Seminar Nasional Teknik Industri 2017 Batu-Malang

INDUSTRY 4.0
The Challenges of Tomorrow

DRADJAD IRIANTO
Manufacturing Systems Research
OUTLINE

PENDAHULUAN
INDUSTRIAL REVOLUTION
i2.0 i3.0
i3.0 i4.0
i4.0 for INDONESIA
IE SUBJECT for i4.0
FUTURE PROFESSION

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PENDAHULUAN
Skema penelitian Lab Sistem Produksi ITB
1998 Internet
Technology

FTP WW W Telnet Email Usenet Gopher IRC

Engineering Commerce Educational/ Service . . . . . . . .

Training Industry
Application Sectors

Advertising Information On-line Customer . . . . . . . .

Services Shopping Services

Design Information Engineering VRML Control/ . . . . . . . .

Support Management Collaboration Simulations Monitoring/
Maintenance
Application Cases

Seminar Sistem Produksi (SSP) 3-4 Dec 1999, tema Menuju

sistem manufaktur tangkas dan pola jaringan kerjasama 3
PENDAHULUAN
The International Academy of
Production Engineering (CIRP)
describes manufacturing system as
having an integrated group of functions,
i.e. marketing, product design,
process design, production planning,
production process, and delivery to
customer (Caggiano, 2014 )
Are these functions still relevant to
Industry 4.0? 4
PENDAHULUAN
Industry 4.0 defines as:
An approach to control production process by
providing real time synchronization of flows
and by enabling unitary & customize
production (Kohler & Weiz, 2016)
A general concept enabling manufacturing with
elements of tactical intelligence using
advanced IOT, cloud & big data technology
(Trappey et al., 2016)
Internet & supporting technologies serve as
backbone to integrate physical objects, human
actors, intelligent machines, product lines and
processes to form a new kind of intelligent,
networked and agile value chain (Schumacher,
Erol & Sihn, 2016) 5
PENDAHULUAN
The German Telecommunication
Association reveals more than 100
different definitions of Industry 4.0 (Bidet-
Mayer, 2016).
A generally accepted definition of the
term does not exist (Hermann, Pentek,
& Otto, 2015).
A generally accepted definition has not
been published so far (Bauer et al.,
2014). 6
PENDAHULUAN
The main objectives of i4.0:

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PENDAHULUAN
Economic benefit of i4.0:
Germany: 30% productivity increase,
2,6% cost reduction/year, 425B economic
growth by 2025.
South Korea: 25% productivity increase,
27% decrease of defectives, >0,5M jobs
created, build 10k smart factories
India: 9% increase in GDP (contributed by
manufacturing industries).
France: create 137k jobs in big data,
double nano electronics production
Source: Deloitte, 2017.
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PENDAHULUAN
I4.0 initiatives for given industries:
Industrial manufacturing: Germany, China,
S.Korea, Japan, India, Spain, USA
Electronics & ICT: Germany, S.Korea, Japan,
China, India, Taiwan, S.Africa
Automotive: Germany, S.Korea, Japan, UK,
USA, Portugal, S.Africa
Chemicals: China, France, India, UK
Pharmaceuticals: France, India, UK, Spain
Fashion apparel: S.Korea, Spain, USA,
Portugal
Source: Deloitte, 2017.
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PENDAHULUAN
i4.0 strategy based on:
Opportunities:
innovation ecosystems,
competitive industrial base,
investment on technologies,
integrate SME & enterpreneurship
Challenge:
industrial readiness,
Skilled trusted workforce,
manageable social-cultural-regulation,
diversification & job creation

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PENDAHULUAN
Manufacturing Competitiveness Index

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REVOLUSI INDUSTRI
i-
Cyber-Physical
Internet of things
Collaborative
manufacturing

Mass production
Interchangeable parts Industry 4.0
Quality control
Standardization Industry 3.0
Mass customization
Industry 2.0 Flexible Manufacturing
Computer integrated
Automation & robotic

Industry 1.0
Revolusi industri
e-
Mekanisasi produksi

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INDUSTRY 2.0
INDUSTRY 3.0
Designed
Satisfaction? Utility/
Quality
Market
? specifications
Set price Price
Profit ROI (Profit)
Total cost Target cost
Finished Finished
good good
Processes Processes
Raw Raw
material material
MASS PRODUCTION MASS CUSTOMIZATION

