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Enabling the Manufacturing Workforce in the Factory of the Future
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1Industry 4.0 2Enabling technologies 3Impact &
challenges 4 PeopleStrategy 5 Conclusion &
Takeaways
AGENDA
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• Personal experience implementing change on the manufacturing floor
• Exposure to advanced manufacturing technology
• Passionate about leadership and technology
Introduction
Why I’m here ?
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Industrial Revolutions
1 st 2 nd 3 rd 4 th
The first industrial revolution used water and steam power to mechanize production
Steam Electricity Computing Smart Manufacturing
The second industrial revolution used electrical power to create mass production
The third industrial revolution used electronics and computers to automate production
The fourth industrial revolution marries advanced technologies with connectivity to create intelligent manufacturing systems
1784 1870 1960 Today (?)
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Everything gets Smart
Smart Phone
Smart Home
Smart Car
Smart Factory
The factory of the future will be “smart”
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Smart Factory • Supplies products with high value added • Flexible enough to respond to swiftly
changing market demand• Fully embraces digitalized production
processes• Exploits the potential of modern
production technologies ( IT/OT)• Carefully handles energy and materials• Human centric vs task centric
Source: http://www.madedifferent.be/en/what-factory-future-40
Smart Factory
Smart factory combine mass production efficiency with custom manufacturing ( on demand) and optimize the supply chain in real time
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Smart Factory
Industry 4.0 is affecting the complete lifecycleAv: Prof. Dr. Detlef Zühlke, Scientific Director, German Research Center for Artificial Intelligence, Innovative Factory systems
HR Too!
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Enabling Technologies
Virtual reality
Blockchain
AI
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Enabling Technologies
Virtual reality
Blockchain
AI
Virtual reality
Senses of Smart Factory
Industrial
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IIoT
A network of Internet connected devices , equipment, machines that are able to collect and exchange data to improve manufacturing and industrial processes
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Augmented reality
overlays information and virtual objects on real-world scenes in real-time.
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Virtual reality & simulation
Create ,test, build, operate and service products and processes in a virtual environment
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Enabling Technologies
Virtual reality
Blockchain
AI Muscles of Smart Factory
Blockchain
Industrial
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COBOT
robots capable to interact with each other and cooperate with humans without the need of safety restrictions
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Additive Manufacturing
Manufacturing objects one fine layer at a time from a 3D model
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BLOCK CHAIN
Incorruptible digital ledger of economic transactions that can be programmed to record not just financial transactions but virtually everything of value
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Enabling Technologies
Virtual reality
Blockchain
AIAI
Brain of Smart Factory
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Cloud Computing
Access information from anywhere, anytime , on any device
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Big Data Analytics
The collection and comprehensive evaluation of large volume of data from many different sources to uncover information including hidden patterns, unknown correlations
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AI / ML
AI works by combining large amounts of data with fast, iterative processing and intelligent algorithms, allowing the software to learn automatically from patterns or features in the data.
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Industry 4.0 Benefits
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Industry 4.0 offers opportunities through a smart combination of:
Digitalization Connectivity Technologies (IT &OT)
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All businesses are made up of PEOPLE
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Industry 4.0 Impact to Job market▪ It will increase the need for certain
jobs
– Automation Engineer
– IT solutions architect
• It will create new jobs
– Robot coordinator
– Industrial data scientist
– Digital twin Engineer
– Predictive Maintenance analyst
– Etc…
Industry 4.0 technologies drive link
between workers, equipment, software,
and machines
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Estimated # jobs directly created by Industry 4.0
Driving growth and directly creating 900K new industry 4.0 jobs by 2025
Jobs along all functions will be affected by Advanced technologies
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Skills Required for Advanced Manufacturing
Social skills• Coordination, persuasion ,
team work , communication, Etc..
Resource Management skills• Time management , work
ethic , priority development , courage to ask questions, etc
General Skills Technical Skills
Technical Skills• Programming , Design and
analysis , trouble shooting , Quality Control analysis, etc..
Learning • Critical thinking ,
mathematics
Complex problem solving
Judgment and decision making
Researching
Adaptive Skills
Basic Complex skills
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Perfect Storm for US manufacturing Strong Economic growth
Baby Boomers retiring ( 10,000/ day)
Misperceptions of manufacturing jobs
Stiff competition from the tech sector for younger workers
STEM education is inadequate for today’s shop floor
Opioid addiction diminish effective pool of workers
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Manufacturing Skill gapStudies show that the skill shortage is expanding
2.0 M 2.4 M
2025 2028
Positions unfilled Source: BLS Data, OEM (Oxford Economics Model), Deloitte and Manufacturing Institute skills research initiative.
600K
2011
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Industry 4.0 People strategy
Retain Retrain Recruit
• Give and request feedback• Invest in employee career
development and re-skilling• Workplace improvement • Flexible work schedule• Paid leave time• Improved benefits package
• Foster a positive perspective on change
• Recognize the adult leaning model• Leverage digital technologies ( Online
competency-based learning programs,)
• Co- mentoring program
• Focus on capabilities, rather than qualifications
• Partnerships with tech programs/schools and community college
• Leverage digitalmanufacturing to attract
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Why do we have to continuously learn and adapt?
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Information Overload
Human Life Spans
Life expectancy
35 years
Life expectancy
45 yearsLife expectancy
80 years…
Egyptian
RomanDark Ages
RenaissanceIndustrial
Revolution
Technological Revolution
Computer Age
Information Age
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Take Away
1 Being competitive in the modern fast-paced business environment requires applying industry best practices in advanced manufacturing technologies , product development processes and organizational culture to the business
2 Knowing what is Industry 4.0, and how it will affect the industry, is only half the battle.
Are you benchmarking, reaching out to industry peers? Do you have a digital transformation strategy ?
Are you meeting with your industry partners to answer the question 5 years out ? What do you see ?
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Take Away
Last but not least, it will have to go beyond teaching the technical skills required by today’s manufacturing world and technologies and teach the adaptive skills that will be needed tomorrow instead
3 The challenge is too complex for a silver bullet solution. It requires a multi-pronged approach
▪ Making the industry more attractive to the new generation ▪ Addressing continual reskilling of workforce.▪ Providing better education and training▪ Developing a digital transformation strategy and new workforce roles
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Do you have partnerships , have you spoken with local universities , do you have intern programs ? How are you communicating about you company ?
Look at your training offering , where are the gaps in your training programs and hiring pool ? Are you looking at those type of skills ?
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