World Class Manufacturing 4.0

World Class Manufacturing 4.0 Delta Model

Today’s standardization is the foundation upon which tomorrow’s innovations will be established. World Class Manufacturing (WCM) has long been the gold standard for achieving excellence in manufacturing processes. However, in today's era of rapid technological advancement, the integration of Fourth Industrial Revolution technologies has given birth to a new paradigm known as World Class Manufacturing 4.0 (WCM 4.0). This revolutionary approach is reshaping the manufacturing landscape, paving the way for a future where waste is minimized, efficiency is maximized, and innovation thrives.

Embracing the Fourth Industrial Revolution

WCM 4.0 represents the marriage of WCM principles with cutting-edge Fourth Industrial Revolution technologies. These technologies, including mobile technologies, cloud computing, artificial intelligence, and the Internet of Things, have already begun to transform the manufacturing sector. WCM 4.0 harnesses the power of these innovations to create intelligent, flexible, and distributed manufacturing systems.

One of the core tenets of WCM 4.0 is the integration of the entire manufacturing facility, providing real-time, accurate, and precise data for decision-making. This fusion of the virtual and real worlds enables manufacturers to achieve new levels of efficiency and productivity.

Digitalizing Standardization

Standardization has always been a cornerstone of WCM, and in WCM 4.0, it undergoes a digital transformation. The application of 6S principles (Safety, Sort, Shine, Set-in-place, Standardize, and Systemize) becomes digitalized, with work instructions published through digital media, field data captured through digital forms, and compliance with safety practices autonomously monitored through technologies like intenseye, an AI integrated into CCTV systems.

Automation and Real-time Monitoring

WCM 4.0 brings automation, streamlining, and real-time monitoring to group activities, resulting in a significant improvement in Overall Labor Effectiveness. Predictability of group activities, prioritization of tasks, and the introduction of digital labor in the form of cobots, humanoids, and intelligent assistance all enhance decision-making processes in manufacturing groups.

Effective Visual Management

Visual management in WCM 4.0 is highly effective, with graphical user interfaces (GUI) and human-machine interfaces (HMI) providing real-time access to a wealth of data and information on and off the shop floor. This visual approach creates a self-ordering, self-explaining, self-regulating, and self-improving workplace.

Data-Driven Improvement

The focused improvement (FI) pillar of WCM 4.0 utilizes data and information from structural elements to achieve its objectives. Real-time data management and processing, coupled with advanced analysis and simulations, such as Monte Carlo, enable a deeper understanding of risk and uncertainty in prediction and forecasting models.

Maintenance and Machine Learning

Both autonomous and planned maintenance pillars benefit from WCM 4.0. Routine maintenance activities are automated and delegated to robots, drones, and sensors, freeing up human capital. Augmented reality is employed for inspections, replacing traditional checklists. Machine learning optimizes maintenance practices, minimizes downtime, and extends equipment life spans through automated fault detection and diagnosis.

Revolutionizing People Development

WCM 4.0 introduces extended reality training techniques, providing employees with immersive learning experiences. Simulators enhance hands-on learning, boost confidence in real-world scenarios, and accelerate industrial learning.

Flexible Process Management

Process management gains improved flexibility in WCM 4.0. Faster decision-making processes with minimal costs allow for changes and improvements to be implemented swiftly. Technologies like artificial intelligence, cloud and quantum computing, and the Internet of Things enhance production efficiency and transparency, resulting in better-designed, optimized, and monitored processes.

Energy Management for the Future

Traditional industrial energy management focuses on efficiency, but WCM 4.0 takes it a step further. New data streams provide a better understanding of the relationship between energy use and operational settings. Manufacturing processes allow organizations to visualize energy demands, develop tailored energy consumption models, and implement data-driven prognostics. Cloud-based solutions benefit from the Internet of Things, revolutionizing energy management.

Environmental Sustainability

WCM 4.0 supports the safety, health, and environment (SHE) pillar by tracking and reducing waste generation and pollution. It monitors the environmental impact of manufacturing activities and ensures compliance with industry regulations. Human errors are reduced, costs are cut, and workplace safety is improved.

World Class Manufacturing 4.0 represents a transformative leap in the manufacturing sector. By embracing Fourth Industrial Revolution technologies, companies can achieve unprecedented levels of efficiency, innovation, and sustainability. WCM 4.0 is not just a glimpse into the future of manufacturing—it's a bold stride towards it. As manufacturers continue to adopt and adapt to these advancements, the possibilities for growth and excellence are boundless.