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To improve agility and cater to diverse product segments, reduce costs in an inflationary environment and improve sustainability, Unilever Sonepat implemented 30+ Fourth Industrial Revolution use cases in its E2E supply chain. Top use cases included boiler and spray dryer process twins, as well as customer data-informed no-touch production planning and inventory optimization. This improved service by 18%, forecast accuracy by 53%, conversion cost by 40% and Scope 1 carbon footprint by 88%. The use of biofuels enabled by a boiler process twin also supports livelihoods for local farmers.
Ballina site, the company’s largest concentrate manufacturing facility, delivers over 3,500 SKUs to 68 countries. To enable growth, build resilience and address increasing portfolio complexity, the site implemented digital, and analytics use cases. As a result, it improved cost by 16% while expanding its SKU portfolio by 30%, and led Fourth Industrial Revolution scaling across the network of 17 sites.
Schneider Electric is constantly leverages new-age technologies to meet ever-changing customer needs.
The Schneider Electric Smart Factory in Hyderabad recently earned the recognition of an Advanced Lighthouse by the World Economic Forum. The Hyderabad smart factory has leveraged Schneider Electric’s Fourth Industrial Revolution (4IR) based EcoStruxure Solutions backed by AI deep learningp learning, IIOT infrastructure, and both predictive and prescriptive analytics.
Schneider Electric, on Thursday (29 Sep 2022), hosted the ground breaking ceremony of state-of-the-art Smart Factory at GMR Industrial Park in Hyderabad (It will be second facility in Hyderabad).
Executive Vice President for International Operations | Member of the Executive Committee | Schneider Electric
Schneider Electric's Hyderabad factory in India has been recognized as a Sustainability Lighthouse by the World Economic Forum. This recognition marks a hat-trick win for Schneider Electric after our Lexington plant in USA (2021) and Le Vaudreuil plant in France (2022) received the same status.We will continue to invest in #4ir technologies and expand our manufacturing capacity in the country.
Over four years, the plant reduced its energy consumption by 59 per cent, improved waste optimisation by 64 per cent, decreased CO2 emissions by 61 per cent, and reduced water consumption by 57 per cent.
To improve energy efficiency and thereby reduce CO2 emissions, the Hyderabad team focused on the highest energy consumers in the plant: air compressors and chillers. An IoT-enabled device, Equaliser 4.0, was installed to regulate the compressors, thereby improving their efficiency. For the chillers, a data-driven energy management system with closed-loop control was fitted to constantly monitor and adjust energy consumption in real-time, optimising energy efficiency.
Industrial Engineering 4.0 - Intelligent Die Casting
Dr Mark Cross, Global Business Development Director - Die Casting at Quaker Houghton
“More intelligent die casting is necessary to improve productivity, efficiency, and quality, reduce costs and enhance sustainability.
“Operations can be further optimized with modern monitoring technology to maintain parameters, helping to improve process stability, reduce cycle times and manufacture consistent high-quality products.
“Our comprehensive product range and unrivalled process expertise and experience at Quaker Houghton provides the complete solution to improving die casting performance throughout the die casting manufacturing value chain."
YIZUMI Intelligent Die Casting Island focuses on providing a complete set of turnkey solutions for industrial production processes like robotic automated intelligent manufacturing systems, peripheral equipment, and related technical support and services. It meets the fully automated production needs of the die-casting industry and completes the full set of automated production processes such as robot take-out, inlaying, spraying, product cooling, de-slagging, trimming, engraving, conveying, etc. in the die-casting and post-processing related industries, and is suitable for different die-casting production lines.
Easy central integrated control
Adopting well-known brand PLC and high-definition touch screen, with the human-machine dialogue interface which is constantly optimized according to the needs of customers' front-line operators, it can conveniently carry out quick view of information and set and read alarms detection for various parameters, etc.
Removal and insertion robot system
Experienced in designing claw hands for various types of inlay pieces, the precise material handle arms and product robot arms ensure stable and reliable gripping.
Robotic grinding and deburring can guarantee the accuracy and reliability of product cleaning while lowering the rate of human scrap. Meanwhile, it could prevent the spread of dust and reduces the dangers of environmental pollution and occupational diseases.