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INDUSTRY 2.0
INDUSTRY 3.0
ENABLERS:
Kualitas, biaya & waktu pengiriman (QCD) sebagai
kunci daya saing industri
Teknologi mikroelektronika, komputer & control
DEVELOPMENT:
Flexible Manufacturing Systems (FMS): Production
automation & robotic, CAD/CAM, ASRS/AGV, CNC
machines, computer integrated manufacturing CIM,
ERP
Product variety, multi-skilled trusted worker, design
engineering

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INDUSTRY 2.0
INDUSTRY 3.0
Industrial automation & robotics

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INDUSTRY 3.0
INDUSTRY 4.0
More on value creation & cost
reduction
Designed Designed
Quality Quality
Market Value added k
specifications
Price Price

ROI (Profit) Value added

Target cost Target cost

Akumulasi biaya
Process k
Finished good Value added 2
Process
Processes Process 2
Value added 1
Raw material Process 1

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INDUSTRY 3.0
INDUSTRY 4.0
More on value creation & cost
reduction
Core competence on process & Designed
Quality
Industry K
worker
Core competence k
Price

Industry
Core competence
Target cost

Akumulasi biaya
Process k
Industry B
Core competence 2
Process

Process 2
Industry A
Process 1
Core competence 1

Value chain, networked, collaborative

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INDUSTRY 3.0
INDUSTRY 4.0
SIPOC
Demand Pull

Outsourcing
Outsourcing + Internet connection
Outsourcing
2 2 2
g g g
Var ( y ) Var ( x1 ) Var ( x2 ) ... Var ( xn ) 18
x1 x2 xn
INDUSTRY 3.0
INDUSTRY 4.0
Internet
connection
INPUT PROCESSES (OUTSOURCING, GLOBAL) OUTPUT

Vendor &
retailers
Industry C
Industry A
Industry B

Industry K
Industry D
Suppliers Industry

Networked &
collaborating Industries

Production processes and products are being digitized (cyber physical);

manufacturers, suppliers and customers are establishing closer networks, and innovation
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cycles are being reduced.
 INDUSTRY 3.0
INDUSTRY 4.0
Process outsourcing: a process selection model
Existing sytem

Stage 1 Stage i Stage N

Scrap 1 Scrap i Scrap N

Process 1 Process 1 Process 1

Rework 1 Rework i Rework N

alternative

Stage 1 Stage i Stage N

Scrap 1 Scrap i Scrap N

Process 1 Process 1 Process 1

Rework 1 Rework i Rework N

Scrap 1 Scrap i Scrap N

Process j Process j Process j

Rework 1 Rework i Rework N

Scrap 1 Scrap i Scrap N

Process M Process M Process M

Rework 1 Rework i Rework N

Jerusalem et al., 2015 20

 INDUSTRY 3.0
INDUSTRY 4.0
Process outsourcing: a process selection
optimization mathematical model to maximize profit
Quality loss
Cost of manufacturing

Cost of process
improvement N M N M
2 2
Y t
ij x
p i
I cm x A I ij
i 1 j 1
i ij ij
i 1 j 1 X i X i 3

N M
N M
f i R rijR R R R
Max P U .I ( N 1) Qij xij I i 1 c ( f i rij ) xij
i 1 j 1 i 1 j 1

1 f i rij
R

R i

N M S S S
I i ci ( f i rij ) xij
i 1 j 1
Sales

Cost of scrap Cost of Inspection

Jerusalem et al., 2015 21
INDUSTRY 3.0
INDUSTRY 4.0
ENABLERS:
Computing power, storage capacities, data analytics,
networking ability,
Internet security & trust for collaboration
DEVELOPMENT:
Collaborative manufacturing, shared manufacturing,
strategic production network, project based
manufacturing systems, i-logistics, i-commerce
Compatibility, interoperability, traceability,
standardization, multi-skilled trusted worker
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DEVELOPING i4.0 for
INDONESIA
i4.0 Implementation Roadmap:
GOALS: industry development, technology
innovation, productivity improvement, inclusion for
SME
WHERE TO PLAY: potential sector (automotive,
ICT, etc.), technology choices (robotics, cloud, AR,
3D printing, etc.), area of application choice
(production, logistics, etc.), geography domain
(global, regional, local)
HOW TO WIN: execution focus choice
(government, corporation, SME, etc.), enabler
choice (policy, infrastructure, R&D, market, etc.) 23
IE SUBJECTS for i4.0
Which subjects that are still relevant?

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FUTURE PROFESSION
Will IE profession be survive?

New (future) job roles

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FUTURE PROFESSION

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TERIMA KASIH
The critical parameters in the introduction of i4.0 are the
design of the process landscape and the identification of the
employee qualification profiles (KPMG, 2016)

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