This is the first in a series of Industry 4.0 posts that aim to help manufacturers take advantage of the power of innovations in manufacturing. To receive the next post in the series, sign up for our newsletter.
In the world of manufacturing, it can be tough to get started on digitalisation due to legacy systems, skill gaps, and other complexities. Even as data becomes an important part of decision making in the future, only about half of industrial manufacturers are actively focusing on data today, per a PwC study. This means that there are plenty of bumps in the road for manufacturers who are looking at Industry 4.0 solutions, but have not been able to start on their digitalisation journey.
To provide some help, we have collated 3 spectacular success stories that every manufacturer should read:
Rio Tinto Predicts Maintenance
One of the world’s largest mining companies, Rio Tinto was working with self-driving dump trucks and needed a method to monitor them. When it comes to productivity, after all, having a vehicle unexpectedly break down in the middle of the work day can lead to losses of up to $2 million.
By installing 200 sensors that monitor every facet of the vehicle 24/7, Rio Tinto can identify problematic trucks remotely and plan maintenance and productivity around this. Called the Autonomous Haulage System (AHS), the 900 trucks produce about 4.9TB of data per day, and can provide information regarding the exact location of the truck, speed, and real-time conditions.
As per itransition, “Rio Tinto’s Mine Automation System provides a real-time 360 degree view of all mining operations consumed via 3D visualizations for predictive maintenance, smart scheduling and servicing.”
In the end, that $2 million in losses become $2 million in daily savings, which is no small amount for any company.
HIROTEC Meets IoT Analytics
HIROTEC Corporation, a Japanese engineering and manufacturing company, also wanted to deal with unplanned downtime. As a producer of automotive manufacturing equipment and parts supplier, HIROTEC is part of a global supply chain, and continuous operations are thus critical.
According to their research, the cost of unplanned downtime to automobile OEMs is $1.3 million per hour, which comes up to $361 per second for downtime. By embracing Industry 4.0, especially in Internet of Things (IoT) platforms, HIROTEC managed to deploy an on-premise cloud platform that led to a ‘100% reduction in time to manually inspect production systems, enabling technicians to re-invest that time in tasks that drive more value to production workflows’.
They accomplished that through a series of pilot tests, that started from collecting and analysing data, to implementing a remote visualization of an automated exhaust system inspection line, using sensors, robots, and other connected devices. These tests helped in proof of concept (PoC), and helped stakeholders sign onto Industry 4.0.
Whirlpool Reduces Waste
American appliance manufacturer Whirlpool Corporation was looking to work on its sustainability commitments, and hence had to deal with a global implementation of waste reduction. With aims of ‘zero waste to landfill from its production facilities worldwide’ by 2020, Whirlpool needed data to help them understand the problem and move this from strategy to implementation.
Through the application of an analytics platform that provided information on the waste and energy consumption of all facilities worldwide, Whirlpool was able to monitor how close each facility was to the goal, and their performances so far in reducing waste.
Whirlpool used the Internet of Things to help them achieve interoperability, and with the data available through web-based dashboards, made it accessible to manage remotely. By looking at the data, they could decide on renewable options, especially in facilities that had higher waste management needs. There has already been considerable progress, with at least three plants in Brazil already hitting that goal.
In the end, all manufacturers will need to get on board with Industry 4.0; investment is predicted to hit $214B by 2023, and even our 2018 cloud adoption overview discusses the projected 22% compound annual growth rate of the total global public cloud market.
Want to learn about a type of Industry 4.0 automation tool that can help your manufacturing business? Read our whitepaper on "Configure-Price-Quote for Manufacturing Industry 4.0: Values and Benefits":