The
SMART FACTORY
Quick Action Guide
SMART FACTORY Quick Action Guide
An Approach to the Internet of Things
The Internet of Things (also known as Iot, Digitalization, or
Industry 4.0) is the key element of modern and smart
factories. Factories, in which all supply chain indicators and
data are available at real-time for all functions involved in
manufacturing and service providing processes.
Hence, being involved in this recent development of
industries means to becoming a person of interest for most
modern companies around the globe.
This e-book will guide you through the very first thoughts you must have in terms of the Internet of Things.
Compare each step of your supply chain carefully with the elements of the SMART FACTORY Quick Action Guide
attached and evaluate, how the connectivity helps you to improve your supply chain processes.
Sincerely, the Smart Factory-Team
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SMART FACTORY Quick Action Guide
Score your current processes in terms of the Internet of Things
1. Inbound container 2. Inbound transport 3. Inbound 4. Inbound
Score 5. Inbound receiving 6. In-house storage 7. Internal call-offs
concept process transports routing warehouse concepts
Pushed supplier 100% check of
Manual storage
Offline tracking of deliveries according Local planning of received parts, Manual call-offs
Static local operated without warehouse
0 containers by local to fixed weekly/ fixed routes and manual scanning (phone, etc.) by line
warehouse management
plant monthly demand equipment and sorting acc. to operator or others
software
forecast storage location
Pull/consumption- Local planning of No 100% check, pre- Call-offs steered by
Tracking of RFID Static centralized Static minimum
1 based supplier milk run routes for sorted deliveries acc. Kanban or Heijunka
tagged containers operated warehouse stock level per part
deliveries inbound parts to storage location board
Centralized planning JIS/JIT receiving with Flexible minimum
Smart containers JIT/JIS supply Warehouse network Auto-pull: Automatic
of milk run routes of pre-aligned order, all stock level according
2 with flexible according to with capacity-on- consumption-based
in and outbound parts linked to to real-time demand,
destinations production forecast demand call-offs
parts fitment points automated bin/pick
Smart single boxes Inbound supply Autonomous fleet No warehouse with Smart receiving, off- Call-offs steered by
Zero inventory, no
3 with flexible based on real-time with flexible dynamic warehouse- loaded box ready to machines based on
in-house storage
destinations demand destinations on-wheels be picked by AGV available capacity
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SMART FACTORY Quick Action Guide
Score your current processes in terms of the Internet of Things
8. Line supply 9. Line-side 10. Line-side parts 11. Training 12. Production 13. Production 14. Production line
Score
concept packaging presentation concepts transport concept layout concept capacity-balancing
Batch production,
Push supply/fork Parts presented in Line-side over-stock Operator trained to Separated stations No line balancing,
manual transport
0 truck deliveries (taxi containers/big with poor inventory perform single or separated process time limits
from station to
principle) loading units control operation production islands balancing capacity
station
Route trains/ 2-bin principles + Operator trained to One-piece-flow with Manual production
Parts stored in small Tacted lines with
1 Mizusumashi (bus dedicated location perform one station, in-transparent line balancing based
loading units/boxes automated transport
principle) for empty box several operations process flow on Yamazumi
One-touch material Operator trained to Straight production Process
AGVs deliver on Sequenced parts per Continuous flow
exchange/shooter operate on entire lines, high visibility of standardization
2 fixed and predefined box aligned to lines with dedicated
based on Trilogiq (or production line, processes and enables smart
routes production lot-size stations
similar) several stations operations operations shifting
No-touch material Operators trained to Product-to-operator: Obeyaka production Autonomous
Shopping baskets/kit
Free flow of exchange by perform cross- Continuous flow with concept without station-pool
3 per product, lot-size
autonomous AGVs autonomous AGV or functional flexible station fixed stations and utilization based on
of 1
similar operations allocation heavy fixtures real-time capacity
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SMART FACTORY Quick Action Guide
Score your current processes in terms of the Internet of Things
15. Total productive 17. Line changeover 18. Production 19. Product 20. Outbound 21. Sales and
Score 16. Product mix
maintenance (TPM) process scheduling standardization transport routing distribution
2 1
M T W T F
No preventive Single-model Single-model line
Weekly or daily Few standards in Fixed routes, local Sales de-coupled
maintenance. processes/lines without change-over
0 manual production product and route planning per from factory, acting
Malfunction result in without mixed of machine and
scheduling processes plant/customer autonomously
machine downtime models material
TPM board in place Mixed-model lines Levelled production Product standards Local planning of Planning based on
Change-over time
1 enabling preventive with several schedule with each enables first process milk run routes for weekly/monthly
less than 1 tact
maintenance products per line part every day standardizations outbound goods sales forecast
Predictive Products mixed One-touch change Levelled production Product and process Centralized planning Customer trends
2 maintenance based between lines, low over of machine and schedule with lot- standards enable of milk run routes considered at
on data analytics lot-size material size of 1 standardized plants for in and outbound production planning
Maintenance Models can be Autonomous Standardization
Autonomous fleet Smart distribution:
decision making mixed entirely, no production enables smart
Zero change-over, with flexible Sales focus on
3 based on real-time limitation to scheduling based on factory concepts
100% flexibility destinations and availability/inventory
data, machines production line real-time demand + with free-flow
customers level and lead time
acting autonomously concept available capacity process sequence
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SMART FACTORY Quick Action Guide
Scoring and result
Score* Rating Description
Poor standardization with a low level of flexibility of assembly processes.
0 - 20 Manufactory Single-model lines and non-transparent process flow. High degree of waste in
manufacturing processes.
Efficient process flow with high level of manual/analog processes and data
21 - 40 Lean Factory
processing (Kanban, Heijunka, etc.). Short lot-sizes and transparent processes.
Efficient process flow with a minimum lot-sizes according to customer
41 - 60 JIS/JIT Factory requirements. High level of manual/analog processes with partially integration
of smart digital solutions.
Elimination of all inventory with a high degree of autonomously acting and
60+ Smart Factory
automated machines and processes. High transparency.
*your total score of all 21 criteria of the SMART FACTORY Quick Action Guide (slide 3-5)
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