11/4/2022 0 Comments Industry 4.0 elements![]() Furthermore, forecasting processes that draw heavily on big data already can drastically reduce inventories and improve service levels today. Advanced analysis of granular data on machining processes, generated in real time, will be fundamental to identifying and addressing the underlying causes of process inefficiencies and problems with quality-faster and more effectively. #INDUSTRY 4.0 ELEMENTS MANUAL#Digital performance management combined with advanced robotics and automated guided vehicles can further automate manual work (for example, in picking and in-plant transportation) and has the potential to improve labor productivity by an additional 40 to 50 percent. ![]() Labor efficiency is another area with high potential. For example, a reduction of total machine downtime by 30 to 50 percent-a feat possible with predictive maintenance or remote monitoring-will greatly increase asset utilization. To generate meaningful impact, companies will have to address all elements of profit and loss while also applying a broad range of solutions at scale. This productivity leap will not come from the application of a single solution. Our estimates, based on numerous studies, show that digitally enabled advancements are unleashing the potential to create value equivalent to efficiency improvements of 15 to 20 percent. Industry 4.0 is the source of the next horizon of productivity gainsĪs cost pressure across all industries continually increases, companies face the need to improve productivity by two to four percentage points every year. All of these changes will bolster the pathway to the real revolution: creating self-optimizing assets that do not require operator interventions.īeyond Industry 4.0 hype: Five core principles for creating value at lean’s next levelīased on our experience working with clients on digital and Industry 4.0 transformations, we have identified five principles that can help companies successfully convert Industry 4.0 solutions into real value and bottom-line impact. However, implementing the newly identified measures requires organizational transformation-new ways of working, new approaches to performance management, and new capabilities. ![]() In a digital world, performance deviations can be monitored in real time and addressed immediately. At a typical plant today, performance management happens more or less after the fact, when performance is checked at the end of the shift. Take the case of performance management on the shop floor. These advances can be complemented with digitally enabled transparency regarding performance. Now new sensors, more data, and advanced analytics can boost the ability to solve problems and identify sophisticated improvement measures, resulting in smarter solutions and new productivity gains. For example, companies have long optimized yield, energy, and throughput by improving process steering. In other words, Industry 4.0 can be understood as digitally enabled lean. ![]() ![]() In addition, a new dimension concerned with data, IT, and connectivity will emerge as another core value driver. Organizations will use these reinvigorated lean methods to implement a new way of working for three dimensions that have long been recognized as pivotal: technical systems (processes and tools), management systems (organization and performance management), and people systems (capabilities, mind-sets, and behavior). At the same time, advancements in data collection, sensors, robotics and automation, new technologies (including 3-D printing), and increased computing power will enable advanced analytics and give established methods a new edge. Proven principles of lean-such as reducing waste in the form of machine breakdowns or non-value-adding activities-will remain fundamental. We believe, however, that Industry 4.0 will be less a revolution than a valuable (and welcome) evolution, making next-horizon productivity gains possible and mirroring developments that have unfolded in the manufacturing environment for more than a century. Companies in this bind may find comfort in the ubiquitous promise that “Industry 4.0” will soon bring sweeping change to industries worldwide-but may also be encouraged to simply wait and see. ![]()
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