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Proceedings,16th IFAC Symposium on

Proceedings,16th
Information ControlIFAC Symposium
Problems on
in Manufacturing
Proceedings,16th
Proceedings,16th
IFAC
IFAC
Symposium
Symposium
Available online at www.sciencedirect.com
on
on
Information Control
Proceedings,16th
Bergamo, Italy, Problems
IFAC
June in
Symposium
11-13, 2018 Manufacturing
on
Information
Bergamo, Control
Italy, JuneProblems
11-13, in Manufacturing
2018
Information
Information Control
Control Problems in Manufacturing
Bergamo, Italy, JuneProblems in Manufacturing
11-13, 2018
Bergamo, Italy,
Bergamo, Italy, June
June 11-13,
11-13, 2018
2018
ScienceDirect
IFAC PapersOnLine 51-11 (2018) 1347–1352
Contextualizing the outcome of a maturity assessment for Industry 4.0
Contextualizing
Contextualizing the
the outcome
outcome of
of a maturity assessment for Industry
Industry 4.0
Contextualizing the
Contextualizing the outcome of aa
outcome of maturity
a maturity assessment
assessment for
maturity assessment for
for Industry
4.0
Industry 4.0
4.0
M. Colli*. O. Madsen**.
U. Berger***. C. Møller****. M.
M. Colli*.
Colli*.
B. Vejrum O. Madsen**.
O. Madsen**.
Wæhrens*****. M. Bockholt******
U. Berger***. C. Møller****. M.
M. Colli*.
Colli*.
B. Vejrum O.
O. Madsen**.
Madsen**.
Wæhrens*****. M.
U.
U. Berger***. C. Møller****. B. Vejrum Wæhrens*****. M. Bockholt******
Bockholt******
U. Berger***.
Berger***. C.
C. Møller****.
Møller****. B.
B. Vejrum
Vejrum Wæhrens*****.
Wæhrens*****.
*Aalborg University, Aalborg Øst, 9220 Denmark (colli@mp.aau.dk)
M.
M. Bockholt******
Bockholt******
*Aalborg University, Aalborg Øst, 9220 Denmark (colli@mp.aau.dk)
*Aalborg
** AalborgUniversity,
*Aalborg University,Aalborg
University, AalborgØst,
Aalborg Øst,Øst,9220
9220Denmark
9220 Denmark(colli@mp.aau.dk)
Denmark (om@mp.aau.dk)
(colli@mp.aau.dk)
** AalborgUniversity,
*Aalborg University,Aalborg AalborgØst, Øst,9220
9220Denmark
Denmark(colli@mp.aau.dk)
(om@mp.aau.dk)
*** Brandenburg ** Aalborg
University
** Aalborg
Aalborg University,
of Technology
University, Aalborg
Aalborg Øst,
Cottbus, 9220
03046
Øst, 9220
9220 Denmark
Germany
Denmark (om@mp.aau.dk)
(ulrich-berger@t-online.de)
(om@mp.aau.dk)
*** Brandenburg ** University of Technology
University, Aalborg Cottbus,
Øst, 03046 Germany
Denmark (ulrich-berger@t-online.de)
(om@mp.aau.dk)
***
*** Brandenburg
**** Aalborg
Brandenburg University
University of
University,
of Technology
Aalborg Øst,
Technology Cottbus, 03046
9220 Denmark
Cottbus, 03046 Germany (ulrich-berger@t-online.de)
(charles@business.aau.dk)
Germany (ulrich-berger@t-online.de)
**** Aalborg
*** Brandenburg University,
University of Aalborg Øst,
Technology 9220 Denmark
Cottbus, 03046 (charles@business.aau.dk)
Germany (ulrich-berger@t-online.de)
****
*****
**** Aalborg
Aalborg
Aalborg University,
University,
University, Aalborg
Aalborg
Aalborg Øst,
Øst,
Øst, 9220
9220
9220 Denmark
Denmark
Denmark (charles@business.aau.dk)
(bvw@business.aau.dk)
(charles@business.aau.dk)
*****
**** Aalborg
Aalborg University,
University, Aalborg
Aalborg Øst,
Øst, 9220
9220 Denmark
Denmark (bvw@business.aau.dk)
(charles@business.aau.dk)
*****
******
***** Aalborg
Aalborg University,
University, Aalborg Øst,
Aalborg Øst, 9220 Denmark
9220 Denmark (bvw@business.aau.dk)
(mack@business.aau.dk)
(bvw@business.aau.dk)
******
***** Aalborg
Aalborg University,
University, Aalborg
Aalborg Øst, 9220 Denmark (mack@business.aau.dk)
