INTRODUCTION FOR  INDUSTRY 4.0 – 11 TECHNOLOGY PILLARS THE STEPS TO ACHIEVE THEM
For nearly five decades, the manufacturing sector has been Malaysia’s economic backbone, with states like Penang, Selangor and Johor having a big chunk of their income from manufacturing. Backed by Malaysian visionaries in the 1970’s, we turned a mostly agriculture and resource based economy into a sprawling industrial hubs with investments from multinational giants such as Intel, Osram, BBraun, Robert Bosch GmbH, Infineon, Jabil Inc, Dell Inc, Dyson and Panasonic. Together with the MNC’s, our SME’s grew earning their stripes to become large local companies (LLCs). Today, there are more than 3,000 SMEs supporting the MNCs and LLCs in the supply chain ecosystem in Penang alone. However, most SME’s do not seem keen to move up the value chain to support the MNC’s drive towards Industry 4.0. This is a worrying trend for the Malaysian manufacturing industry and this workshop plans to address this gap in a simple but detailed manner.

COURSE OBJECTIVES

• The importance of Industry 4.0 for your KPI, company & Malaysia
• Eleven technological pillars in Industry 4.0
• Understanding how the system integration works between the various aspects of Industry 4.0
• Steps to implementing Industry 4.0 at your workplace
• Challenges to be expected & how to overcome them
• Successful case studies

PREREQUISITE

• None.

METHODOLOGY

• Videos
• Activities
• Sharing of success stories

DURATION 
Two days

INTENDED AUDIENCE 

• Section Managers
• Department Heads
• Managers
• Directors
• CEO’s, COO’s
• Company owners

COURSE CONTENT
DAY 1

• What is Industry 4.0 and its importance for your KPI, company and Malaysia ?
  • The origin of Industry 4.0
  • The impact of Industry 4.0 in terms of Safety, Quality, Cost & Delivery
  • Industry 4WRD – Malaysia’s Policy on Industry 4.0

•  Eleven pillars of Industry 4.0 that are transforming industries in Malaysia
• • Big data & analytics
  • Autonomous robots
  • Simulation
  • Horizontal & vertical system integration
  • The industrial Internet of Things (IoT)
  • Cybersecurity
  • The Cloud, Edge and Fog computing
  • Additive manufacturing
  • Extended Reality (Augmented Reality-AR, Virtual Reality-VR & Mixed Reality-MR)
  • Supply Chain
  • Artificial Intelligence

• Advantages & disadvantages of each technology to your organization

• Implementation steps
  • Big data analytics dashboard & top management vision
  • Training the workforce & embracing culture change
  • Setup pilot line
  • Planning full implementation
  • Plant wide implementation & repeat steps 1 – 5

• Step 1 – Big data analytics dashboard & top management vision
  • Change is inevitable – setting the positive change culture from top down
  • Project charter
    • Mission
    • Vision
    • Internal application or new source of revenue
  • Establish KPI’s & dashboard
  • Establish budget & strategy
  • Organization chart changes (where appropriate)

DAY 2

• Step 2 – Training the workforce & embracing culture change
  • Using IoT to converge IT & OT
  • Machine, automation and linking it to business goals
  • Training approach using augmented reality
  • Organization wide training plan

• Step 3 – Setup pilot line
• • Conditions for selecting a pilot line
  • Establish Team Members, roles & responsibilities
  • Identify critical processes and machine parameters
  • Set baseline & targets
  • Establish big data structure & data collection inputs
  • Connecting input and output parameters
  • Establish connectivity
  • Identify & fix root causes
  • Check dashboard results (actual vs target)
  • Genba by management

Step 4 – Planning full implementation

• Next focus areas
• Resource planning
• Establish final dashboard & KPI’s
• ROI analysis
• Risk & opportunity assessment
• Top management review & setting direction
• Vendor selection
• Compliance to standards & other regulatory requirements
• Seeking customer approval & notification

•  Step 5 – Plant wide implementation & repeat steps 1 – 5
  • Horizontal vs vertical integration & implementation plan
  • Establish standards and training plan
  • Paperless organization

• Control phase

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