory Conference 2019
EMEA
BRANDS AND PRODUCT LEADERSHIP
Indesit Built-in Suite
Indesit Innex
Whirlpool SmartCook
Whirlpool SupremeCare
KitchenAid Black Steel Collection
KitchenAid Culinary Center
Whirlpool Corporation - Confidential Smart Factory Conference 2019
BRANDS AND PRODUCT LEADERSHIP
EMEA
Bauknecht WM 100 stainsHotpoint 3DZone wash Hotpoint Go Healthy range
Whirlpool Corporation - ConfidentialWhirlpool Corporation - ConfidentialWhirlpool Corporation - Confidential Smart Factory Conference 2019
Industry 4.0 in Whirlpool EMEA
Whirlpool Corporation - Confidential Smart Factory Conference 2019
Whirlpool EMEA Industry 4.0 TimelineConcepts of Industry4.0 and Smart Mnafacturing permeate to top management: SCM Invited at WHR Global Operations Commitee.
2013
2015 2016 2017World Manufacturing Forum in Milan consolidate I4.0 concepts in european industries
2013
GE Indutrial Internet of Things
Whirlpool go on the Cloud with complete Google based platfrom
EMEA Deployment Plan
2012
Germany Industrie 4.0 published
EU project FITMAN: Future Internet of Things forManufacturing
2014
SCM study presented at WFM2014
MFG 2020 Program Started
EMEA I4.0 Pilot in Poprad (SLO)
2018
EU project MAN-MADE: First Cooperative Robot experiment in Whirlpool EMEA
2015 2016
EU project PERFoRM: Concept of Middleware and Plug &produce inspire I4.0 Architecture
2017
Whirlpool EMEA in OsservatorioI4.0 Advisory Board
Whirlpool Corporation - Confidential Smart Factory Conference 2019
Main steps of I4.0 in Whirlpool
1. Inception2. Concept elaboration3. Strategy development4. Pilot5. Deployment and Governance6. Current Challenges
Whirlpool Corporation - Confidential Smart Factory Conference 2019
Concept Elaboration: enabling technologies deep dive
Big Data and Analytics
SimulationAugmented Reality
Automated Material Handling
Collaborative Robots
Additive Manufacturing
Agile Processes
Industrial Internet of Things
Cloud Computing
Traceability
Mobile Devices
Automated/Advanced Testing
Horizontal / Vertical Software Integration
Whirlpool Corporation - Confidential Smart Factory Conference 2019
NAR
EMEA
LAR
Asia
Focus:
● Identify key use cases for initial applications
● Leverage external successful implementations - don’t reinvent the wheel
● Push early implementations for lessons learned and improvements
Tactics:
● Upgrade the mfg network infrastructure
● Require all new equipment to be IIoT capable
● Aggressively pursue structured pilots and spread successful systems
rapidly
● Leverage equipment that promotes cohabitation of local and connected
networks on existing infrastructure
Enablers:
● Senior Leadership buy in and support
● Vision and strategy well defined
● Resources for initial applications
● Mobility of assets from site to site
Benefits (to be further defined):
● CapEx savings 10%-30%; Inventory reduction 15%-33%; Innovation
Increase 8%; Quality Improvement 13%-45%
● Increased supply chain flexibility and speed
● Connection of design & mfg
● Unknown connected benefits
2020 2025
Impact on Regions Critical Systems
ConnectedFully Connected Mfg
Plants
Challenges:
● Electronics are our competitor’s strength - Samsung & GE are already
working here. We need strong action to compete.
● Payback for small, piece applications is not always substantial
● Different systems across and between regions
● Joining GIS & Operations effectively
Technology deep dive (2016) : example
Whirlpool Corporation - Confidential Smart Factory Conference 2019
Strategy Development (2016)
Whirlpool Corporation - Confidential Smart Factory Conference 2019
Future Technology impact envision
Whirlpool Corporation - Confidential Smart Factory Conference 2019
EMEA I4.0 ROUTE MAP
● Global drive● Pilots implementation● Top Down approach
● Core areas identification● From use cases to 6
workstreams● Setting the basis for an
end to end integration● Governance start-up
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3
PILOT DEPLOY EXTEND & DRIVE
Transformation
Disruptive technologies introductionSpecific skills internalization
Strategy workstreams
Skills and competencies diffusion. From “Manufacturing” 4.0 to
Industry 4.0
2016-2017 2018-2019 2020+
● Regional Drive● From deployment to roll
out● Full Value chain integration● Strategic partnership
1
Whirlpool Corporation - Confidential Smart Factory Conference 2019
I4.0 CORE AREAS IMPLEMENTATION
Supplier Scouting
● Contact/ evaluate/ engage suppliers
● Identify/ develop solutions
Trials
● Technologies try out in the factory
○ Assess technology solution applicability
○ Address process/ organization impact
Pilot
● First complete implementation in a factory narrow context
○ costs/benefits identification
○ process/ organization harmonization
Standardization
● After one/two completed pilot extensions
● Use case ready to be replicated (TO BE):
○ Standardized capabilities
○ Technical/ systems/ process/ organization requirements
Deployment
● Gap analysis for implementation identified in each factory:
○ Technical
○ Organizational
○ Operational
● Handover completed and Local/central competence available
● STD refinement
Rollout
● STD Solution ready for roll out
● Full roll out costs known
● Prioritization and implementation driven by factories
Technology Scouting
● Identify solutions according to knowledge intake process