(bvw@business.aau.dk)
******
****** Aalborg University, Aalborg Øst,
Øst, 9220
9220 Denmark
Denmark (mack@business.aau.dk)
(mack@business.aau.dk)
****** Aalborg University, Aalborg Øst, 9220 Denmark (mack@business.aau.dk)
Abstract: The transformation of the manufacturing sector towards Industry 4.0 is setting the scene for a
Abstract:
Abstract:
major The
The
industrial transformation
transformation
change. Currently, of
of the
the manufacturing
manufacturing
the need for assisting sector
sector towards
towards
companies Industry
Industry 4.0
4.0 is
is
in this transformation setting
setting the
the scene
scene
is covered for
for byaaa
Abstract:
major
Abstract: The
industrial
The transformation
change. Currently,
transformation of
of the
the manufacturing
the need for assisting
manufacturing sector
sector towards
companies
towards Industry 4.0 is
in this transformation
Industry 4.0 is setting
setting the
the scene
is covered
scene for
for bya
major
amajornumber industrial
industrial change.
of maturity
change. Currently,
models
Currently,thatthe need
assess
the need for
their
for assisting companies
digital maturity
assisting companies andin
in this
provide
this transformation
indicationsis
transformation is covered
accordingly.
covered by
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amajor
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industrial maturity
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Currently,that assess
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needrecommendations
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companies and provide
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transformation isaccordingly.
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cope with this challenge,
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paper provides
companies, there
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of However,
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cope
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- 360 with
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digital maturity company-specific.
company-specific.
assessment approach To cope
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this
Assessment paper -provides
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illustration
on the
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of aa new digital
Based maturity
Learning assessment
(PBL) model. approach - 360 Digital Maturity Assessment - which is based on the
of a new
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digital
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digitalLearning
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© 2018, IFAC
Problem
Problem
Keywords: Based
Based (International
DigitalLearning
Learning Federation
(PBL)
(PBL)
transformation, model.
model. of Automatic
Maturity Control)
assessment, HostingBased
Problem by Elsevier Ltd. All
Learning, rights reserved.
Industry 4.0, Smart
Keywords:
Keywords:
manufacturing Digital transformation,
Digital transformation,
transformation, MaturityMaturity assessment,
Maturity assessment, Problem
assessment, Problem
Problem Based Based Learning,
Based Learning,
Learning, IndustryIndustry
Industry 4.0, 4.0, Smart
4.0, Smart
Smart
Keywords:
Keywords:
manufacturing Digital
Digital transformation, Maturity assessment, Problem Based Learning, Industry 4.0, Smart
manufacturing
manufacturing
manufacturing 

