Roland Berger: Industry 4.0: Automotive industry sets the standards for digital manufacturin

Industry 4.0: Automotive industry sets the standards for digital manufacturing

What distinguishes firms which are making speedy progress in digitalizing their manufacturing operations from these that aren’t? The brand new Roland Berger research on “The present state of Business 4.0” has discovered that it’s a mixture of 4 components: the clear prioritization of functions, the setup of a devoted cross-functional Business 4.0 staff, the definition of a very harmonized IT/OT goal panorama and a robust give attention to respective worker coaching. Drawing on the experiences of main automotive OEMs and Tier-1 suppliers, the research presents the important thing success components for digital manufacturing.

“When the time period ‘Business 4.0′ was coined an excellent ten years in the past, there have been immense hopes round it,” says Bernhard Langefeld, Associate at Roland Berger. “Within the meantime, firms have in some circumstances invested some huge cash, however most of them are nonetheless far-off from the unique imaginative and prescient of an clever, absolutely versatile and self-organizing manufacturing unit.”

Digital manufacturing typically fails in follow owing to circumstances corresponding to largely autonomously working manufacturing websites with heterogeneous IT/OT architectures, the usage of outdated tools, or difficulties quantifying the added worth of Business 4.0 use circumstances. Regardless of these challenges, the automotive business specifically has made important progress in Business 4.0 lately. The consultants’ evaluation based mostly on the experiences of main producers and suppliers reveals that to drive the identification, prioritization and implementation of use circumstances, the digital pioneers depend on organizational setups that effectively allow a centralized (hub-and-spoke) strategy to answer growth. This avoids the identical work having to be repeated at totally different firm amenities. Not solely that, however the ensuing processes are simpler to roll out and scale up throughout a number of crops if there’s one central physique in management.

Group and know-how are essential

The implementation of particular person use circumstances requires competency in information evaluation, IT and manufacturing. That’s the reason profitable OEMs usually bundle their digital actions on a cross-functional foundation in an Business 4.0 heart of excellence. Working in shut coordination with the crops, this central staff will decide the concrete necessities and pilot new functions. To handle the varied particular implementations, firms additionally want an overarching IT/OT goal structure. That is the place IIoT-based cloud platforms have gotten more and more essential. This goal panorama helps to keep away from the redundant buildup of IT infrastructure and interfaces for various use circumstances, and ensures that the use case implementation roadmap is aligned with the funding in new methods.

The research discovered that the automotive business has achieved appreciable success lately:

  • Situation monitoring and predictive upkeep of plant and equipment are already at a sophisticated stage of technical maturity.
  • Imaginative and prescient-based and course of data-based inspections include excessive worth added throughout totally different use circumstances, from engine manufacturing to closing meeting.
  • Autonomous materials dealing with is used significantly in intralogistics for engine and automobile meeting.
  • Fashionable monitor and hint methods assist the monitoring of transports alongside the provision chain, serving to to attain higher course of transparency and facilitating the seamless monitoring of incoming elements.
  • In-process (real-time) machine optimization shows the bottom diploma of technical maturity. There are at present some preliminary pilot use circumstances in press and paint outlets.

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