○ R&D
○ Competence centers
○ Benchmarking
○ Trade shows
FactoryOE - Tech
Technical Readiness
Key Deliverables
First Pilot complete
Communication Events
OE - I4.0Main Accountabilities
Functional Readiness Cost/Organization Readiness
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Whirlpool Corporation - Confidential Smart Factory Conference 2019
I4.0 TECHNOLOGIES MAJOR APPLICATIONS
CoreTechnological
Areas
Use Cases● Scouting: 81● Trial: 8● Pilot: 29● Deployment: 2
Augmented Reality
Human Centered
Automation
Data Visibility
Advanced Testing
Traceability
Training on critical workstations
Augmented Reality
Training on critical workstations
Virtual Reality
3D digitization for full line and equipment
Collaborative Automation
Cobots for panel screwing
Collaborative Automation
Mobile robots for material delivery
Visibility and Analytics
Cloud based KPI’s
Visibility and Analytics
Real Time Energy Management
Vision Systems
Smart Quality Control
Industrial Inspection
Drones for visual and thermal inspection
Real Time Location Systems
Forklifts and tuggers tracking
Tools at Suppliers Location
E Tooling. Remote performance monitoring
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Whirlpool Corporation - Confidential Smart Factory Conference 2019
Challenge #1 Assess and measure progress
DREAMY
Different tools with different starting points/approaches/metrics - apparently complementary
Cassinetta RF* - Machines
Whirlpool Corporation - Confidential Smart Factory Conference 2019
Challenges #2 Change Management
• New Skills
• New Jobs
• New Organization Model
• New Business Processes
• Mindset transformation
Whirlpool Corporation - Confidential Smart Factory Conference 2019
Challenge #3 Innovation Engine
EU Research Projects
EMEA Mfg R&D + IT Innovation
EIT Manufacturing
Concepts
Core Areas
Technologies
Whirlpool Corporation - Confidential Smart Factory Conference 2019
Factory Automation Edge Computing Operating System Reference Implementation
H2020 Research and Innovation Action - This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement N. 723094
The project will research and provide a novel factory automation platform (operating system) based on an edgecomputing architecture and IoT/CPS technologies enabling a decentralized automation solutions for the factories of thefuture.
Allows Smart Factories to take advantage of EdgeComputing – i.e., having computing power in close proximity to where it is actually needed
Smart Machines
EnterpriseSystems
FactoryControl
CPSControl
Distributed Ledger Technology as a key enabler of:Decentralization of process control (orchestration)Decentralization of data analysis (aggregation)Real-to-digital synchronization (digital twins)
Advantages over centralized architectures:Flexibility / Modularity (plug-and-produce)Robustness / Resiliency (no single point of failure)Flexibility / Cost-effectiveness (elasticity with no cloud infrastructure)
Whirlpool Corporation - Confidential Smart Factory Conference 2019
WHR Use Case To-Be
24H2020 Research and Innovation Action - This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement N. 723094
• self-contained CPS composed by autonomous smart objects • CPS flexible to adapt to changing environment (factory upstream and needs of warehouse) and easily modified by operators.
Whirlpool Corporation - Confidential Smart Factory Conference 2019
Edge Nodes logic
25H2020 Research and Innovation Action - This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement N. 723094
Each bay provides its status:
• Availability to receive products
• Number and type of products in queue
• Recent unload performances
1
The conveyor provides its status:
• Number and type of products in queue
2
Blockchain Smart Contract:
• Elaborates status from bays and conveyor
• Fill-up the Bay Assignment List
3
The bay act:
• Read the Bay Assignment List
• Actuate the Bay selector
4
Whirlpool Corporation - Confidential
TIER 1 SUPPLY
BASE
TIER 1 SUPPLY
BASE
Raw materialRaw material
Change in Tier 2Change in Tier 2
Wrong InstructionsWrong Instructions
SPARE PART CENTERSPARE PART CENTER
Parts deliveryParts delivery
PREDICTION
TOOL
PREDICTION
TOOL
Prod. Orders Request
and wharehouse
management suggestion
Planning and
Quality suggestion
Warning alert,
training and
medium term planning
PRODUCTION FACTORYPRODUCTION FACTORY
WHR Use Case
H2020 Research and Innovation Action - This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement N. 780732
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Standardization and Reference Architecture
Cyber Physical System
Horizontal Integration through Value Network
End to End Digital Integration of Value Chain
Vertical Integration and Networked Manufacturing Systems
Managing Complex Systems
Broadband Infrastructure
Safety and Security
Work Organization and Design
Training and Development
Regulatory Framework
Resource Efficiency
The challenge’s challenge
There is more to Industrie 4.0 than its technical dimension.Industrie 4.0 means a paradigm shift in companies’ manufacturing strategies
Source: Think Act beyond Mainstream The Industrie 4.0 transition quantified - Roland Berger
Whirlpool Corporation - Confidential Smart Factory Conference 2019
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