 In order to answer this need, several digital maturity models
1. INTRODUCTION  In order
1.
1. INTRODUCTION
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have
In beento
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an overview digital
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in Schenk maturity
et al.,models
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an overview
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digital maturity
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maturity 2015).
models
Globally, the manufacturing 1. INTRODUCTION industry is experiencing a have They been
providepublished
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level2015).
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2405-8963 © 2018, IFAC (International Federation of Automatic Control) Hosting by Elsevier Ltd. All rights reserved.
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Peer review©under
2018 responsibility
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of International Federation of Automatic
Copyright © 2018 IFAC 1373
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areas and implementation strategy (see Appendix A, table 1),


they all present basically the same structure in terms of
progression and arguments behind the different stages. Each
maturity model provides a definition of the different digital
stages and an indication of the considered dimensions. These
elements create the framework used in order to map the
current digital capabilities of the organization. These are
assessed according to the definition of the different digital
stages. The digital stage the organization is aiming for can
then be identified. Through a gap analysis, the weaker
dimensions are pinpointed as areas to be improved through
the application of pre-defined activities selected depending
on the digital stage.

3. THE MATURITY MODEL

The digital maturity model we are using is taking in


consideration a number of existing digital maturity models
(see Appendix A, table 1), ACATECH maturity model firstly
(Schuh et al., 2017). In order to use a more familiar
terminology and fitting scale for the Danish companies that
Fig. 1. Digital transformation direction of diverse
are currently addressing – or starting to address - the digital
organizations towards different and changing goals.
transformation, a “zero digitalization” level has been
The contribution of this paper consists in bringing up the introduced and the two “basic digitalization” levels presented
need for contextualization within the maturity assessment by ACATECH have been unified. As an outcome, the
process in order to provide, as an outcome, company-specific maturity model used to assess the digitalization level of an
guidelines, and propose an approach to cope with it. This organization is composed by six sequential digital maturity
leads to the following research question: is the PBL model stages:
suited as a methodological approach to contextualize the
1. None: no digital awareness, idea or plan nor
outcome of a digital maturity assessment? To answer this, a
presence of digital data within the organization (e.g.
new digital maturity assessment approach, the 360 Digital
everything is registered on paper or not registered)
Maturity Assessment (360DMA) is proposed. It is composed
by a novel maturity model used to structure collected 2. Basic: digital processes are in place and operative as
information and by a methodology, based on the PBL model, they generate digital data (e.g. machines on the
to operationalize the assessment process. The paper provides production floor generate digital data related to their
an overview of the state of the art in terms of digital maturity process) and there is a willingness towards the
models and defines the used one. Eventually it outlines the digital transformation from the management side
developed assessment methodology and describes a
demonstration case to support the final discussion. 3. Transparent: data is collected and shared according
to value streams needs (e.g. alert data from the
2. STATE OF THE ART equipment are collected and transmitted to the
service department) and there is a digitalization plan
Both researchers and research institutions have published from the management side in terms of development
several digital maturity models (Lanza et al., 2016; Leyh et direction
al., 2017; Lichtblau et al., 2015; Schuemacher et al., 2016),
e.g. Fraunhofer IFF (Schenk et al., 2015) and Acatech (Schuh 4. Aware: data is analysed to capture valuable
et al., 2017). Their common goal is to assess the digital information in order to understand the business
maturity level of an organization and provide an indication of insights (e.g. proactive activities identification by
activities needed to increase this level. In order to do that, all crossing error data, product number, machine
of these models are based on the hypothesis that the digital downtime, etc.) and there is a clear digitalization
transformation towards Industry 4.0 is an evolutionary agenda (e.g. resources and activities are defined)
journey (Kagermann et al., 2013) across a number of shared at all hierarchical levels
sequential digital stages, characterized by an increasing
5. Autonomous: decision making is performed
digital integration complexity. In other words, as a first key
autonomously based on automatically synchronized
principle, they build on a cumulative capability perspective
data from the organization and its direct customers
(Miller et al., 1994). As a second key principle, the digital
and suppliers (e.g. logistics scheduling is
transformation process is considered to involve a number of
automatically performed based on production state,
activities within multiple decision areas. Although different
customer orders and location, traffic condition etc.)
digital maturity models vary in terms of digital stages,
and digital development is a well-established
number of dimensions that cover the different organization
company practice at all hierarchical levels

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6. Integrated: decision making is performed methodology is intended to be used iteratively in order to be


