- 93% of global product leaders say that predictive maintenance combined with real-time equipment monitoring enabled by integration is a must-have for factory planning today.
- 75% of global product leaders plan to implement factory of the future initiatives and programs in the next five years or less, starting with Industry 4.0
- 67% of automotive executives expect that new technologies enabled by real-time integration will enable their teams to reach and exceed lean management and continuous improvement goals starting this year and accelerating through 2030.
Boston Consulting Group’s recent article, The Factory of the Future provides insights into a recent global survey the consulting firm conducted of more than 750 manufacturing product leaders from leading companies in three industrial sectors: automotive (which includes suppliers and original equipment manufacturers, or OEMs), engineered products, and process industries. The survey’s objective is to define the vision for the factory of the future in 2030. Determining long-term benefits and the roadmap to implementation are also goals of the study Boston Consulting Group (BCG) and its research partner, the Laboratory for Machine Tools and Production Engineering at RWTH Aachen University, achieved. The Factory of the Future is a vision for how manufacturers should enhance production by making improvements in three dimensions: plant structure, plant digitization, and plant processes.
5 Ways Integration Fuels The Factory Of The Future’s Growth
Real-time integration based on intelligent objects that connect diverse enterprise systems including SAP, Salesforce and others is the foundation that manufacturing companies must adopt to excel in their Factory of the Future efforts. These real-time objects illustrate the future of Application Programmer Interfaces (API). APIs that will fuel and drive the Factory of the Future will enrich each real-time integration points across manufacturing networks. Intelligent Objects pervasively used today are the precursors to the most valuable APIs that will enable Factories of the Future tomorrow. With APIs continually improving and gaining the capability to provide insight and intelligence, the essential role of real-time integration in all factories of the future becomes clear.
The following are the five ways integration is enabling the Factory of the Future today:
- Real-time integration enables the value chains supporting the Factories of the Future to continually accelerate, excel and improve with additional insight that drives future growth strategies. Bringing greater intelligence into each integration point across the value chains supporting the Factories of the Future leads to new technologies delivering greater lean management benefits. Real-time integration will deliver strong benefits in the areas of lean management, predictive maintenance, modular line setups, and the orchestration and collaboration of smart robots.
- The Implementation Roadmap for the Factory of the Future shows how critical real-time integration is to the Factory of the Future’s vision being attained. Multidirectional layouts, modular line setups, sustainable production, the orchestration of smart and collaborative robotics and attainment of big data and analytics plans all are dependent on real-time integration. The following graphic from the study illustrates just how central integration is to the optimizing of plant structure and plant digitization.
- By integrating large-scale enterprise systems including those from SAP, Salesforce and others with legacy, 3rd party and homegrown systems, every area of production quality will improve. The most urgent need global manufacturers have is finding new ways to improve product, process and service quality without raising costs. Improving the quality of these three dimensions makes any manufacturer more trusted and successful in selling next-generation products. By aggregating data using real-time integration so that Big Data and advanced analytics can be used to find new patterns, some of the world’s most well-known manufacturers are excelling on product quality. To produce cylinder heads at its plant in Untertürkheim, Germany, Mercedes-Benz uses predictive analytics to examine more than 600 parameters that influence quality. Mercedes-Benz is an early adopter of using Big Data and advanced analytics to improve quality management and bring high precision to engineering. Bosch has implemented software that analyzes data about its production of fuel injectors in real time. The software monitors process adherence and recognizes trends. It automatically transmits information about deviations to operators, allowing them to improve the process accordingly.
- Real-time integration across and within manufacturing systems enables multi-directional layouts of production workflows. The Audi R8 manufacturing facility in Heilbronn, Germany, does not have a fixed conveyor so the teams there has greater multidirectional flexibility in building customized vehicles. Real-time integration across the Audi factory floor is essential to provide R8 production teams with the specifics of how they can best collaborate and deliver the highest quality vehicles in the shortest amount of time. Real-time integration is enabling driverless transport systems, guided by a laser scanner and radio frequency identification technology in the floor, which moves the car bodies through the assembly process. These systems enable assembly layout changes quickly with no impact on existing production. Enabling real-time integration often involves extensive field mapping between different systems, which is a lengthy and error-prone process. Integration technology provider enosiX has developed a unique, real-time integration technology that obsoletes the need for field mapping and supports bi-directional data updates.
