Restructuring Existing Workforce
Towards Higher-skilled Workers.
Industry 4.0 – Centre Of Excellence
Leading the Factory of the Future
13 September 2017
2017.01.12/MarComm
INDUSTRY 4.0: Challenges in Malaysia
1 2
LOW INTEREST IN ENTRY-
THE
LEVEL JOBS
MIDDLE Population (eg General, Mundane,
CLASS Job Opportunities Repetitive Work, 3D-Related
Jobs)
3 4
HIGH
UNEMPLOYABILITY SMALL POPULATION
Prevalent Among Non- (30 MILLION)
Engineering and Low Consumer Utilisation
‘Relevant’ Information High labour Cost Due to
Technology Graduates, Less Competition
which Covers 85% of
Graduates.
INDUSTRY 4.0: Solution for the above challenges.
PSDC ROLE: TO ADDRESS 2 KEY ISSUES
SME as Support Pillar for Industry 4.0 Talent
- To be led by SMEs, not by Principals Current Future
Pneumatic Pneumatic
Hydraulic Hydraulic
Electrical Electrical Motor
Motor Simulation &
Supply Chain Industrial Internet Horizontal &
of Things Vertical Integration Augmented Reality
Horizontal & Vertical
Integration
Industrial Internet of
Things
Cybersecurity Cloud Big Data Analytics
Cybersecurity
Cloud
Additive
Manufacturing
Supply Chain
Autonomous Simulation & Additive
Robot Augmented Reality Manufacturing Big Data Analytics
Autonomous Robot
THE 11 TECHNOLOGY PILLARS
INDUSTRY 4.0: HUMAN CAPITAL
Distinct abilities in complexity management, Qualification for short-term and less predictable
problem solving and learning aptitude as well as activities
high flexibility
Interdisciplinary experts with comprehensive IT
knowledge and in-depth expertise in processes, Planning, control and analysis as work priorities
production and logistic
INDUSTRY 4.0: TECHNOLOGY Vs SKILL
Cyber-Physical
Mechanisation Electrification Digitalisation System (CPS)
Mechanical Mechatronics Automated CPS
System System System System
TECHNOLOGY COMPLEXITY
Embedded ICT
communicate
with Physical
IT & IP things
numerical-digital
controls/CNC,
PLC IT & IP
Electronics Electronics Electronics
Mechanical Mechanical Mechanical Mechanical
Assemblies Assemblies Assemblies Assemblies
DEVELOPMENT OF NEW EMERGING TECHNOLOGIES SKILLS
INDUSTRY 4.0: GOVERNMENT
KEY ACTIONS NEEDED
NATIONWIDE
MAXIMIZE JOB STRATEGIC
PROMOTING & REVIEW, REVISE
CREATION ROAD MAP
ENFORCEMENT POLICIES
THROUGH I4.0 ACROSS
MINISTRY
INDUSTRY 4.0: INDUSTRIES
KEY ACTIONS NEEDED
ADAPT & ADOPT STRATEGIC
RETRAIN/UPSKILL
NEW ORG INDUSTRY 4.0 WORKFORCE &
CURRENT
STRUCTURES & RECRUITMENT RETENTION
EMPLOYEES
CULTURE PLANNING
INDUSTRY 4.0: EDUCATION
KEY ACTIONS NEEDED
BROADER NEW
SKILL SET CLOSE THE IT FORMAT FOR HYBRID
(MULTI- SKILL GAP FURTHER PROGRAM
DICIPLINE) STUDY
INDUSTRY 4.0: TRANING STRATEGY
TALENTED & COMPETENT
WORKFORCE
(SMART PEOPLE)
INDUSTRIES GRADUATES TERTIARY
(UNEMPLOYED) (TVET & ACADEMIC)
INDUSTRY 4.0: TRANING STRATEGY
ORGANIZATION
Corporate Culture • Industry 4.0: Leading the factory of
the future
• Corporate Framework • Industry 4.0: Balancing ROI &
INDUSTRIES • Strategic (Vision, Mission) Productivity improvement
Program Management • Industry 4.0: Step 1 to 6
TOP DOWN
• Predictive Maintenance through
• Master project planning Industry 4.0
• Project deliverables • IT for OT (Non-IT)
• IoT design using Adriano /
Execution Raspberry
• Project lead • 2D AR Design Lab
• Sustainability • Advance Image processing
Architecture
• Industry 4.0 National Conference
• PSDC member’s
sharing/competition
INDUSTRY 4.0: TRANING STRATEGY
ACADEMIC LEVEL
SECOND DEGREE • Statistical data modelling for
• Data Scientist predictive action plan
GRADUATES • Strategic System Integrator • Industrial technology & challenges
FIRST DEGREE • Augmented Reality system
TOP DOWN
development for 2D & 3D
• System Developer/Designer • Cyber security for SSL,HA for IoT
• Cloud/Cyber security experts embedded system
DIPLOMA/CERT./TVET • What is predictive maintenance?