autonomously based on automatically synchronized able to adjust the transformation direction according to
data from the whole organization’s network (e.g. company goals changes and newly available digital
suppliers’ suppliers and customers’ customers) and technologies. The operationalization of the methodology
digital development is a well-established practice at requires, from the assessing party, the presence of field
all hierarchical levels within the whole experts for the areas that have to be investigated, a mediator
organization’s network that directs the activities according to the methodology and a
rapporteur that collects the information along the way. The
Each digital stage is considered to be the necessary enabler of assessment process consists of five sequential steps, built
the following, as its features need to be in place in order to parallel to the PBL seven steps (Maurer et al., 2012) (Fig. 2).
pursue the digital transformation on a further level, e.g. to
perform data analytics – aware stage - it is necessary to have At first, the creation of awareness is addressed in order to
data available – transparent stage - in the first place. present and clarify involved concepts and set the scene for
In order to map the digital capabilities of the organization, the investigation. An overview of digitalization and of what
they are grouped into five areas, called digital dimensions. is included in the industry 4.0 agenda in terms of
These have been obtained by clustering dimensions from the technologies (e.g. cloud computing), implications (e.g. IT
existing digital maturity models that have been analysed (see security) and use cases (e.g. predictive maintenance or
Appendix A, table 1). They consist of: autonomous guided vehicles) is provided. This activity can be
done in several ways such as study visits, workshops with
 Governance: indication of the current state of the external experts and demonstrations in imaginary Industry
company at an organizational level (e.g. strategy and 4.0 factories (e.g. Madsen et al., 2017).
plan, resource allocation, digital awareness, engagement
on different hierarchical levels). The next task, representing for PBL the formulation of a
research question, consists in the definition of scope from the
 Technology: presence of the elements that make possible company side: the unit of analysis considered in the
to generate and process digital data (e.g. business investigation of the digital maturity is identified (e.g. one
intelligence tool, cloud computing platform, MES, ERP, production line, one department, etc.). The scoping of the
augmented and virtual reality tools) investigation goes through a short presentation by the
organization about their understanding, status, strategic focus
 Connectivity: availability of the infrastructural elements and perspectives in relation to the digital transformation.
needed for data transmission inside and outside the
organization (e.g. data sharing capabilities, IT security,
Data collection is then performed, consisting in collecting
standard data structuring or data transmission
information related to the organization and, specifically, to
architectures)
the defined unit of analysis. This operational step covers the
 Value creation: ability to capture value from available three PBL steps related to idea collection, idea structuring
data (e.g. pay-per-use or pay-per-save business model, and question identification. These tasks are here represented
take-back program, data usage for orders forecasting or by the analysis of organization’s information material, by the
product usage monitoring to enable predictive submission to relevant stakeholders (e.g. managers of
maintenance or guide the product design) functional areas involved in the digital transformation) of a
“self-assessment” questionnaire and by the eventual
 Competence: presence of the mind-set and of the skills preparation and execution of an expert interview workshop.
(internally or based on external partnerships) needed for This involves the relevant stakeholders and it is focused on
performing the digital transformation and operate with low-graded and mismatching questionnaire answers. The
digital solutions (e.g. digital competences, training workshop is divided in a number of sessions that covers the
culture, learning culture) different areas that have to be addressed (e.g. IT, logistics,
etc.) together with the related field experts from the company.
4. THE METHODOLOGY
The evaluation and solution selection is aiming to answer to
The developed methodology is based on the PBL model and the formulated learning objectives by mapping the collected
it is meant to act as a dialog tool between a company and the information within the defined digital maturity model. The
assessment party, whose aim is to provide a case-specific current maturity stage of the organization (of the defined unit
assessment outcome. The assessment paradigm therefore of analysis) is therefore assessed both at an overall level and
shifts from the currently used expert model, where a in relation to each digital dimension. This is done by relating
diagnosis is completely outsourced to external experts the collected information to the definition of the digital
(Schein, 2009) to the external helper model, which bases the maturity stages that have been stated in the maturity model.
diagnostic process, facilitated by external experts, on the The visibility of the maturity level of each digital dimension
interaction with the assessed party (Schein, 1995, 2008). The makes possible to identify the areas where digital enablers are
involvement of the company in the assessment process not lacking and therefore defines a direction for the improvement
only enables a better learning of the case but also the activities.
acquisition of more valid data related to it (Lewin, 1997). The

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answers, critical points have been identified as an undefined