- Enabling the Factory of the Future’s production operations to flex in response to rapidly changing customer requirements is entirely dependent on real-time, reliable integration of production and customer-facing systems. The implications of the study on the future of manufacturing underscore just how critical it is for manufacturers to be agile enough to create entirely new business models while gaining insight and intelligence into how they can continually improve lean manufacturing. When real-time integration unifies a value chain for any manufacturer, their speed, scale and ability to simplify the complex processes required to serve customers turns into a formidable competitive advantage.
- Enabling real-time integration across on-premise and cloud platforms often involves integrating SAP, Salesforce, third-party and legacy systems. 2017 will be a break-out year for real-time integration between SAP, Salesforce, and third party systems in support of Internet of Things and Industrial Analytics.
- McKinsey Global Institute predicts that the Internet of Things (IoT) will generate up to $11T in value to the global economy by 2025.
- Predictive and prescriptive maintenance of machines (79%), customer/marketing related analytics (77%) and analysis of product usage in the field (76%) are the top three applications of Industrial Analytics in the next 1 to 3 years.
Real-Time Integration Is the Cornerstone Of Industrial Analytics
Industrial Analytics (IA) describes the collection, analysis and usage of data generated in industrial operations and throughout the entire product lifecycle, applicable to any company that is manufacturing and selling physical products. It involves traditional methods of data capture and statistical modeling. Enabling legacy, third-party and Salesforce, SAP integration is one of the most foundational technologies that Industrial Analytics relies on today and will in the future. Real-time integration is essential for enabling connectivity between Internet of Things (IoT) devices, in addition to enabling improved methods for analyzing and interpreting data. One of the most innovative companies in this area is enosiX, a leading global provider of Salesforce and SAP integration applications and solutions. They’re an interesting startup to watch and have successfully deployed their integration solutions at Bunn, Techtronic Industries, YETI Coolers and other leading companies globally.
A study has recently been published that highlights just how foundational integration will be to Industrial Analytics and IoT. You can download the Industrial Analytics Report 2016/17 report here (58 pp., PDF, free, opt-in). This study was initiated and governed by the Digital Analytics Association e.V. Germany (DAAG), which runs a professional working group on the topic of Industrial Analytics. Research firm IoT Analytics GmbH was selected to conduct the study. Interviews with 151 analytics professionals and decision-makers in industrial companies were completed as part of the study. Hewlett-Packard Enterprise, data science service companies Comma Soft and Kiana Systems sponsored the research. All research and analysis related steps required for the study including interviewing respondents, data gathering, data analysis and interpretation, were conducted by IoT Analytics GmbH. Please see page 52 of the study for the methodology.
- With real-time integration, organizations will be able to Increase revenue (33.1%), increase customer satisfaction (22.1%) and increase product quality (11%) using Industrial Analytics. The majority of industrial organizations see Industrial Analytics as a catalyst for future revenue growth, not primarily as a means of cost reduction. Upgrading existing products, changing the business model of existing products, and creating new business models are three typical approaches companies are taking to generate revenue from Industrial Analytics. Integration is the fuel that will drive Industrial Analytics in 2017 and beyond.
- For many manufacturers, the more pervasive their real-time SAP integration is, the more effective their IoT and Industrial Analytics strategies will be. Manufacturers adopting this approach to integration and enabling Industrial Analytics through their operations will be able to attain predictive and prescriptive maintenance of their product machines (79%). This area of preventative maintenance is the most important application of Industrial Analytics in the next 1 – 3 years. Customer/marketing-related analytics (77%) and analysis of product usage in the field (76%) are the second- and third-most important. The following graphic provides an overview of the 13 most important applications of Industrial Analytics.
- 68% of decision-makers have a company-wide data analytics strategy, 46% have a dedicated organizational unit and only 30% have completed actual projects, further underscoring the enabling role of integration in their analytics and IoT strategies. The study found that out of the remaining 70% of industrial organizations, the majority of firms have ongoing projects in the prototyping phase.
- Business Intelligence (BI) tools, Predictive Analytics tools and Advanced Analytics Platforms will be pivotal to enabling industrial data analysis in the next five years. Business Intelligence Tools such as SAP Business Objects will increase in importance to industrial manufacturing leaders from 39% to 77% in the next five years. Predictive Analytics tools such as HPE Haven Predictive Analytics will increase from 32% to 69%. The role of spreadsheets used for industrial data analytics is expected to decline (i.e., 27% think it is important in 5 years vs. 54% today).