LEAP Series Die Casting Machine
YIZUMI fully benchmarks against the performance and functions of world-class die-casting machines . Through the joint efforts of the international and domestic R&D teams with years of experience in the die-casting industry, we developed this series from concept to product, and have independent intellectual property rights in its technology. Yi-Cast real-time closed-loop injection system makes every injection with quality assurance. ORCA control system adopts the world's most advanced control technology and algorithm. The easy-to-use HMI enables the full digitalization of the die-casting machine. Supported by highly innovative servo + feedimng energy-efficient pump units, the machine has achieved higher Overall Equipment Effectiveness (OEE).
Die Casting Industrial Engineering 4.0 - Intelligent Die Casting
Dr Mark Cross, Global Business Development Director - Die Casting at Quaker Houghton
“More intelligent die casting is necessary to improve productivity, efficiency, and quality, reduce costs and enhance sustainability.
“Operations can be further optimized with modern monitoring technology to maintain parameters, helping to improve process stability, reduce cycle times and manufacture consistent high-quality products.
Quaker Houghton provides the complete solution to improving die casting performance throughout the die casting manufacturing value chain.
YIZUMI Intelligent Die Casting Island focuses on providing a complete set of turnkey solutions for industrial production processes like robotic automated intelligent manufacturing systems, peripheral equipment, and related technical support and services. It meets the fully automated production needs of the die-casting industry and completes the full set of automated production processes such as robot take-out, inlaying, spraying, product cooling, de-slagging, trimming, engraving, conveying, etc. in the die-casting and post-processing related industries, and is suitable for different die-casting production lines.
Easy central integrated control
Adopting well-known brand PLC and high-definition touch screen, with the human-machine dialogue interface which is constantly optimized according to the needs of customers' front-line operators, it can conveniently carry out quick view of information and set and read alarms detection for various parameters, etc.
Removal and insertion robot system
Experienced in designing claw hands for various types of inlay pieces, the precise material handle arms and product robot arms ensure stable and reliable gripping.
Robotic grinding and deburring can guarantee the accuracy and reliability of product cleaning while lowering the rate of human scrap. Meanwhile, it could prevent the spread of dust and reduces the dangers of environmental pollution and occupational diseases.
LEAP Series Die Casting Machine
YIZUMI fully benchmarks against the performance and functions of world-class die-casting machines . Through the joint efforts of the international and domestic R&D teams with years of experience in the die-casting industry, we developed this series from concept to product, and have independent intellectual property rights in its technology. Yi-Cast real-time closed-loop injection system makes every injection with quality assurance. ORCA control system adopts the world's most advanced control technology and algorithm. The easy-to-use HMI enables the full digitalization of the die-casting machine. Supported by highly innovative servo + feedimng energy-efficient pump units, the machine has achieved higher Overall Equipment Effectiveness (OEE).
With the proven automation packages for modern and cost-effective gravity die casting, KUKA supplies the ideal basis for high casting quality.
Gravity die casting: the technology
Gravity die casting is a casting process in which the melt is poured from above into a permanent metal mold through a sprue. The mold is filled through the effect of gravity alone. The high thermal conductivity of the mold provides for accelerated cooling of the solidifying melt. This in turn results in a dense and fine-grained structure with improved mechanical properties.
Automated gravity die casting
There are extensive product range of robots, software tools, deburring systems, casting carousels, casting machines, systems for pre-machining and the required peripheral equipment.
The tilting gravity die casting machines with their innovative drive, operating and control concept provide you with the basis you need for high casting quality. The software function in the KRC ROBOTstar synchronizes the pouring motion of the robot with the tilting motion of the casting machine providing for a precise filling process.
Automated Gravity die casting: the advantages
Robust, low-torsion mechanical construction with a low-backlash drive concept characterizes the series of single and double tilt casting machines.
Positionally accurate due to the servo drive, the machines are suitable for linear casting cells as well as for gravity die casting in combination with casting carousels.
The app-based KUKA casting machine controller can be intuitively operated and offers maximum ease of use.
Additional positive effects of automating gravity die casting include increased productivity, improved casting quality and high profitability of your production system.
In contrast to sand casting, gravity die casting has low space requirements.
Full mechanization using robots is possible for gravity die casting.
The robots ensure a high pouring rate meeting the requirements of each casting.
