Review and Notes taken during Industrial Transformation Asia Pacific 2019 for Industrial 4.0 & A...

Review and Notes taken during Industrial Transformation Asia Pacific 2019 for Industrial 4.0

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Review and Notes taken during Industrial Transformation Asia Pacific 2019 for Industrial 4.0 & Additive manufacturing current state and future applications - by a junior mechanical engineer in semiconductor back-end machine industry by Mind Map: Review and Notes taken during Industrial Transformation Asia Pacific 2019  for Industrial 4.0 & Additive manufacturing current state and future applications - by a junior mechanical engineer in semiconductor back-end machine industry

1. Singapore Smart Industry Readiness Index - information taken from the white paper

1.1. Why EDB develop this index?

1.1.1. Industrial 4.0 is transforming manufacturing

1.1.1.1. Industry 4.0 will create a world where processes are increasingly digitized and integrated; where devices, machines, and systems can autonomously optimize processes and manage operations; and where humans and machines work together to create smart facilities that are efficient, flexible, and adaptive.

1.1.1.2. Industry 3.0

1.1.1.2.1. Enterprise - Operations Management - SCADA- device -process

1.1.2. Manufacturing is a key pillar of SG's Economy

1.1.2.1. hub for high-value manufacturing

1.1.2.2. According to a study by the Boston Consulting Group, Industry 4.0 could add S$36 billion in total manufacturing output, boost labour productivity by 30 per cent, and create 22,000 new jobs in Singapore by 2024.

1.1.3. the lack of a clear vision, strategy, and a systematic roadmap were the biggest challenges hindering Industry 4.0 adoption.

1.1.3.1. The Singapore Smart Industry Readiness Index (“the Index”) is a deliberate attempt to address these challenges.

1.1.3.2. comprehensive tool for all companies regardless of their size or the industry that they are operating in.

1.1.4. The Index offers a practical and usable framework for companies to determine where to start, how to scale, and what they could do to sustain growth.

1.1.4.1. What Industry 4.0 is and the tangible benefits it could yield;

1.1.4.2. The maturity levels of their organizations and facilities; and

1.1.4.3. How they can improve in a targeted and incremental manner

1.2. How to apply this index?

1.2.1. LEAD Framework

1.2.1.1. LEARN

1.2.1.2. EVALUATE

1.2.1.2.1. What to evaluate?

1.2.1.2.2. who to evaluate?

1.2.1.2.3. How to evaluate?

1.2.1.3. ARCHITECT

1.2.1.4. DELIVER

1.3. What is the index?

1.3.1. 3 building blocks; 8 pillars; 16 dimensions

1.3.2. 1 PROCESS

1.3.2.1. 1 Operations

1.3.2.1.1. 1 Vertical Integration

1.3.2.2. 2 Supply Chain

1.3.2.2.1. 2 Horizontal Integration

1.3.2.3. 3 Product Life-cycle

1.3.2.3.1. 3 Integrated Product Life cycle

1.3.3. 2 TECHNOLOGY

1.3.3.1. 4 Automation

1.3.3.1.1. 4 Shop floor

1.3.3.1.2. 5 Enterprise

1.3.3.1.3. 6 Facility

1.3.3.2. 5 Connectivity

1.3.3.2.1. 7 Shop floor

1.3.3.2.2. 8 Enterprise

1.3.3.2.3. 9 Facility

1.3.3.3. 6 Intelligence

1.3.3.3.1. 10 Shop floor

1.3.3.3.2. 11 Enterprise

1.3.3.3.3. 12 Facility

1.3.4. 3 ORGANIZATION

1.3.4.1. 7 Talent Readiness

1.3.4.1.1. 13 Workforce Learning & Development

1.3.4.1.2. 14 Leadership competency

1.3.4.2. 8 Structure & Management

1.3.4.2.1. 15 Inter- and Intra- company collaboration

1.3.4.2.2. 16 Strategy & governance

2. Why do our customers (semiconductor manufactures) need a industrial 4.0 factory in the future?

2.1. COST REDUCTION by maximize machine & labour investment by Reduce downtime

2.1.1. AI predictive maintenance: know in advance what is going to fail/ needs maintenance so that a controlled and minimum line down maintenance can take place

2.1.1.1. Automation with LEAN process

2.1.1.1.1. MECHANICAL TEAM - DESIGN FOR AUTOMATION

2.1.1.2. Digitization of the process

2.1.1.2.1. Select digitized controller, meter, valves etc.

2.1.1.2.2. Wireless communication if necessary

2.1.1.3. Real-time data collection

2.1.1.3.1. Data can be shared with common protocol/ across different software

2.1.1.3.2. Machine to machine communication

2.1.1.4. Analysis data for self correction

2.1.1.4.1. Know-how transfer from expert to system knowledge

2.1.1.4.2. Caution: rubbish in rubbish out

2.1.1.5. Predictive analysis to alert if any action need to be taken

2.1.1.5.1. Machine learning

2.1.1.6. Adaptive factory floor to implement maintenance with least distraction to production

2.1.2. Precision raw material used (no wastage/ leakage)

2.1.2.1. Know the amount supplied to the plant and the amount actually used by the machine (e.g. gas, liquid)

2.1.2.2. Analysis the data to find out if there's any leakage

2.1.3. Reduce labour cost

2.1.3.1. Towards full automation - lightoff factory

2.1.4. Reduce energy usage

2.1.4.1. Process optimization

2.2. How to implement the change towards industrial 4.0 factory?

2.2.1. New machine implementation

2.2.1.1. Easier to implement

2.2.2. Legacy machine

2.2.2.1. No sensor no data -- need to find a way to digitize

2.2.3. Integrate with other vendor/system

2.2.3.1. Industrial standard/protocol across different companies

2.3. What are the risks?

2.3.1. Rubbish in rubbish out

2.3.2. Every change have the risk to go wrong - may reduce efficiency especially during implementation stage

2.3.3. Industrial internet security - once connected and the manufacturing floor can be manipulate by data, there is risk of security attack which may be disastrous

3. What can I (a mechanical engineer do) to better prepare myself for industry 4.0?

3.1. R&D

3.1.1. MECHANICAL ENGINEERING

3.1.1.1. Design for 3D printing

3.1.1.1.1. TBC

3.1.1.2. Product Life Cycle design

3.1.1.2.1. Automated product lifecycle processes are actively analysing and reacting to data.

3.1.1.3. Shop floor automation

3.1.1.3.1. Flexible production and support processes are converged with enterprise and facility automation platforms to form highly autonomous networks.

3.1.1.4. Digital Twin

3.1.1.5. L&D

3.1.1.5.1. Digital confidence

3.1.1.5.2. How to work along side with machines? How to best utilize data/ software?

3.2. Other department see below Singapore Smart Industry Readiness Index

4. ITAP EXHIBITOR

4.1. ADDITIVE MANUFACTURING

4.1.1. 3D LAB LTD

4.1.2. 3D SYSTEMS CORPORATION

4.1.3. ADMATEC

4.1.3.1. ceramic

4.1.3.2. Metal

4.1.4. ADVANCED TECHNOLOGY ENTERPRISE PTE LTD

4.1.5. ALPHA PRODUCTS & SYSTEMS PTE LTD

4.1.5.1. Distributor

4.1.6. AML TECHNOLOGIES

4.1.6.1. Wire-arc AM

4.2. DIGITAL FACTORY

4.3. INDUSTRIAL AUTOMATION

4.4. INTRA-LOGISTICS

4.5. INTEGRATED ENERGY