HKPC Smart Enterprise Practical Training

Smart Enterprise Practical Training series were organized by Hong Kong Productivity Council (HKPC) on 4^th & 24^th Sep and 15^th & 29^th Oct 2018.  I attended the training on 15^th Oct 2018 and summarized it as follows. In the beginning, HKPC Fraunhofer Certified i4.0 expert & trainer - Mr. Lyan Law (Lead Consultant, HKPC) was the first speaker and he introduced the whole training series, as well as, Hong Kong Federation of Innovative Technologies and Manufacturing Industries (FITMI).

Then Mr. Law introduced the INC Invention Centre – The Hatch opening on 11^th Oct 2018 and issued the first certificate for 1i to pilot company.  HKSAR CE had also attended after her policy address announcement on that morning.  

The second speaker was Mr. Henry Kwan (Trio Engineering) and he shared his local i4.0 case.  He introduced his company background that EMS provider established in 1983 and listed in HKEX in 2017.  He also briefed their product type evolution in three generations as follows:

1^st Generation – Winding & Transformer

2^nd Generation – PCBA and Assembly

3^rd Generation – Power supply & Security devices

Then he explained why they needed to go to i4.0 because of competitiveness, Branding and Global Trends. Strategic framework of i4.0 included Business Operation & Production, ICT and Enterprise Innovation.

Mr. Kwan based on HKPC strategic roadmap to develop their i4.0 adaptation.

The detail implementation and recognition schedule was discussed from 2016 to 2018.  

After that he briefed their information exchange model which was end-to-end digitalization.  Actually, it was a vertical integration from Toyota Production System (TPS), to Manufacturing Execution Systems (MES), to Enterprise Resource Planning (ERP), and then to Business Intelligence (BI).

Finally, he shared some problem they faced during project implementation.  He told us that their next step was toward 2i development.  

The third speaker was Ms. Sherman So (Business Solutions Manager, Epicor) and her topic named “Enablement to Industry 4.0 for Manufacturers”. 

She briefed the four Design Principles of Industry 4.0 included Interoperability (IoT), Information Transparency, Technical Assistance (Analytics & BI) and Decentralized Decision-Making (Automation).  

Then Ms. So briefed their solutions based on Industry 4.0 including Product Lifecycle Management (PLM), Enterprise Resource Planning (ERP) + Advanced Planning and Scheduling (APS), Manufacturing Execution Systems (MES) and Advanced MES (AMES), etc.

After that she demonstrated some cases including CAD Integration, APS, etc.  There were some methods to collect shop floor data such as manual/paper based time-sheets, Scanning bar-codes and direct from machines.  The following diagram showed their AMES network structure.

Lastly, she mentioned their real-time shop floor plan monitoring and quality control, as well as mobile monitoring demonstration.

The fourth speaker was Mr. Danny Lai (Senior Consultant, HKPC) and his topic named “Industry 4.0 Foundation: Digital Lean”.  

He first briefed TPS/Lean model and Lean Six Sigm - 8 wastes in the production value stream.  He demonstrated different example related to each waste below.

i)             Inventory: Intelligent logistic boxes for reordering (e.g. DAIMLER)

ii)            Motion: Real time material stream mapping (e.g. BOSCH)

iii)           Waiting: Real time visualization (e.g. TRUMPF)

iv)           Transportation: Quality data over the whole supply chain (e.g.BOSCH)

v)            Defects: Individualized serial production for polymer products (e.g. ARBURG)

vi)           Overproduction: Real time monitoring of assembly process by throughput detection (e.g. KARCHER)

vii)         Overprocessing: MES for CNC machine (e.g. KOMET)

viii)        Talent: underutilizing people’s talents, skills & knowledge.

Then Mr. Lai introduced HKPC & Fraunhofer maturity model and showed that Digital Lean was fundamental framework at 0i level.  

The Digital Lean framework was showed as following diagram that data driven for process optimization.  

The fifth speaker was David Lo (Senior Consultant, EM Division, HKPC) and his talk was “Factory Energy Management Systems”.  Firstly, he briefed the approach of online EnMS.  

The Online Energy measurement framework was described using Smart Meter and Internet Connection.  

Why need to measure energy consumption? He explained that the driving force was from government.  All factories faced this challenges.

After that he demonstrated some cases which energy (/electricity consumption) were measured and analyzed that could be automated diagnosis through machine learning because each equipment had unique energy consumption footprint.  

Before the end of the training, Mr. Louis Ho (HKPC) introduced Smart Industry One (SIO) to us.

Reference:

HKPC I4.0 (SIO) - https://www.hkpc.org/en/industry-support-services/support-centres/smart-industry-one

Related I4.0 Activities:

20150820: HKIE Seminar on Industry 4.0: The 4th Industrial Revolution - https://qualityalchemist.blogspot.com/2015/08/hkie-seminar-on-industry-40-4th.html

20160827: HKSQ Seminar on Future Manufacturing - https://qualityalchemist.blogspot.com/2016/08/hksq-seminar-on-future-manufacturing.html

20161111: HKSQ Seminar on Reliability & Maintenance: Enablers of Industry 4.0 - https://qualityalchemist.blogspot.com/2016/11/hksq-seminar-on-reliability-maintenance.html

20161116: HKSQ Study Mission for Industry 4.0 – Day 1: Visit to CSQ - https://qualityalchemist.blogspot.com/2016/11/hksq-study-mission-for-industry-40-day.html

20161117: HKSQ Study Mission for Industry 4.0 – Day 2: Visit to FineTek Group & King Design Industrial - https://qualityalchemist.blogspot.com/2016/11/hksq-study-mission-for-industry-40-day_17.html

20161118: https://qualityalchemist.blogspot.com/2016/11/hksq-study-mission-for-industry-40-day_18.html

20161119: HKSQ Study Mission for Industry 4.0 – Day 4: Attend to the International Symposium of Quality Management (ISQM) 2016 - https://qualityalchemist.blogspot.com/2016/11/hksq-study-mission-for-industry-40-day_19.html

20161212: HKSQ Seminar on Industry 4.0 – Taiwan Experience - https://qualityalchemist.blogspot.com/2016/12/hksq-seminar-on-industry-40-taiwan.html

20170109: IndustryConnect@Science Park – Industry 4.0 & Smart Living Solution - https://qualityalchemist.blogspot.com/2017/01/industryconnectscience-park-industry-40.html

20170913: HKSTP TecONE Seminar “Industry 4.0 and Its Potential Opportunities for Tech Companies” - https://qualityalchemist.blogspot.com/2017/09/hkstp-tecone-seminar-industry-40-and.html

20180530: FHKI Industrialist Forum 2018 - https://qualityalchemist.blogspot.com/2018/05/fhki-industrialist-forum-2018.html

20180903: HKPC Seminar on Hong Kong Industry towards “Industry 4.0” Deployment - https://qualityalchemist.blogspot.com/2018/09/hkpc-seminar-on-hong-kong-industry.html

20180914: Industry 4.0 Interactive League Platform - https://qualityalchemist.blogspot.com/2018/09/industry-40-interactive-league-platform.html