Uzwil (Switzerland), November 3, 2021 – With the Carat 840 and the Carat 920, Bühler has further extended its portfolio as the automotive industry’s demand for larger and more complex parts continues to increase.
Bühler's vision for the future of the die casting industry is: 0% scrap, 40% less cycle time, and 24/7 uptime.
U20 Die Casting Machine
Product of 25 ton class can cast at parting injection
U Series Features
Less air trapped in the metal flow during die fill, it makes the casting parts excellent.
With parting injection system, it makes less re-melting material and can reduce a lot of re-melting cost.
Sprueless system it makes die opening stroke shorter. https://hishinuma.jp/english/menu/2013/11/u20english.html
Kaushiks International is the exclusive manufacturers' representatives in India for numerous world class products catering to core engineering industries, foundry and other applications.
These include CFD simulation software, machineries and ancillary equipments for productivity improvement.
Dr. Ravindran B
Owner, Kaushiks International
Bengaluru Area, India
https://www.linkedin.com/in/dr-ravindran-b-74a5bb17
Increasing Productivity and Reducing Emissions through ... - NREL
For the entire domestic die casting industry (6,000 die casting units):. • Energy savings of 24.6 trillion. Btu and 24 million kWh per year. • Savings of 18 million ... https://www.nrel.gov/docs/fy01osti/27622.pdf
Read the information available on each plant to become aware of the effective use made by these companies of Industry 4.0 Technologies in various processes and systems.
Apple Inc. - Industrial Engineering Activities - Industrial Engineering 4.0
I participate in this blogging challenge regularly. Good to be in touch with other bloggers and cooperate with them to learn as well as to increase readers for the blogs of participants.
Theme for the year 2024 - Industrial Engineering 4.0
In more detail it is.
A to Z 2024 Blogging - Theme - McKinsey - WEF Lighthouse Smart Manufacturing Industry 4.0 Plants - Factories
This year I want to write on Industrial Engineering 4.0 in manufacturing companies of the world. I would like to specially focus on those plants that implemented Industry 4.0 in an excellent and got noticed as lighthouse plants by McKinsey - WEF assessment.
I wish all the bloggers participating in the challenge happy and effective blogging. Look forward to interaction through comments.
I got a more urgent exercise in April. To write on elections to the Parliament in India.
2024 India Lok Sabha - Parliament Elections Information Board
Industrial engineering is improvement in various elements of engineering operations to increase productivity. Along with engineering elements, industrial engineers evaluate and improve many other elements also as they are responsible for productivity and cost of items produced in a process. Through assignments of improving productivity and efficiency of information technology and software engineering processes, industrial engineers specializing in IT were given responsibility for business processes also. Thus industrial engineers with focus on various branches of engineering provide their services to companies and society to improve various elements of the products and processes on a continuous basis over the product life cycle. They are active in engineering or production-maintenance-service-logistic processes and business processes.
Productivity improvement always focuses on quality and flexibility issues as productivity improvement should not lead to any deterioration in quality or flexibility. Delivery and cost are always at the core of industrial engineering. Thus when QFCD paradigm came, that is attention to quality, flexibility, cost and delivery became prominent, many industrial engineers were given the responsibility of managing this function of continuous improvement.
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Focus Areas of Industrial Engineering - Brief Explanation
Industrial Engineering Statistics: Using statistical tools like data description, sampling and design of experiments in industrial engineering activity. Statistics and Industrial Engineering
Human Effort Industrial Engineering: Redesign of products and processes to increase satisfaction and reduce discomfort and other negative consequence to operators. Motion Study - Human Effort Industrial Engineering
Productivity Measurement: Various measurements done by industrial engineers in industrial setting to collect data, analyze data and use the insights in redesign: Product Industrial Engineering and Process Industrial Engineering. Industrial Engineering Data and Measurements
Productivity Management: Management undertaken by industrial engineers to implement Product Industrial Engineering and Process Industrial Engineering. Management processes industrial engineering is also part of productivity management. Productivity Management
Applied Industrial Engineering: Application of industrial engineering in new technologies, existing technologies, engineering business and industrial processes and other areas.
Our production system is future-focused, undergoing a major transformation in response to the changing challenges of the automotive industry and the expectations of our customers. The 4.0 revolution is ushering in new business functions, new skills and new tools. It is the driving force behind a connected, agile and competitive production base.