digitalization strategy (in regards to both resources and plan),
unclear data accessibility and usage, a non-standardised IT
infrastructure, low training practices, unclear digital
capabilities, no benchmarking in relation to competitors, low
digital devices in production and remote work possibilities.
The data collection workshop has been planned involving the
same company stakeholders and with a focus on these critical
points, addressed in four sessions to cover the unit of
analysis: customer ordering and production setup and
execution, procurement and internal logistics, product
development, IT. By discussing them, the non-standardised
IT architecture and the unclear data accessibility and usage
have been identified as particularly critical points in relation
to the company goals. Once all the information related to the
multiple critical points have been collected, the assessment
Fig. 2. 360DMA methodology operational sequence parallel process was finalized by mapping them within the maturity
to PBL seven steps. model according to the definitions of the different maturity
stages. The organization has been assessed as aiming for the
These activities are then selected according both to the transparent stage. The gap that has to be addressed in order to
measured digital maturity stage and to the strategic focus, achieve it concerns the connectivity area (Fig. 3). The
goals and perspectives of the company, identified in step 2 limitations for the digital transformation are represented by
(i.e. definition of scope). the company tendency of developing tailor-made branches of
the IT infrastructure anytime they are needed and by a lack of
Eventually, a debriefing covers the PBL post-discussion step:
data structure. Due to them, the capability of collecting and
the assessment outcome is presented plotted on a spider graph
sharing data according to value stream needs, i.e. transparent
(Fig. 5). A number of pilot projects in order to address the
stage, is limited. According to that, one recommendation was
identified needs and achieve the next digital maturity stage
to consider the introduction of a standard in regards to the IT
are proposed.
infrastructure in order to facilitate the integration of new
elements. Moreover, it has been suggested to standardise the
5. DEMONSTRATION CASE
way data are structured in order to enable data analytics and,
eventually, sharing and visualization.
The 360DMA has been tested and initially validated by the
authors within a large Danish manufacturing company. The
aim was, other than the outcome for the assessed company, to
validate the approach. In accordance to the presented
methodology (Fig. 2), the assessment process started with the
creation of awareness related to the industry 4.0 agenda. The
authors, covering the field expert, mediator and rapporteur
roles, provided an overview of new technologies, use cases
and research projects to company stakeholders directly
involved in the digital transformation of the organization.
From their side, they presented the company business, key
performance indicators and goals. The company vision has
been identified as pointing towards the improvement of
operations efficiency in the Danish production facility to
increase the turnover of 10% yearly by reducing the impact
of labour on product cost. The specific goals in order to move
towards this vision concern production data visualization and
analytics and the introduction of autonomous internal Fig. 3. Digital stage in relation to the five digital dimensions
logistics. These elements helped defining the scope of the (demonstration case example).
investigation by focusing on the Danish production facility
and, specifically, on production data and internal logistics. A 6. DISCUSSION
multiple answer questionnaire composed by 24 questions has
been adapted accordingly and provided to the relevant The demonstration case shows how all the recommendations
company stakeholders (including the COO/executive vice that have been provided as an outcome of the assessment
president – project sponsor - the project manager for the process are not only based on the maturity stage but also
digitalization agenda and four project team members: a directly related to the initial goals stated by the company. The
corporate senior manager, an operations controller and the process that led to their identification started from the initial
corporate senior director from the IT department and the company presentation and continued through a sequence of
supply chain director). Through the analysis of questionnaire

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dialog elements – the questionnaire first, the expert interview Leyh, C.; Schäffer, T.; Ble, K.; Forstenhäusler, S. (2016).
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transformation limitations concerning the specific context. Enterprise-wide IT and Software Landscape Focusing on
However, to generalize the contextualization capabilities of Industry 4.0. Proceedings of the Federated Conference
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different characteristics and goals. A different outcome in Lichtblau, K.; Stich, V.; Bertenrath, R.; Blum, M.; Bleider,
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Appendix A

Table 1. Industry 4.0 maturity models

Model name/ Maturity stages Dimensions Comments


reference
SIMMI 4.0 Five stages: Four dimensions: - Focus on the IT-
Leyh et al (2016) 1. Basic digitization 1. Vertical integration landscape
level 2. Horizontal - General activities
2. Cross-departmental integration: enabling stage
digitization 3. Digital product transitions are
3. Horizontal and development presented
vertical digitization: 4. Cross-sectional
4. Full digitization technology criteria
5. Optimized full
digitization
Schuemacher et al. Likert-scale reaching from 1- Nine company dimensions, - General
(2016) “not distinct” - to 5 - “very further detailed into 62 questionnaire
distinct” -. maturity items:
1. Strategy
2. Leadership
3. Customers
4. Products
5. Operations
6. Culture
7. People
8. Governance
9. Technology
ACATECH Six stages: Four dimensions (Industry - Capabilities are
Schuh et al (2017) 1. Computerization 4.0 capabilities), each one examined for each
2. Connectivity defined by two principles: area of the
3. Visibility 1. Resources company
4. Transparency 2. Information - Questionnaire
5. Predictive capability systems combined with
6. Adaptability 3. Organisational visits
structure
4. Culture

IMPULS Six stages: Six dimensions which are - On-line self


Lichtblau et at (2015) 0. Outsider further detailed into 18 assessment
1. Beginner fields: - Actions for stage
2. Intermediate 1. Strategy and transition are
3. Experienced organization presented
4. Expert 2. Smart factory
5. Top performer 3. Smart operations
4. Smart products
5. Data-driven
services
6. Employees

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