How Industry 4.
0 is transforming
Lean Manufacturing
Presented by:
Madi Castillo & Pablo Tosta
Tulip Interfaces
Proprietary & Confidential. Copyright 2019, Tulip Interfaces, Inc.
Webinar Objectives
• Become acquainted with key Industry 4.0 technologies
• Understand what Lean 4.0 means for manufacturers
• Review Lean 4.0 use cases, and how they drive efficiency and profitability for
manufacturers
Proprietary & Confidential. Copyright 2019, Tulip Interfaces, Inc.
What is Industry 4.0?
18th century 19th century Mid 20th century Today
Cyber physical systems,
Enabling Steam power Electricity
ICTs
Internet of things (IoT),
Technology Electronics networks
Production Mass production and Automation and Intelligent, flexible,
Mechanical production
Change assembly lines networked production distributed production
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Defining Cyber Physical Systems (CPS):
“CPS are the result of a closed loop of sensor based physical process data
acquisition combined with software based cyber data processing &
autonomous actuator based process controlling connected with the internet
and its data and services”
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Put simply, connecting & collecting data
from production
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3 Ways to Collect the Data via CPS
Human to Machine Machine to Machine Data Acquisition & Processing
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What is the value of the lean
methodology for manufacturers?
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“Lean Toolbox”
Production Smoothing Error-Proofing Cellular Manufacturing Kanban
Continuous Improvement 5S Audits Just In Time Production Standardized Work
Cycle Time Reduction Gemba Walks Quick Changeover Competitive Benchmarking
etc...but not the same for everyone
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Industry 4.0 + Lean manufacturing = Lean 4.0
Industry 4.0 Lean Manufacturing Lean 4.0
10% - 15% 10% - 15% +40%
Source: BCG Analysis: [Link]
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Value of Lean Manufacturing
WITHOUT INDUSTRY 4.0 TECHNOLOGY ...WITH INDUSTRY 4.0 TECHNOLOGY
Changeovers are time consuming, Sensors and software enable more efficient
Flexibility or plants require additional
changeovers
production lines
Machine data collection improves machine
Machine downtime and resource maintenance, enables engineers to easily
Productivity constraints hurt productivity monitor uptime and downtime
Data is collected sporadically, used Real time data drives production management,
Speed when it’s already outdated truly continuous, accountability
Operators prone to error and
Quality defects are found downstream
Ensures accurate self inspection, removes waste
Bottom up transformation and optimization
Low buy in to continuous
Culture improvement programs from internal stakeholders
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Where Industry 4.0 can fail...
Hard/Impossible to Too rigid and Rigid solutions based on All-or-nothing, high
use by operators and expensive to specific customization. risk implementation
supervisors implement, deploy, Standardizing a solution approach
and maintain is often times
impossible
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The Continuous Improvement Loop - Lean 4.0
Learn, Test, Scale
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Manufacturing Apps: A Definition
Manufacturing App Platform can turn your workflows into instrumented, data collecting,
digital processes.
Continuous Improvement, Lean
Create, test, and deploy quickly--then iterate and
improve.
Visual
User-friendly interfaces and rich media provide an
intuitive experience.
IoT Enabled
Connect with machines, tools, and sensors.
Data-driven
Automatically collect production data.
Interactive logic
Guide workflows with dynamic logic.
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Lean 4.0 with Manufacturing Apps
Flexible, bottom up app development and optimization and faster error detection and
improvement drive fast return and ensure future continuous improvement
PLAN COLLECT
SHOP-FLOOR PROCESS REAL-TIME
MANUFACTURING APP
PRODUCTION DATA
PROCESS
OPTIMIZATION
IMPROVE
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Adopting Apps in Your Operations Digitizes Lean 4.0
From work instructions to quality checks, to the right machine setup, all the lean
processes in your shop floor can be managed through apps
Root Cause
Analysis Visual
5S Audits
Management
Standardized
Work
Poka Yoke
SMED,
Machine
Maintenance
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The Continuous Improvement Loop - MFG Apps
Create, Test, Scale
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Real-World Use Cases from
Customers Using Tulip Apps
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Fewer operator mistakes with digital poka yoke through error
APPS
VISUAL WORK INSTRUCTIONS
TRAINING
QUALITY
DEVICES USED
BARCODE
SCANNER
CAMERA
RESULTS
“the system allows us to control a highly complex process PICK TO LIGHT
100% 99% with hundreds of thousands of variations while leveraging
Error Rate Training Time the investment we made in our existing backend systems”
- Sr. Process Engineer
Proprietary & Confidential. Copyright 2017, Tulip Interfaces, Inc Shared under NDA.
Real Time Data Speeds Up Continuous Improvement
APPS
VISUAL WORK INSTRUCTIONS
AUDIT & QUALITY
TRAINING
DEVICES USED
BARCODE
SCANNER
CAMERA
RESULTS
TABLETS
60% 10% 4 Weeks “Now we have real-time insights that let us
optimize even low volume production runs” -
Quality Issues Production Yield Time-to-value Quality Engineer
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Faster root-cause analysis and improvement with better data
APPS
VISUAL WORK INSTRUCTIONS
TRAINING
AUDIT & QUALITY
LEAN APPS
DEVICES USED
BARCODE
SCANNER
RESULTS
CAMERA
“Now we have a lot more confidence in the
50% 35% 2 Weeks data, and we can digitize the analysis.”
Time to Market Quality Errors Time-to-value - VP Innovation TABLETS
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Cultural Impact of Lean 4.0
Prevention vs
Active Problem Reaction
Solving
Flexible workers Shared destiny
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Thank You for Joining!
Register for our next webinar: Digital Transformation for
SMB Manufacturers, April 8th @ 2PM est/11 AM pst
Learn more: [Link]
Pablo Tosta Madi Castillo
pablo@[Link] madi@[Link]
Proprietary & Confidential. Copyright 2019, Tulip Interfaces, Inc.
Tulip, the Manufacturing App Platform, is a no code platform-as-a-service that lets
manufacturers build IoT-enabled manufacturing apps without having to write any
code. Some of the world’s leading manufacturers are already using Tulip to increase
the productivity, quality, and efficiency of their operations. Launched out of MIT, the
company has customers in over 14 countries, is headquartered in Somerville, MA,
with offices in the UK and Germany.
"Tulip’s distinctive "Tulip’s key differentiator is "The platform’s flexible, "Tulip merges the needs "Tulip and its fellow
nature is its simplicity." its ease of use and time to self-serve, smart of the human workforce pioneers are front and
value." manufacturing apps enable with data-centric IIoT centre in shaping the
people, processes, and devices." ongoing Fourth
machines to work together." Industrial Revolution."
© 2019 Tulip Interfaces, Inc.
