Applying Industry 4.0 to the steel industry · 2017-06-19 · © 2016 KPMG AG Wirtschaftsprüfungsgesellschaft, a member firm of the KPMG network of independent member firms affiliated

1© 2016 KPMG AG Wirtschaftsprüfungsgesellschaft, a member firm of the KPMG network of independent member firms affiliated with KPMG International Cooperative (“KPMG International”), a Swiss entity. All rights reserved. The name KPMG and the logo are registered trademarks of KPMG International.

Applying Industry 4.0 to the steel industry The Human FactorMichael BremickerMarkus ZeimesWarsaw, June 2017


Agenda

01 Scenario of the future

02 Industry 4.0 Toolset

03 Integrated processes require new skills from employees


All over targets have not changed since decades

Targets supported by the implementation of Industry 4.0 technologies

Reduce costs

Value Analysis / Value Engineering (VA/VE)

Supply Chain Management

Reduce inventories

Rolling planning & forecasting Defined Responsibility Integrated and continuous

processes

Reduce lead time

Integrated and continuous processes

Bill of material structure Set-up times


Scenario of the future: Modern technologies will enable organization’s to act faster

Technical innovations are disrupting industrial companies around the world

are putting customers in the driver’s seat, allowing the creation of truly customized products at lower costs.

Demand driven supply chains and 3D printing

are revolutionizing manufacturing throughput by improving efficiency and productivity.

Robotics and machine to machine communications

are revolutionizing manufacturing throughput by improving efficiency and productivity.

Big data and cloud

objects can be tracked remotely across the factory floor, reducing operating costs.

With the advent of the Internet of Things,

integrated smoothly into the manufacturing process, saving time and money. Cognitive systems are supporting decision making in real-time.

Digital factory simulations allow new products to be


Agenda





Industry 4.0 toolset 1/2

Every organization takes those technologies which bring value to their strategy

Demand Driven Supply ChainConnecting every element of the supply chain as one virtual process allows you to align your business to customer needs. Our supply chain expertise enables you to personalize the customer experience, leading to improved profitability.

Machine to Machine Communications (M2M)The Smart Factory relies on M2M to continuously adapt and improve operations and productivity. Our operational analytics teams can help you exploit this heightened flexibility to react quickly when new innovations emerge.

Internet of Things (IoT)Increased connectivity, improved networks and the massive rise in mobile devices is revolutionizing data sharing. Our specialists will help you identify opportunities such as real-time asset monitoring to improve efficiency and cut operational costs.

CloudCloud provides a virtual environment for digital supply chain management, enabling truly collaborative manufacturing. Our experience of leading cloud projects through the full lifecycle enables you to realize its value, for example, through a pay per use model.

RoboticsAutomation reduces labor costs, boosts product reliability and improves adaptability. With practical manufacturing experience and our Innovation Lab behind them, our robotics team creates the flexibility you need to power a demand driven supply chain.


Industry 4.0 toolset 2/2

Every organization takes those technologies which bring value to their strategy

Big dataData analytics across your organization can drive process improvement, increase operational efficiency and provide automated decision support. Our big data expertise and global technical partnerships will help turn your data into agile manufacturing.

Cyber SecurityOperating in cloud with multiple touchpoints puts your data, assets and value at risk. Our practical experience of creating secure environments, platforms and products will help your business remain secure as your organization evolves.

3D PrintingThe demand driven supply chain means you need to adapt products, build customized components and create viable prototypes fast. Our Innovation Factory and network of specialists can help you make the most of 3D printing.

Augmented Decision SupportThe increased availability of real-time data and sophisticated Artificial Intelligence systems enable technology-based decisions and predictions. Working with expert partners, we will help you realize the value of cognitive technologies.

Digital Product Development and ManufacturingDigital twinning creates virtual factories where you can test product designs, streamline production, improve efficiency and maximize both unit and individual performance. We combine technical knowledge and industry experience to help you reap the benefits.


