industry 4.0 evolved over a - joburgindaba · [email protected] constantino seixas...

Industry 4.0 evolved over a period of time, converging information and operational technology.

1970 – RECENTINDUSTRY 3.0

Electronics and IT for automation of production and front/middle/back office

TODAYINDUSTRY 4.0

Cyber physical production systems

20TH CENTURYINDUSTRY 2.0

Mass production based on the division of labor and powered by electrical energy

18TH CENTURYINDUSTRY 1.0

Mechanical production powered by water and steam

TOMORROWINDUSTRY X.0

Copyright © 2018 Accenture. All rights reserved. 2

DEFINED IT-OT GOVERNANCE

CONNECTEDANALYTICS SUPPORTED

OPTIMIZED

(UNIFIED ARCHITECTURE,ONE GOVERNANCE)

(ROC, CENTRALIZED INFRA, MOBILITY)(PREDICTIVE ANALYTICS,DIGITAL TWINS)

(APC, DIGITAL TWINS)

WORKEREMPOWERED FLEXIBLE AUTONOMOUS PREDICTIVE

(WEARABLES, VR/AR) (MAKE TO ORDER, PULL) (MINE, YARD, TRAIN LOADING, PORT) (IN THE PIT ORE CHARACTERIZATION, ON THE FLY BLENDING, DYNAMIC CONC. SET-UP)

Transform the COREDigital technologies allow today’s mining operations to reach new levels of performance across the whole mining value chain from mine to market.

4

CASE:

AUTONOMOUS TRAIN LOADING

Sensor Revolution:

radar + laser + HP GPS

(for the dynamic volume measurements)

=

New loading & trimming algorithms

▪ Dynamic algorithm adapts in real time to ore fluidity and moisture variations

▪ Adapts to hydraulic restrictions on the silo gates

• 2% increase in tons/car

• Even ore distribution, reducing derailment risk

• Reduction in overload error

• Reduced loading time

Holistic Project encompasses several processes:

• Wireless Communication

• 3D Yard Mapping

• collision avoidance algorithms

• Autonomous Stackers & Reclaimers

• Operational Simulation of any Yard Operation

• Dynamic stockpile blending

• Ore quality in stockpile

• Volumetric Inventory Management

• Automatic Scheduling to best Yard occupancy

• Routes Optimization

• Drones stockpile volume reconciliation (monthly)

CASE:

AUTONOMOUS YARD

RESULTS FOR RP 08


CASE:

MULTIVARIATE STATISTICAL MONITORING OF FE-NI ELECTRIC REDUCTION FURNACE

BUSINESS CHALLENGE

• The client aimed to leverage value-added initiatives in Advanced Analytics in its Nickel operation.

• The business challenge refers to identify changes in furnace condition operations that could impact on process shutdown or wearbased on multivariate temperature data.

PROJECT HIGHLIGHTS

Shaped in 8-week effort, Accenture developed an Analytical Solution focused on online monitoring of the operational condition of two smelting furnaces based on a multivariate statistical process control (PCA) technique from temperature measurements existing in the process.

OUTCOMES

• Great detection assertiveness of abnormal conditions, such as: events of fast and slow variations, abnormal behavior patterns of variables and even instrumentation problems;

• Self-adaptative analytical models to “learn” process changes

• Dedicated analytical models for each furnace region → allow a better understanding of potential abnormality events, speeding up the diagnosis and corrective actions decision-making.

Exploratory Data Analysis PCA Model structuring and modeling

Web Interface for Monitoring Drill Down Analysis of Main factors

FEATURES:

• Operation order barcode scanner

• O.O. is downloaded from cloud

• A.R. Engine

• Voice Instructions

IMPACT:

• Improves performance by 500%

• Zero error operation

• Reduces training needs

• Improves ergonomics

Focus on Experiences & OutcomesSmart glass application supports Airbus cabin Assembly Positioning marking

RESULTS:

EXTERNAL

• Costumers

• Start-ups

• Universities

• Technology Partners

• Main Suppliers

• Government entities

• OEMs

• Regulatory Agencies

• Communities

INTERNAL

• IT + OT

• HR

• Production & Operations

• EHS

• Quality

BUILD NEW ECOSYSTEMS


BUILD A DIGITAL-READY WORKFORCE

50

Digital Work Permit

WearablesPeople Location

Turnaround

A.R / V.R

Immersive Digital Training

Connected Mine

Digital Field Services On-line

documentation


TIME

BU

SIN

ESS

OU

TCO

MES

Transform the Core

DigitalizeEngineering,Manufacturing & Service

New BusinessModels & Revenue Streams

CORE TO NEW

TRANSFORMPRODUCTS

2018 2025

Digital unlocking oftrapped value in the

enterprise

New Flexibility &Efficiency

Innovation drivengrowth

Ecosystem, platforms,Experience…Outcome based

economy…Wise pivot

Legacy Product…installed base

Pivot 1Smart connected Products

Pivot 2Smart ServicesNew Services & New Experiences

PIVOT WISELYUnlocking the value from the core, applying and creating the new ... Now


2. CONCEPT DEVELOPMENT / RAPID PROTOTYPE AND MVPS¹

The ‘digital factory’ combines the discipline and agility to address business issues and scale solutions to the whole company.

1

2

34

5

Ideas approved

Pilot approved

Rollout approved

Pilot Pivot

Business Issues

H1 - INNOVATION AT SCALE

H2 - INCREMENTAL INNOVATION

H3 - DISRUPTIVE INNOVATION

1. IDEATION 3. PILOT 4. SCALE 5. OPERATE

VALUE REALIZATION OFFICE

UNCERTAINTY HORIZONS1 Minimum Viable Products

QUESTIONS ?

ACCENTURE

Alta Vila - Rua Senador Milton Campos, 115 - Vila da SerraNova Lima/ MGBrazil

Phone: +55 31 [email protected]

CONSTANTINO SEIXAS FILHO, MSC

Managing DirectorIndustry X.0 Production & Operations Capabilities Lead

mailto:[email protected]

industry 4.0 evolved over a - joburgindaba · [email protected] constantino seixas...

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