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Innovation Cluster Connected Industry | Bosch India | Digital | 23 Nov 2018

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Industry 4.0, Game ON!Dattatri Salagame , Vice President & Head of Digital Business, Bosch India

Bosch India | Digital | 23 Nov 2018




Digital

Enterprise

#JumpStart Digital

Connected ProductsConnected Industry

Frameworks, Tools and Methodology to craft strategic roadmap

Strategy & Change Management

Driving Efficiency Enabling Business Design

Automation Applications

Access to technology across digital stack for ideation to PoC to New Business Models

Sensors Software Services

Driving Data -> Intelligence -> Action to optimize

Industry 4.0

Simplifying DIGITAL!



An Unprecedented Rate of Change

Connectivity

Computation

Storage

Cognitive

Digital Native Worker Highly Automated Work

hared

ensorizedSEconomy

Technology-The Common Denominator

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10101100010100101010101010101010101010111001110101010101001111001011011001110010101100101010



Digital: The Game ChangerIndustry 4.0 – A level playing field

Small Investment leading to

Disproportionate Value

Creation

Quality

Productivity

Enterprise silo to ecosystem

collaboration

A level playing Field

for all

Affordable technology

• Advanced technologies are made affordable through innovative As-a-service model

Availability of large technical competency

Option to start small

• Small iterative low investment led approach being followed by small and large players

Democratization of Market Access

Enterprise

Customer

End Consumer

Supplier

Digital: The Game ChangerOpportunity for India

Mechanical Assembly Mass Production Industrial Automation

Re

lati

ve S

ign

ific

ance

Natural Resources

Automation & Data

Low Cost Production

Timeline

China won the cost arbitrage game. Lost opportunity for India.

India poised to win: - 3 decades of IT expertise - Technology leadership- Engineering talent hub

1.0 2.0 3.0 4.0

Factors Driving Industrial Revolutions



Digital: The Game ChangerHolistic Approach to Define Strategy

Why are we doing this?From growth as a commercial agenda to growth as a visionary agenda

How do we build ‘Automation Culture’?From people as managers of competitive advantage to makers of competitive advantage

How are we

managing our

plant & infra?

Are our

processes

evolving?

What are we

doing?

How are we

engaging

customers?

Are we integrated with

our partners?



Digital: The Game ChangerDecide on entry point

Option 1: Design

Strategic drive; Flexible design and multi-directional layout

Option 2: Point Solutions

Implementing multiple point solutions to improve sub-parts, parts of the process

Option 3: Digital Infra

Connecting machines, IT/OT integration, setting up network, platform integration etc. to set up the entire digital infrastructure for ‘Factories of the Future’



Digital: The Game ChangerMulti-faceted approach for Transformation

ExploreDesign of Experiments

Transformation Strategy

Change Management

InfraPoC

RoI to Scale

Idea

Frameworks, Tools and Methodology to craft digital strategic roadmap

Assess Readiness, Define Strategy

Idea to PoC

Enterprise Architecture

Connected Industry Automation

Digital baselining for enterprise readiness – architecture, data readiness etc.

Commercial Off the shelf products

1 2

4 3

Access to technology across digital stack for ideation to proof of concept

Begin the change: KPI-Led digital interventions

ApplicationsSensors Software Services

ExploitProven solutions for transformation

Ind

ust

ry 4

.0 I

nn

ova

tio

n l

eve

l

2013 2014 2015 2016 2017 2018 2019 2020

1) Pilot projects

2) Value streams

3) IPNs

IPN = International Production Network

Bosch’s JourneyOur journey towards future has begun…..