Agenda





All relevant information are available in real time and need to be considered

New requirements to new employees

Verkauf Auftrags-bearbeitung

Bedarfs-planung

Material-disposition

Kapazitäts-planung(M&M)

Fertigungs-steuerung

Produktion Test & Qualität

Verpackung& Versand

Sales Order processing

Demand planning

Materials scheduling

Capacity planning(HR&M)

Production control

Production Test & Quality

Packaging & Shipping

Workflow

Cu

sto

mer

/ K

un

de

Cu

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mer

/ K

un

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?


Process integration requires many different interactions


Customer

- Product variant- Delivery time- Price, quantity

Production

- Capacity planning- Investment planning- Industrial master plan

Management

- Profitability- Financial requirement- Growth

Logistics

- Shipping companies- Carrier- Customs documents

Procurement

- Supplier strategy- Price negotiation

Machine production

- Machine utilization- Tool availability- Lead time

Assembly

- Material availability- Human Resoruces- Lead time

Sales

- Customer relation- Payment practice

Supplier

- Material availability- Short-term capacity

changes


DEEP KNOWLEDGE

OF BRANCH AND

BUSINESS MODELL

AWARENESS OF

TRENDS AND

STRATEGY

IT KNOWLEDGE

KNOWLEDGE OF

PRODUCTION

TECHNOLOGY

INTERDISCIPLINARY

COMPETENCES

ANALYTICAL AND

CREATIVE SKILLS

ENTREPRENEURIAL

MINDSET

Most important core competences of employees



Future challenges for companies dealing with industry 4.0 topics


Development of transparent processes

Integrate production workers into communication and information processes

Increase employees‘ motivation

Qualify employees to meet the future needs of new tasks and challenges

Development of new job profiles

Improve human machine interaction possibilities along the production process

Development of new control and support systems


The relation of routine operations and exceptions will change towards exceptions.


ROUTINE

TASKS

EXCEPTIONAL

TASKS

Rela

tio

n o

f ro

uti

ne a

nd

exce

pti

on

al

task

s

Industry 4.0 maturity level

To have the increased amount of exceptional tasks performed successfully, employees need to have a profound understanding of the whole company, its environment, trends, competitive factors and the business model.

The future employee is characterized by a strong entrepreneurial mindset!

This presentation is for information only and does not constitute a binding offer. All services that are described in this presentation are presented and agreed in detail in a separate written offer. This is based on the general order conditions for auditors and auditing companies from 1 January 2002. KPMG confirms that the content of the written offer in terms of general description of activities, prizes and team members is binding for a period of 90 days from receipt of the offer.

The information contained herein is of a general nature and is not intended to address the circumstances of any particular individual or entity. Although we endeavor to provide accurate and timely information, there can be no guarantee that such information is accurate as of the date it is received or that it will continue to be accurate in the future. No one should act upon such information without appropriate professional advice after a thorough examination of the particular situation. Our services are provided subject to verifying that the provision of services is permissible on a case-by-case basis.

© 2016 KPMG AG Wirtschaftsprüfungsgesellschaft, a member firm of the KPMG network of independent member firms affiliated with KPMG International Cooperative ("KPMG International"), a Swiss entity. All rights reserved. The name KPMG and the logo are registered trademarks of KPMG International.

www.kpmg.de

Your contact persons

Michael Bremicker Partner

Operations Consulting

T +49 89 9282-3773M +49 175 939 50 71 [email protected]

KPMG AG Ganghoferstr. 29

80339 Munich

Markus ZeimesPartner

Audit Corporate

T+49 211 475-8642

M+49 172 6862304

[email protected]

KPMG AG

Tersteegenstraße 19-2340474 Düsseldorf

http://kpmg.com/socialmedia

Documents

Applying Industry 4.0 to the steel industry · 2017-06-19 · © 2016 KPMG AG Wirtschaftsprüfungsgesellschaft, a member firm of the KPMG network of independent member firms affiliated