Solving the Industry 4.0 "Blindspot" EMS Summit, Berlin, 5 - - PowerPoint PPT Presentation

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May 18, 2023 261 likes •553 views

Solving the Industry 4.0 "Blindspot" EMS Summit, Berlin, 5 th November, 2019 Digital daily management for manufacturing teams Pragmatic Industry 4.0 Empower frontline teams E&J Gallo The Worlds Largest Winery 1 in 5

SLIDE 1

Solving the Industry 4.0 "Blindspot"

EMS Summit, Berlin, 5th November, 2019

SLIDE 2

✓ Empower frontline teams

Digital daily management for manufacturing teams ✓ Pragmatic Industry 4.0

SLIDE 3

E&J Gallo The World’s Largest Winery

✓ 1 in 5 bottles of wine sold in US ✓ 6000 employees, 21 Wineries, 83m cases ✓ 70% of revenue comes from brands which did not exist 15 years ago ✓ High performance work teams

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January 19 ZAPTIC

80% of shop floor tasks are performed by people.

People are the biggest driver of value and process variability.

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Paper, spreadsheets & pocket notebooks prevailed

“lack of accessibility to standard work, reporting and real time communication on the shop floor… …creates gaps in safety, compliance checks, onboarding and high performance work teams”

Training Execution Measurement Analyse & improve

Manual & ad-hoc analysis Gemba walks & stopwatches Notebooks & tribal knowledge Paper based procedures & classroom training

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Frontline workforce Office users

An Industry 4.0 blindspot

80% of data about frontline operations is trapped in spreadsheets & people’s heads

Planning MES / ERP Compliance QMS / EHS Learning LMS

Execution

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Reporting Guidance Data entry Communication

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From 5 to 30+ use cases within 6 months

What Phase 1 use cases Use cases added by users

Operations Shift Changeovers and startups Work instructions & SOPs Centerlining Waste management Pest control 5S Suggestion box Action tracking Safety Near miss, incidents and BBOs Safety checklists and walkabout Vehicle safety checks Maintenance Autonomous maintenance Maintenance tags Quality QA checks & inspections GMP audits CCPs Sanitation tracking Cleaning

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Teams digitise their own procedures

Based on operational knowledge, not programming knowledge

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1 2 3

Troubleshoots and other complex workflows

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Mobile, on the Floor Task Lists and Standard Work

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EJ Gallo’s First Digital Gemba Board

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Faster Problem Solving

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Autonomous Maintenance

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Issue management (HSEQ)

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Leader standard work

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Changeovers & short interval control

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Paperless standard work & skill matrix

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Productivity

37% more output than last year
15 million more gallons of water treated
Reduced onboarding to less than 1 month

Quality

Tank sanitation scores improved by 25%
Best GMP attainment scores in Gallo
5x first time right rate (e.g. loading targets )

Safety

Leading indicators vs lagging
2x more hazards + NMs reported
Half day per team lead/week saved on paperwork

Compelling business case

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Single line to multi-site in less than 12-months

Pilot commencement

Single line Pilot Site deployment Multi-site roll out 2 months 6 months

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What about strategy?

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1. Target early adopters

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2. Avoid Pilot Purgatory

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3. Choose the right use cases to cross the chasm

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4. Think about network effects for scale

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5. Start before you feel ready

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January 19 ZAPTIC

✓ Empower frontline teams

✓ Pragmatic Industry 4.0

SLIDE 28

Sandy Reid

Chief Customer Officer Email: sandy@zaptic.com

Thank you for listening

Digital daily management system for manufacturing teams