• What is M2M interconnectivity?
• Industry Specialist
• Robot system programming &
• Automation & Robot Specialist safety
• Special grant for Industry 4.0
entrepreneurship among
unemployed graduates
INDUSTRY 4.0: TRANING STRATEGY
ACADEMIC LEVEL
SECOND DEGREE
• Data Scientist
TERTIARY • Industry 4.0 System Integrator
FIRST DEGREE
TOP DOWN
• Product Developer/Designer
• Cloud/Cyber security experts
DIPLOMA/CERT./TVET
• System Integrator Specialist
• Industrial IoT Specialist
• Industrial Trainee program @
Industry 4.0 compliance site
INDUSTRY 4.0: FRAMEWORK
DSN - BLOCKCHAIN
IaaS
Private
PaaS
Public
Hybrid
SaaS
Supplier Manuf’rg Customer
NETWORK
Measure
Analyse
Act
SENSORS & ACTUATORS
TECHNOLOGICAL TOOLS
INDUSTRY 4.0: & THE PILLARS
WHAT IS IT? TYPICAL APPS BENEFITS
o Digital Supply Chain Network (DSN) o Manufacturing process o Zero Defects
o Digitalization of the supply chain o Digital Value Stream Mapping (DVSM) o Zero variance
o Fully integrated o Digital Spaghetti Mapping o Reduce man hours and man power
o Multi-Directional End To End o On Time Delivery o Real time decision making process
o Real-time data exchange o TIMWOOD reduction o Increase productivity & efficiency
o Fully integrated Supplier to Customer o High Value Adds o Achieve Digital LEAN manufacturing
o Improve OEE & Business performance
o Horizontal: Integrate through o SAP Hana, Oracle o Zero variance
network & value chain from o Shop Floor system o Reduce man hours and man power
Suppliers, the company itself, and the o ERP (Enterprise Resource Planning) o Real time decision making process
customers. o MES (Mfg Execution System) o Increase productivity & efficiency
o Vertical: Integrate through network & o Paperless Lot traveller o Achieve Digital LEAN manufacturing
value chain across functional o RFID tag o Paperless & fully digitalize
department ie.,Sales, R&D, o Data, information, location
Procurement until customer services.
o The used of IoT in the industrial o Critical process , machine, o Reduce man hours and man power
apps products parameter monitoring o Real time decision making process
o Interconnectivity between sensor o Self correction and adjustment o Increase productivity & efficiency
via cyber physical system closed loop control system o Ability to perform Big Data Analytics
o Complete cycle involve Measure, o Self optimization and improvement o Data for Predictive Analytics
Analyse and Act (MAA) o Closed loop system monitoring and
o Sensor replace human (ears, eyes, control
nose, touch, etc.)