Plant Maintenance

Supplier Quality

Quality Management

Process Engineering

Planning

Logistics

Plant Operations



Digital: The Game ChangerAssessment: An I4.0 example

Current State• Plant Maintenance function not in any integrated ERP system; Spare parts

planning not optimized; Condition monitoring not used (4.5)• Supplier Quality information is captured in SAPQM, lot# is used for

tracking supplier material. Scope for improving SAP process (5.5)• Quality Management information capture is in multiple siloed systems;

not data integration and analysis possible. Traceability is manual (5)• Process Engineering in-process parameters in standalone application;

machine setup parameters not integrated with MES (4.5)• Planning and production scheduling driven from SAP – Material and

Machine is covered; scope for including manpower planning (6)• Plant Operations scope for online OEE reporting and plant connectivity (5)

The State of each process is benchmarked with respect to Transparency,Interaction and Intelligence• Transparency – Complete capture and visualization

of data on HMIs and Andons or Mobiles (6)• Interaction – Integration with different platforms for

immediate availability of data acrossthe departments in the organizationwithout latency (8)

• Intelligence – Insights based on historic dataanalysis and trend recognition withminimal human interference (10)

Transparency Interaction Intelligence

5 6 7 8 9 10

Industry 4.0 MaturityCurrent State Expected State

4



Digital: The Game ChangerBuild a Roadmap and Iterate with Use cases

Note: Use-case position within a box does NOT indicate relative priority

Value Stream Mapping1

Use Case Identification2

Use Case Prioritization3

Build a roadmap4

Case Studies

I4.0 in a box for SME segment



Machine and Production Analytics

Bosch Energy Signature Analyzer

Bosch Mechanical Signature Analyzer

Backup Generator

➢ Asset-lite model (Pay-per use)➢ Retrofit and non-intrusive➢ Rapid deployment (1-2 weeks)

Grid

Bosch Machine Controller Analyzer

GSM

/GP

RS

GSM

/GP

RS

GSM

/GP

RS

Key Features

➢ Machine OEE & Industry Benchmarks➢ Production Part OEE➢ Productivity Improvement Analytics➢ Machine Capacity Utilization ➢ Production and Capacity planning

Bosch Energy Analytics

Active Time

Power On/OffMachine

Productivity

Power Quality Consumption

Production Count

MTBF / MTTF

Machine OEE

Dashboard and Analytics


Energy Management - Kwh Saved, Dollars Earned


11+Sites Covered

900+Machines Connected

60+Gateways Installed

20+ Data points collected

million

Jaipur

Ahmedabad

Pune

Bangalore

Chennai

Nashik

800+MWh Energy Saved

640+Ton of CO2 Reduced

ISGF Award 2017

640+Ton of CO2 Reduced


Smart Manpower Planning – Efficient Plant Operations


Ton of CO2 Reduced 640+

Before AfterINPUT PROCESS OUTPUT

FLM Task:

▪ Associate manual attendance every shift

▪ Manpower allocation according to skill matrix

▪ Shortage/Excess manpower allocation

▪ In case of allocation, additional documentation for productivity calculation

▪ Job rotation of associate done manually

▪ Manual record of production output in log book

Time/shift

~4 minutes

~4 minutes

~7 minutes

▪ Auto attendance & manpower allocation according to skill matrix

▪ Value stream priority setting for advance planning (VE & NHA)

▪ Auto trigger for Shortage/Excess manpower allocation for all value streams

▪ SMS information to associates on allocation workstation / machines

▪ Interlocking of critical station with associate ID card (RFID)

▪ Paperless working in production (digital log book)

▪ Online display of available Emergency Response Team (ERT) in plant

InControl –Assisted Outflow Prevention



Vehicle 1

VIN-NUMBER-1234567890

B-NO-1234 E-NO-1234

Smart & Connected Hydraulic Machines



Specialized Bosch sensors for hydraulic machines

Data and specialized algorithms hosted on cloud

Bosch IoT Gateway to collect data from sensors

❑ 28 Hydraulic and 17 Energy parameters monitored real-time

Light-weight protocol to solve connectivity issues in semi-urban and rural areas

Real-time Condition monitoring & Diagnostics

Alerts & Notifications Higher Machine utilization & lower break-down costs

New service models

Field inputs to improve product design

Competitive Advantage

Customer Benefits Bosch Advantage

Track and Trace -Improving supply chain traceability and reliability



industry 4.0, game on! - imtma · industry 4.0 simplifying digital! ... plant maintenance supplier...

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