1. The global manufacturing community is lagging behind in its adoption of Fourth Industrial Revolution technologies.
2. More than 70% of companies are still stuck in “pilot purgatory”, while only a select group of leading manufacturers are able to deploy advanced manufacturing at scale, generating new value and customer experiences within the factory or across value chains.
3. To close this gap and accelerate a more comprehensive and inclusive adoption of advanced technologies in manufacturing, the World Economic Forum’s Shaping the Future of Advanced Manufacturing and Production platform has set up the Global Lighthouse Network.
4. This community of manufacturers shows leadership in using Fourth Industrial Revolution technologies to transform factories, value chains and business models, for compelling financial and operational returns.
5. To date, 90 manufacturing Lighthouses have been identified from different industry sectors, including 3 Sustainability Lighthouses.
6. They have embarked on a joint learning journey, partnering on collaborative projects, developing insights and incubating new potential partnerships.
7. The Weichai Power Company, a powertrain, vehicle and construction machinery producer in China, is an E2E Lighthouse that has achieved technology-enabled connectivity across multiple functions.
WEICHAI CASE: OPTIMIZING E2E PRODUCT DEVELOPMENT CONNECTIVITY
1. Faced with rising market competition, Weichai embarked on a plan to focus on “costs, core technologies and quality”, guided by an emphasis on customer satisfaction.
2. Zhiyue Cao, VicePresident and Chief Information Officer, explained that “with the application of new technologies, Weichai has gradually formed a smart R&D system, a customer-centric smart internet of vehicles (IoV), lean-oriented intelligent manufacturing management and flexible automated intelligent warehousing, all of which have enabled Weichai to achieve end-to-end, full value-chain connectivity”.
3. Through digital rapid modelling design, virtual development simulation and intelligent IIoT-based testing, Weichai has built an end-to-end product development system that has shortened new product development from 24 months to 18 months.
4. Using modularization and parametric design, designers are able to input model parameters, whereupon the system automatically pushes the most relevant modules or automatically generates new 3D and 2D models. Relative to traditional manual drawing, the product design reuse rate has increased by 30%.
5. Weichai’s engineers use virtual simulation technology to create digital prototypes for product design parameters. Simulation enables timely discovery and handling of design problems, reducing test costs by more than 20%.
6. Operators are able to carry out test-bench transformation, taking advantage of increased sensors that provide realtime acquisition and uploading of test results.
7. A mobile app allows for intelligent control of operations, reducing labour costs by 75%, shortening the R&D cycle by more than 20% and reducing design failure by 20%.
8. Yanpeng Zhang, a test worker and dispatcher, remarked that “we used to be able to monitor only one test bench in the lab. We also had to learn different monitoring software, and manually switch the monitoring parameters.
9. With the application of intelligent testing, we can monitor and manage multiple test benches on one screen … The system can predict test-bench failure and push the pre-warning to my mobile phone and mailbox in real time, so that I can eliminate the fauLt in advance.”
10. To better understand the performance metrics of engines in real-world operation, Weichai built an IoV system to collect real-time data on engine speed, fuel consumption and power under various working conditions.
11. Customer connectivity intersects with E2E product development as big data analysis shapes engine design using real vehicle data from actual user driving habits, road conditions and engine performance.
12. Feng Han, Deputy Director of the R&D Center, explained the impact: “Traditionally, engine R&D relied mainly upon the personal experience of design engineers, making it difficult to fully understand engine reliability after it is put on the market. With deep application of information technology and digital technology, traditional engine R&D is being subverted.”
13. Weichai’s emphasis on customer connectivity and E2E product development has also been reflected in post-market efforts. Weichai carried out four connectivity-powered initiatives to improve the quality of service.
14. First, an appbased car networking platform provides users with efficient service solutions including repair orders, customer support and satisfaction reports.
15. Second, a customer member management system builds loyalty through a membership system, articulates member rights and privileges and implements a point mall (including dynamics for collection and consumption of points).
16. Third, remote maintenance guidance conducts online fault diagnosis, assists on-site maintenance personnel, and saves time for customers. Engine maintenance time is reduced by 15%, saving 20% of document audit workload.
17. Finally, the generation of visual AR models for Weichai engines supports pre-sale technical exchange, engine assembly and after-sales maintenance guidance. Unrestricted by location or by the physical exhibition machine, this AR method improves training and on-site support while enhancing the company’s image.
18. This end-to-end linkage shows the power of interconnectivity of functions throughout the value chain, extending to the customer.
Source:
https://www.weforum.org/projects/global_lighthouse_network
https://www3.weforum.org/docs/WEF_Global_Lighthouse_Network.pdf
