Quality Alchemist (品質煉金術師): HKSQ Seminar on Future Manufacturing

2016年8月27日星期六

HKSQ Seminar on Future Manufacturing

The HKSQ seminar named “Future Manufacturing – Industry 4.0, Made in China 2025 and Internet+” co-organized by Hong Kong Society for Quality (HKSQ) and SEEM Dept., CityU on 27^th Aug 2016. Industry 4.0, Made in China 2025 and Internet+ are the trend of future manufacturing. Dr. YC Chau was invited to share his view on those elements and update after HKIE seminar on Industry 4.0 held one year ago. Before the seminar, I (HKSQ) took a photo with my old friend Ir. Dr. YC Chau and Dr. CF Luk.

Dr. KS Chin represented SEEM Dept., CityU to give welcome speech. Dr. Chin encouraged industrial professionals could study for research degree like Dr. YC Chau.

Then Mr. Peter Fung (Chairman, HKSQ) gave an opening speech and introduced HKSQ to all participants. This year is also our society 30^th Anniversary.

After that I introduced Dr. YC Chau to all and briefed his background. Dr. YC Chau graduated from PolyU and received MBA from University of South Australia, as well as, PhD from SEEM Dept., CityU. Dr. Chau had been working in TDK (Tokyo Denki Kagaku) Corporation since 198, where he was currently the Vice President of China Operation Improvement Group. He was also an Adjunct Professor and Industrial Adviser with CityU. Moreover, he was member of HKIE, Senior member of IIE and member of IET.

In the beginning, Ir. Dr. YC Chau (Vice President, China Operation Improvement Group, TDK) introduced the background of Industry 4.0. He had written an article entitled “Industry 4.0 with Implications for Made-in-China 2025” in HKIE magazine named “Engineer” Vol 44, May 2016. He also briefed the history from the 1^st to 4^th Industrial Revolution. He said Industry 4.0 was not equal to the 4^th Industrial Revolution but they happened at the same time. Industry 4.0 was only Germany Manufacturing Strategy.

Then Dr. Chau briefed USA stated White House SMART Manufacturing, Japan mentioned Factories Connected Together, China has talking about Made in China 2025, and Germany promoted German Manufacturing DNA. He mentioned China economic had achieved over England and reaching USA (超英趕美). Dr. Chow agreed with SIEMENS Vision of Industry 4.0 that “A vision of tomorrow’s manufacturing: Products finding their way independently through the production process. In intelligent factories, machines and products communicate with each other, cooperatively driving production.”

Dr. Chau introduced three Key Technology of Industry 4.0 and they were Big Data, Internet of Things (IoT) and Cybert Physical Systems (CPS). He said we collected big data within workshop which could be changed from Preventive Maintenance to Predictive Maintenance. Then he showed video of Pizza example (In Chinese) in which demonstrated how accuracy sale in future.

IoT connected among Supplier, Manufactor, Distributor and Customer; and formed IoT supply chain migration with cost opportunities. He used Video of Intel’s Vision of IoT to demonstrate IoT concept.

He then stated Cyber Physical System (CPS) in which 3C model of CPS was mentioned where 3C for Computation, Communication and Control. Dr. Chow said employing CPS was very expensive and one example was MTR Operations Control Centre.

He told us MTR should be no need to have driver actually but citizen had not ready to accept it. Another application was Off Line Equipment Diagnostic such as CPS Opportunities in Jet Turbine. He said airplane could be hijacked through internet theoretically; therefore, airplane companies hadn’t shared all information online.

Another example was Baidu Smart Chopsticks. Many applications were related sensor. So the sensors would become smaller, cheaper, more versatile and it could measure more data and interact with each other.

Dr. Chau said from the integration of Big Data, IoT and CPS, we got from Industrial 4.0 was “4S” where 4S stands for Smart Factory, Smart Products, Smart Process and Smart Services. Dr. Chow concluded that Industrial 4.0 goal was seamless manufacturing through a merging of industry and IT, machines and systems would gain the flexibility to adapt to today’s rapidly changing processes.

In addition, he said Real Time Overall Equipment Effectiveness (OEE) System would be achieved using the Framework included Vertical and Horizontal Integration Manufacturing Execution System plus ERP system. After that he introduced the further business opportunities through “System of Systems” (SoS). Dr. Chau asked us two things should be considered in Industry 4.0 that was Human Position and Quality Role.

