Industry 4.0 Case Studies (curated)
Topic
General Industry 4.0
Subtopic
Industry 4.0 Overview
Cost: Free
Duration: 0.75 Hour(s)
Certification Available: No
Course Level: Introductory
Prerequisites: None
Administered By: Various
Description
Curated Set of Case Studies demonstrating problem, solution, and results of implementing Industry 4.0.
What You'll Learn
- Optimizing Overall Equipment Efficiency and Utilization (Avalign Technologies & machinemetrics)
- https://www.machinemetrics.com/avalign-case-study requires free login, 10 page pdf article download
- Who – Avalign Technologies medical device company utilized machinemetrics for machine and operational data
- Problem – Needed to decrease downtime and increase throughput.
- Solution – deployed measuring, monitoring, dashboards for equipment like grinding, and lathes across 132+ machines at 4 facilities
- Results – 40% increase in OEE, 9.9% increase in throughput, $4.5M capacity utilization increase, 14k hours saved, across 9 months
- BJC HealthCare adopts IoT for inventory and supply chain management
- Who - BJC healthcare, service provider that operates at multiple hospitals in Missouri and Illinois
- Problem - Inventory tracking is labor intensive and inefficient.
- Solution - RFID tagging to track and manage thousands of medical supplies. Reduced manual labor to maintain inventory.
- Results - Reduce onsite stock by 23% at facilities.
- Big Data decision-making at Bosch Automotive factory in China
- Who - Bosch Automotive Diesel System factory in Wuxi, China
- Problem - Bottlenecks and production efficiency problems
- Solution - Collect machine monitor sensors' data, combine data sources, and use machine learning analytics to predict equipment failures, thus schedule maintenance before failure.
- Results - Higher uptime durations, contributing to > 10% production output increase in some areas
- Fetch Robotics help DHL improve warehouse operations
- Who - Fetch Robotics (California) and DHL distribution center (Netherlands)
- Problem - Improve efficiencies for locating, tracking, and moving inventory in warehouse and logistics facilities
- Solution - Used collaborative Autonomous Mobile Robots (AMRs) to pick and place alongside the workers. AMRs autonomously learning and sharing most efficient travel routes.
- Results - Reduce order cycle time up to 50%, provide up to 2x picking productivity gain.
- Fast Radius’ digital additive manufacturing solutions to enable new business models
- Who - Fast Radius Chicago, contract manufacturer with multiple locations.
- Problem - Improve efficiencies for fast turnaround and mass customization of products.
- Solution - Collect data for every part design and identify applications suitable for 3D printing.
- Results - Reduce costs in storing parts through virtual inventory, decrease cycle time.
- Racing to win with digital twins
- Who - Siemens and American pro racing squad Team Penske
- Problem - Speed up the race car development process
- Solution - Create a digital twin, digital representation of a real-world product, machine, process, or system, that allows companies to better understand, analyze and optimize their processes through real-time simulation based on machine learning. Sensors were fitted to a real car and collected data real-time continuously, such as tire pressure, engine control and wind speed, which is then converted into a virtual car model. It’s this model that allows engineers to test different design configurations.
- Results - Reduce testing costs, and time, and ultimately a faster vehicle.
- AI visual insights drive manufacturing efficiency gains
- Who - IBM manufacturing of mainframes, servers, storage, and IT appliances, in Canada, Hungar, mExico and US.
- Problem - Increase efficiencies of visual inspection and product quality. Manual inspections lead to missed defects. Traditional automated inspections also provide too many false positive results.
- Solution - Used IBM Maximo Visual Inspection, an AI-powered computer vision solution to automatically detect quality defects in manufacturing. System was trained using deep learning.
- Results - Up to 5x efficiency gains, 20% reduction in false positives.
- Summer Garden Food Manufacturing Reduces Downtime and Improves Machine Performance
- Explained in 7 minute video and implementation of plex.
- Who - Summer Garden Food Manufacturing
- Problem - Not enough productivity and low OEE, no visibility.
- Best Maid food product provider 185% ROI in 0.5 years
- Who - Best Maid food product provider
- Problem - No ERP system - legacy database and excel spreadsheets. Difficulty managing inventory (5 manual audit days/month), Production planning (schedule written day before), challenging for Safe Quality Food Certification.
- Solution - Plex implementation - training, implementation, within 8 months.
- Results
- Inventory Management - reduction in raw material inventory of $0.5M, eliminate $50k mislabeled items, eliminate lost 1% due to spoilage.
- Streamline Order to Cash - deliver within 3 days window to avoid penalties (was 1% of orders delayed w/penalties and 50% of Best Maid's revenue)
- Financial management - financial close process now 25% of previously required - was 4 months behind, now closes within 4 weeks of month end.
- Industry 4.0 Examples
- Areas with videos, BBC mostly, Logistics, Construction, Public Transport, Manufacturing, Food production, Fieldwork
Industry 4.0 Academy Disclaimer
The courses offered in this catalog are a curated collection of learning materials that provide an overview of Industry 4.0. It is designed to provide resources that businesses can use to understand and implement Industry 4.0, covering topics such as technology adoption, data utilization, and workforce development. While some of the course providers may provide a certification, the intent of this website is to provide information on knowledge-building opportunities. RIT provides no certification or degree credit for any of this content.
Some materials are free, while others require a fee. Neither RIT or the Center of Excellence in Advanced and Sustainable Manufacturing (COE-ASM) has received compensation from the organizations that have created and published the course materials. The Industry 4.0 Academy supports a COE-ASM initiative to advance the adoption of Industry 4.0 technologies and practices among manufacturers in New York State and is funded by the New York State Department of Economic Development.