An illustration of this digital shift is our recent partnership with Google Cloud.
With an ambitious objective: a sharing of industrial and technological experience between two leaders to encourage the creation of new industrial solutions. This ambition illustrates the continuation of our digital transformation, initiated in 2016: connecting our production sites, managing industrial data, transforming our logistics processes around the world, with the aim of continuously improving our standards of excellence. At the heart of this plan, our teams will have the opportunity to strengthen their data culture, with coworking sessions and high-level training with Google teams.
4 Key initiatives to drive digital transformation
Real-time supply management
As soon as a customer orders a vehicle, suppliers are informed, raw materials are prepared and logistics flows are established.
Simpler processes with connected tools
In our production plants, digital technology helps employees to be more mobile and proactive and to share information. It also contributes to easier decision-making on the production line.
Continuous traceability
Vehicle parts, assembly and packaging are tracked in real time, so customers can follow the progress of their order.
Data for planning
Data are sent and analyzed continuously to conduct remote operations and simulations as well as to optimize maintenance.
#01
People and robots, hand in hand
In the production plant of the future, the production line resembles a futuristic ballet.
Robots and machines of all sorts work alongside human operators. Automatic trolleys zip around continuously, carrying the required kits, articulated arms help operators in their work, a cobot or collaborative robot fits parts with a high degree of precision, alongside an operator...
In industry 4.0, people and robots work together.
8000
robots in our plants
Our perspective:
With the continuous increase in product customization to satisfy customer expectations and the presence of connected project managers, the 4.0 plant allocates the heaviest and most repetitive tasks to robots: handling unwieldy parts or part picking. This takes the strain off the operators who are thereby able to concentrate on tasks of greater added value, such as the quality of engine or vehicle assembly. The 4.0 plant has an essential component at its core: people!
It’s a real revolution. The energy of the cobot needs to be controlled since there is always somebody next to it. The movements mustn’t be too fast. A shared pace of work needs to be established, based on task-sharing.
JAIME
Cobot Manager, Séville plant (SPAIN)
#02
Virtual reality, real progress!
With VR, we train operators, anticipate maintenance issues and conduct production line simulations that resemble reality as closely as possible. For example, we can study how best to integrate a new part on the line and optimize configuration. As a result, we can carry out all sorts of tests and adjustments without interrupting the flow.
4364
people followed VR training in Brazil
Our perspective:
VR can be used to model the production line and make sure in advance that space is used efficiently. We can also study the best way to build several versions of a vehicle without stopping the lines for reconfiguration. The virtual and real worlds are synchronized. This improves on-site productivity. With respect to learning, VR ensures that trainees learn the right techniques and movements safely. VR is an essential tool in industry 4.0, delivering benefits that are both economic and operational.
Here we deploy all digital themes. For training, Virtual Reality (VR), used as a complement to practical cases, allows us to learn by example. At the forefront of this approach, we worked with a local VR/3D startup to develop immersive and fun virtual tours with them.
ISABELLE
Lean and Digital Manager, Cléon plant (FRANCE)
#03
Total traceability, nothing is wasted!
Total traceability is one of the pillars of digital transformation, one of the main driving forces in the 4.0. plant.
As part of an approach to maximize quality, the Full Track and Trace project provides the history of the vehicle as it is put together, rather like an ID card! We can see the context in which it was built, who by, and we can track it through to delivery. The customer has access to all the stages preceding vehicle reception.
The Packaging Managing System tracks every parcel. As packaging can be expensive – sometimes costing more than the part inside – real-time tracking is a major objective. In this way, the plant is able to keep a tight rein on inventory and procurement. All efforts are made to avoid disrupting production.
2200
LoRa Sensors
Our perspective:
Full traceability is at the core of our approach to quality. It also contributes to cost efficiency. By improving part identification, standardizing traceability, associating a part with a production process and implementing geolocation data, we are able to track logistics in real time. We save time in managing inventory, which is sized to the minimum necessary. In the plants, various technologies such as RFID chips and the LoRa protocol (Long Range) are used.
New technologies create value for our business. We have made real savings in packaging. We are proud to have developed the first Alliance logistics flow featuring geolocated packaging, using LoRa technology. This protocol allows small amounts of data to be collected in real time, with great accuracy and customization.