o Allows M2M and M2H
communications & data exchange
INDUSTRY 4.0: & THE PILLARS
WHAT IS IT? TYPICAL APPS BENEFITS
o Robot that work independently o Loading & unloading of materials o Zero Defects
o Interconnectivity & interoperability o Inspection o Zero mistake & zero discipline issues
o M2M & M2H communication o Logistic of materials o Reduce man hours and man power
o Collaborative robot with Human o Hazardous operation o Increase productivity & efficiency
o Warehousing management o Improve OEE & Business performance
o Assembly, test o Optimize layout
o Drone, COBOT, Industrial Robot, o Eliminate people manager time
AGV, Mobile Robot o No human constraint opn
o Replace foreign worker
o Simulation: 3D simulation by merging o Gaming o Paperless organization
virtual and physical world together. o Non Gaming: Navigation, o Security & Proprietary control
o Augmented Reality: Its an Marketing, Repair & Maintenance, o Interactive learning process
environment that includes both Operating Method, Supervisory o Simplify problem solving approach
Virtual Reality and the Real world Tools, Education, Training o Real time merging of data,
information & action
o Improve compliance to regulatory
standard
o New innovation & skills
o A process by which digital 3D design o High-mixed Low-volume products o Fast turn around time
data is used to build up a component o Consumer & industrial apps o No need to stock up materials
in layers by depositing material. o Obsoleted spare part, JIT parts o No design constraint anymore
o The term ‘3D printing’ is increasingly o Metal: Stainless steel, palladium, o Eliminate components assembly
used as synonym for AM. aluminium, titanium o Eliminate waste from Subtractive
o Plastic: Polyamide, prime grey, Manufacturing
transparent resin, ABS o Support personalization and mass
o Fused Deposition Modelling (FDM) customization new demand patterns
o Stereo lithography
o Powder, Liquid and Solid materials
INDUSTRY 4.0: & THE PILLARS
WHAT IS IT? TYPICAL APPS BENEFITS
o A technologies, processes, & o System, network, program, data o Zero downtime
practices designed to protect o BYOD for personal devices o Zero loss (money, resources)
networks, computers, programs, , o Internal & external treats o Security & privacy
data & machines from attack, o Cyber terrorism, hacking, ransom o Protection of confidentiality of
damage, or unauthorised access. ware, malware, virus attack sensitive, highly classified
o It includes all aspect of inter- o IIoT system protection information
connected devices, machines & o Firewall, System patching,
systems in whole ecosystem encryption of password,
penetration test and etc.
o A model for enabling ubiquitous, o Apps o Zero Capex & internal resources
convenient, on-demand network o Data o Broad network access
access to a shared pool of o Runtime o Rapid elasticity & development
configurable computing resources (eg o Middleware o Measured service
networks, servers, storage, o O/S o On demand self service
applications, and services) o Virtualisation o Shared service & scalable
o Service models: SaaS, PaaS, IaaS o Servers o Resource pooling
o Deployment model: Public, Private, o Storage o Location independence
Hybrid o Networking o Zero upgrade cost
o Big data analytics is the process of o Diagnostic, Descriptive, Predictive, o Reduce man hours and man power
examining large data sets to uncover Prescriptive Analytics o Real time decision making process
hidden patterns, unknown o Repair & maintenance o Increase productivity & efficiency
correlations, market trends, customer optimization – reduce major o Data automation
preferences, and other useful breakdown & spare part o Closed loop system monitoring and
business information. management control
o The analytics is a form of data o Customer demand pattern, trend o Drive for positive business results
automation for accurate and fast & preference o Dashboard ream time visibility
decision making process o Process, products & industrial
data, information analysis
INDUSTRY 4.0: Roles &Responsibilities
CURRENT INDUSTRY 4.0
Fire fighting Data driven
Manual data tracking & analysis BIG Data & auto analysis
Manual recording Electronics data pull
Reactive problem solving Proactive problem solving
+
Human dependant operation
Just focus on IT
Autonomous machineries
Need to know operation
Outsourced to 3rd party In house expertise
CLOUD adoption CLOUD and integration to IIoT
General IT System integrator (S/H/SI)
+ Centralisation Cross functional
Lack of operation knowledge Must well verse with operation
Fragmented system Integrated system
Too much of paperwork Electronics based system
+
Document for compliance
MBO (Management By Obj.)
Auto reporting for compliance
MBD (Management By Data)
On site, Remote Virtual but Visible
Micro & Macro Managing SMART Management
TRUST on PEOPLE TRUST on DATA
TEAM
NEW PARADIGM CONVERGENCE OF OT + IT
INDUSTRY 4.0: Best things to happen to Malaysia
• I4.0 will address high un-employability and growing middle
class populations.
• Jobs for non Engineering & Information Technology
graduates.
• I4.0 will address Influx of Foreign workers.
• Automation and digitization will replace foreign labours
• High Degree of complexity in manufacturing and High
Labour cost.
• The manufacturing can stay in Malaysia.
• Only if we choose to address the challenges collaboratively
and systematically.
Thank You
[Link]
PSDC | 1, Jalan Sultan Azlan Shah, Bandar Bayan Baru, 11900 Bayan Lepas, Penang, Malaysia