Production Management Certification Training, Module One

Process Choice

Order Winners and Qualifiers

Winners and Losers

Dramatic changes are occurring within the supply chain. We are entering what is called Industry 4.0. The following videos explain Industry 1 -3 and provides an expanded explanation of Industry 4.0.

Industry 4. 0

Industry 4.0 Implementation

Review the handout: Industry 4.0 Implementation.

Industry 4.0 Technologies

Next, we look at the technologies that make up Industry 4.0:

  • The Smart Factory
  • Cloud Computing
  • Internet of Things (IoT)
  • Robotics 
  • Blockchain
  • Predictive Analytics
  • Virtual Reality
  • 3D Printing
  • Advanced Materials
  • Nanotechnology 

The Smart Factory

The video mentions the term metrology. Metrology is the science of measurement, embracing both experimental and theoretical determinations at any level of uncertainty in any field of science and technology.

Cloud Computing

The Internet of Things

Internet of Things: Example: Asset Tracking

Review the handout: Internet of Things (IoT)

Predictive Analytics

Industry 4.0: Robotics

1. Industrial Robots

2. Collaborative Robots (Cobots)

    • Hazardous Environments
    • Repetitive Tasks
    • Material Handling
    • Material Handling/Put-Away

Industrial Robots

Cobots for Use in Hazardous Environments

Cobots for Repetitive Tasks

Note the short ROI on this cobot.

Cobots for Material Handling

Cobots for Picking and Material Handling

Review the handout: Robotics

Industry 4.0: 3D Printing

3D Printing: How IT Works

3D Printing: Applications

3D Printing: Line Application

3D Printing: Application

3D Printing: Large Custom Parts

3D Printing: Tools, Jigs, and Fixtures

 

Note the dramatic reduction in lead times and cost.  Short ROI is noteworthy too.

3D Printing: Application

3D Printing: Forecast 3D 

Forecast 3D provides industrial 3D printing, short-run manufacturing, and high-volume production services. They offer Additive and Digital Manufacturing technologies to include MJF (Multi Jet Fusion) by HP, SLA (Stereolithography) models, PolyJet high-precision color 3D printing, FDM (Fused Deposition Modeling) patterns in engineering-grade thermoplastics, DMLS (Direct Metal Laser Sintering) by SLM for additive metal parts, CNC Machining, and ProCAST RTV tooling for high-quality urethane castings.

They provide 3D printing and custom manufacturing to customers in a variety of industries. From a quick turn, intricate surgical device to a large intake manifold for a jet engine to a production run of 4,000 radomes, they have the technology and experience to deliver.

They operate the most innovative 3D Printing technologies available, coupled with extraordinary service and craftsmanship. 

Note about a third of the way into the video (:26-:30) the gentleman scanning a part into a cad program. Using this technology, you can send them a new or worn part, and they can create a cad model, replicate the worn areas of a used part, and 3D print the part for you, ideal if you are dealing with obsolete parts.
 

3D Printing: Protolabs

This company offers an online 3D printing service consisting of six 3D printing technologies to produce plastic, metal, and elastomeric parts and can deliver those parts within days. In addition to a broad material selection, they offer several post-processing options to improve cosmetics or enhance mechanical properties.

4D Printing is the Future of Design

4D Printed Structures Remember Their Shape

What Do 3D Printers Cost?

Desktop Options: $3,500 – $14,999
An Aluminum-replacement printer allows you to print in Onyx reinforced with Carbon Fiber, Kevlar, Fiberglass, and HSHT Fiberglass (high temperature), ideal for high strength, precision applications.

Industrial Options: $36,990 – $69,000
Higher precision and a larger build volume fit perfectly into manufacturing environments that demand highly functional, one-off custom parts. It offers a wide range of composite materials and various features for manufacturing professionals and the highest rate of return compared to any machine. Printing overnight gets your business a foot in the door to ‘lights-out’ manufacturing.

Advanced Industrial: $160,000 – $200,000 (All-in Cost)
Advanced Industrial 3D printers is a three-part system comprised of the Printer, Wash Station, and Sintering Furnace. It can print Stainless (17-4), Tool Steels (H13 and A2), and Inconel 625. In the next few months, also Titanium and Copper.

Review the handout: 3D Printing

Industry 4.0: Artificial Intelligence (AI)

Artificial Intelligence: What Is It?

Industry 4.0: Blockchain

Blockchain

Review the handout:  1. Capturing the Details of a Simple Transaction and 2. Blockchain.

Industry 4.0: Virtual/Augmented Reality

Virtual/Augmented Reality

Training Applications

Virtual/Augmented Reality

Design Applications

The technology shown in this video looks like science fiction but is being used by Nike to rapidly create, develop, and produce sneakers at an accelerated pace. The video switches back and forth between the old way of doing things (the woman running in a prototype sneaker) and the new way of testing the sneaker in virtual reality.

Virtual/Augmented Reality

Process Improvement

Terms You Might Not be Familiar With

SMEs: Small and medium-sized companies.

Vendor Education Center (VEC) Sandpit: The Sandpit methodology allows participants to access and explore the latest digital technologies in a safe, neutral, and technology-agnostic environment.

The VEC Sandpit effectively transfers the risk of digital experimentation out of the corporate environment and into the lab.

Collaboration is key. Engineers bring together their expertise with the company’s industry knowledge and explore digital tools, academic research, and access the latest digital infrastructure to enable digital innovation to help solve your business challenge.

Industry 4.0: Advanced Materials/Nanotechnology

Advanced Materials

Nanotechnology

This technology, combined with the capabilities of 4D printed material to repair itself, is of great interest to the aerospace industry. One of that industry’s biggest problems is inflight damage to the skin of an aircraft or spaceship. Once these technologies are perfected, bird strikes will no longer be one of their most common repairs.