NOVEMBER 29, 2019 All news RENAULT-NISSAN-MITSUBISHI ACCELERATE OPERATIONAL EFFICIENCY OF THE ALLIANCE
PRESS RELEASE – November 29, 2019
Renault-Nissan-Mitsubishi, the world’s leading automotive alliance, held its monthly Alliance Operating Board Meeting in Boulogne-Billancourt, France, attended by Jean-Dominique Senard, Chairman of the Alliance Operating Board and Renault, Makoto Uchida, nominated CEO Nissan Motor Co, Osamu Masuko, Chairman Mitsubishi Motors, Clotilde Delbos, acting CEO Renault, Takao Kato CEO Mitsubishi Motors, Ashwani Gupta, nominated COO Nissan Motor Co, Jose-Vicente de Los Mozos, acting Deputy CEO Renault and Olivier Murguet, acting Deputy CEO Renault.
The meeting concentrated on improving the efficiency of the Alliance with a deep, common understanding of the work to be achieved by the Alliance in the future.
The Board members all agreed on programs to significantly enhance and accelerate the operational efficiency of the Alliance for the benefit of the three companies, including action plans to maximize the contribution of the Alliance to support each company’s strategic plan and operating profit.
RENAULT-NISSAN-MITSUBISHI INCREASE ANNUAL SYNERGIES TO €5.7 BILLION PRESS RELEASE – Paris/Yokohama/Tokyo, June 13, 2018
• Annual synergies rise 14%, from €5 billion in 2016 to €5.7 billion in 2017 • Mitsubishi Motors reports first full year of synergies as Alliance member • Further convergence underway in Aftersales, Quality & Total Customer Satisfaction and Business Development • The Alliance reaffirms synergy target of more than €10 billion by the end of 2022 https://www.alliance-2022.com/news/renault-nissan-mitsubishi-increase-annual-synergies-to-e5-7-billion/
Lean Leadership March 24, 2014
Renault-Nissan Consulting’s Managing Consultant Dean Simpson shares his view on Lean Leadership principles.
Lean principles
What are the key concepts of Lean thinking?
A clear focus on everyone meeting the external customer’s requirement A clear definition of internal/supplier relationships
Where is industrial engineering in Renault's lean?
All value-adding activities in the organisation should be improved All non-value adding activities should be removed A faster process is a better process Effective measurement and analysis of processes
All the above four are achieved by IE methods and techniques
• In charge of Aftersales APW (Alliance Production Way) activities for European Division • APW and Lean Coach • DMD Auditor through European Spareparts Warehouses (7 countries) • Realisation of “Lean Improvement Chantier” at Suppliers and internally • Monitorisation of Standard Operation definition for the new WMS project • Support for training and monitoring of the QRQC Problem Solving method • Carry out Quick win Kaizen actions • Definition of shared standard methods and tools with NISSAN https://www.linkedin.com/in/mesut-gurcan-55aa9171/
kamar ait lemqeddem Industrial Engineer chez Renault-Nissan-Mitsubishi Paris Area, France https://www.linkedin.com/in/kamar-ait-lemqeddem-641073a0/
RENAULT CHOOSES DASSAULT SYSTÈMES FULL V6 PLM TO IMPROVE THE COMPANY’S PRODUCTIVITY
Renault and Dassault Systèmes pioneer ground-breaking approach: Global online Collaboration to boost Innovation. Renault has selected Dassault Systèmes’ V6 PLM (Product Lifecycle Management) as its new global product development solution, in order to improve productivity.
Renault has already started to implement the ENOVIA V6 based collaborative platform and CATIA V6, and will rapidly move to the full DS V6 portfolio to enable the company and its suppliers to collaborate on the creation of new product designs in real time.
Renault will deploy V6 PLM in all geographies and throughout all brands. The online access to the digital mock-up (DMU) will lead to a simplification of the collaboration between engineering sites. This use of a unique, collaborative interface for all developers worldwide supports simultaneous product/process engineering to get it ‘right the first time’. https://www.cadcam-group.eu/blog/renault--press-release
Ryan McDaniel Director, Manufacturing Strategy & Planning Office at Nissan North America United States https://www.linkedin.com/in/ryan-mcdaniel-74b77012/