The 2^nd part introduced Internet+ and Made in China 2025. Dr. Chau quoted China’s Premier Li Keqiang announcement about Made in China 2025 in earlier March 2015 in Beijing. The program was created to drive smart technology in China’s manufacturing plants. He said China was pursuing an “Internet Plus” action plan that seek to drive economic growth by integration of Internet Technology with Manufacturing and Business. Then Dr. Chau explained the reason of Internet+ using Asia Pacific Internet Speed data that China was very low speed in 2015. Singapore and Hong Kong were number 1 and 2. Therefore, Hong Kong had our own advantage using internet.

Based on Premier Li’s report, “Internet Plus” entailed integration of Mobile Internet, Cloud Computing, Big Data and Internet of Things (IoT); which included modern manufacturing, fostering new industries and business development (e.g. e-Commerce, Industrial Internet and Internet Finance). That transformed from “+ Internet” to “Internet +”. The following diagram demonstrated what Internet + different industries which created different products / services.

After that Dr. Chau introduced “Made in China 2025” that was the first 10-year action plan designed to transform China from a manufacturing giant into world manufacturing power. The three step strategy was shown as follows:

2015-2025: From Manufacturing Giant (工業大國) to World Manufacturing Power (工業强國)

2025-2035: Form Elementary Level to Medium Level

2035-2049: Leading Manufacturing Power which marks (the 100^th anniversary of the founding of PRC)

“Made in China 2025” had 5 key engineering areas, included “Innovation Center”, “Smart Manufacturing”, “Self-sufficiency in Infrastructure”, “Green Demonstration Projects” and “Indigenous R&D”.

Dr. Chau said Hong Kong had many SMEs but they hadn’t capability to implement Industry 4.0 but one thing his suggested to following the China strategies and used our advantages to find opportunities. The 10 sectors of “Made in China 2025” were “New Information Technology”, “Numerical Control Tools”, “Aerospace Equipment”, “High-tech Ships”, “Railway Equipment”, “Energy Saving”, “New Materials”, “Medical Devices”, “Agricultural Machinery” and “Power Equipment”.

Moreover, Dr. Chau also mentioned the Nine Tasks as follows:

- Improving Manufacturing Innovation

- Integrating Technology and Industry

- Strengthening the Industrial Base

- Fostering Chinese Brands

- Enforcing Green Manufacturing

- Promoting Breakthroughs in 10 Key Sectors

- Advancing Restructuring of Manufacturing Sector

- Promoting Service Oriented Manufacturing and Manufacturing-related Service Industries

- Promoting International Manufacturing

And then Dr. Chau compared Germany Industry 4.0 and Made in China 2025 that they were same as National Strategy. The difference was showed as follows:

For Industry 4.0, it focused on the development of fully-automated “Smart Factories” that made products fully customization.

For Made in China 2025, it span the whole manufacturing industry to apply advanced idea not only form Germany but also from the US and Britain among others.

Dr. Chau told us China government had draft the National Smart Manufacturing Standard consultation paper in October 2015 and the guideline (國家智能製造標準體系建設指南) was published in August 2016.

Then Dr. Chau showed the video about the bearing made in Germany and China that indicated the level difference. We need to catchup the gap as soon as possible.

Finally, Dr. Chau said the road to be Manufacturing Power was difficult. When others walk, we need to run. Others run, we need to fly!

In Q&A Session, many questions were discussed.

Mr. Edmond Cheung asked how SMEs started Industry 4.0 because of resource limitation. Dr. Chau said it depended on their need. The start part could be some existing manufacturing equipment data such as micro real time OEE.

Dr. Aaron Tong said the short product life cycle and system changed so fast that could be difficult to adopt such standardization. Dr. Chau agreed that we needed more flexibility and customization. He quoted Nike sport shoes as example that they could employ 3-D printing technology and tail-made a sport shoes for each customer.

Mr. Peter Fung asked how Hong Kong achieved reindustrialization. Dr. Chau said most SMEs in Hong Kong seek for surviving and he advised SMEs based on their own capability to adopt different position under China policy.

Finally, I gave close remark and added a comment that quality consultant could provide a service for evaluating manufacturing plant to achieve which industry level and could adopt what kind of Industry 4.0 technology.

At the end, Mr. Peter Fung (Chairman, HKSQ) presented a souvenir to Dr. YC Chau. It was a very successful seminar and there were 50 participants.