- The Industrial Analytics technology stack is designed to scale based on the integration of legacy systems, industrial automation apps and systems, MES and SCADA systems integration combined with sensor-based data. IoT Analytics GmbH defines the technology stack based on four components inclouding data sources, necessary infrastructure, analytics tools, and applications. The following graphic illustrates the technology stack and underscores how essential integration is to the vision of Industrial Analytics being realized.
- Industrial Internet of Things (IIoT) and Industry 4.0 will rely on real-time integration to enable an era of shop-floor smart sensors that can make autonomous decisions and trade-offs regarding manufacturing execution. IoT Analytics GmbH predicts this will lead to smart processes and smart products that communicate within production environments and learn from their decisions, improving performance over time. The study suggests that Manufacturing Execution System (MES) agents will be vertically integrated into higher level enterprise planning and product change management processes so that these organizations can synchronously orchestrate the flow of data, rather than go through each layer individually.
- By 2021 there will be 9B mobile subscriptions, 7.7B mobile broadband subscriptions, and 6.3B smartphone subscriptions.
- Worldwide smartphone subscriptions will grow at a 10.6% CAGR from 2015 to 2012 with Asia/Pacific (APAC) gaining 1.7B new subscribers alone.
These and other insights are from the 2016 Ericcson Mobility Report (PDF, no opt-in). Ericcson has provided a summary of the findings and a series of interactive graphics here. Ericcson created the subscription and traffic forecast baseline this analysis is based on using historical data from a variety of internal and external sources. Ericcson also validated trending analysis through the use of their planning models. Future development is estimated based on macroeconomic trends, user trends (researched by Ericsson ConsumerLab), market maturity, technology development expectations and documents such as industry analyst reports, on a national or regional level, together with internal assumptions and analysis.In addition, Ericsson regularly performs traffic measurements in over 100 live networks in all major regions of the world. For additional details on the methodology, please see page 30 of the study.
Key takeaways from the 2016 Ericcson Mobility Report include the following:
- Internet of Things (IoT) sensors and devices are expected to exceed mobile phones as the largest category of connected devices in 2018, growing at a 23% compound annual growth rate (CAGR) from 2015 to 2021. Ericcson predicts there will be a total of approximately 28B connected devices worldwide by 2021, with nearly 16B related to IoT. The following graphic compares cellular IoT, non-cellular IoT, PC/laptop/tablet, mobile phones, and fixed phones connected devices growth from 2015 to 2021.
- 400 million IoT devices with cellular subscriptions were active at the end of 2015, and Cellular IoT is expected to have the highest growth among the different categories of connected devices, reaching 1.5B connections in 2021. Ericcson cites the growth factors of 3GPP standardization of cellular IoT technologies and cellular connections benefitting from enhancements in provisioning, device management, service enablement and security. The forecast for IoT connected devices: cellular and non-cellular (billions) is shown
- Global mobile broadband subscriptions will reach 7.7B by 2021, accounting for 85% of all subscriptions. Ericcson is predicting there will be 9B mobile subscriptions, 7.7B mobile broadband subscriptions, and 6.3B smartphone subscriptions by 2021 as well. The following graphic compares mobile subscriptions, mobile broadband, mobile subscribers, fixed broadband subscriptions, and mobile CPs, tablets and mobile routers’ subscription growth.
- Worldwide smartphone subscriptions will grow at a 10.6% compound annual growth rate (CAGR) from 2015 to 2012. Ericcson predicts that the Asia/Pacific (APAC) region will gain 1.7B new subscribers. The Middle East and Africa will have smartphone subscription rates will increase more than 200% between 2015–2021. The following graphic compares growth by global region.
- Mobile subscriptions are growing around 3% year-over-year globally and reached 7.4B in Q1 2016. India is the fastest growing market regarding net additions during the quarter (+21 million), followed by Myanmar (+5 million), Indonesia, (+5 million), the US (+3 million) and Pakistan (+3 million). The following graphic compares mobile subscription growth by global region for Q1, 2016.
- 90% of subscriptions in Western Europe and 95% in North America will be for LTE/5G by 2021. The Middle East and Africa will see a dramatic shift from 2G to a market where almost 80% of subscriptions will be for 3G/4G. The following graphic compares mobile subscriptions by region and technology.
- Mobile video traffic is forecast to grow by around 55% annually through 2021, accounting for nearly 67% of all mobile data traffic. Social networking traffic is predicted to attain a 41% CAGR from 2015 to 2021. The following graphic compared the growth of mobile traffic by application category and projected mobile traffic by application category per month.
- Ericcson also provided mobile subscription, traffic per device, mobile traffic growth forecast, and monthly data traffic per smartphone. The summary table is shown below: