The so-called Industry 4.0 is by its agitators commonly denoted as the fourth industrial revolution and promises to turn the manufacturing sector on its head. However, everything that glimmers is not gold and in the backwash of hefty consultant fees questions arises: What are the drivers behind Industry 4.0? Which barriers exists? How does one prepare its manufacturing procedures in anticipation of the (if ever) coming era? What is the internet of things and what file sizes’ is characterised as big data? To answer these questions, this thesis aims to resolve the ambiguity surrounding the definitions of Industry 4.0, as well as clarify the fuzziness of a data-driven manufacturing approach. Ergo, the comprehensive usage of data, including collection and storage, quality control, and analysis. In order to do so, this thesis was carried out as a case study at GKN Aerospace Sweden (GAS). Through interviews and observations, as well as a literature review of the subject, the thesis examined different process’ data-driven needs from a quality management perspective. The findings of this thesis show that the collection of quality data at GAS is mainly concerned with explicitly stated customer requirements. As such, the data available for the examined processes is proven inadequate for multivariate analytics. The transition towards a data-driven state of manufacturing involves a five-stage process wherein data collection through sensors is seen as a key enabler for multivariate analytics and a deepened process knowledge. Together, these efforts form the prerequisites for Industry 4.0. In order to effectively start transition towards Industry 4.0, near-time recommendations for GAS includes: capture all data, with emphasize on process data; improve the accessibility of data; and ultimately taking advantage of advanced analytics. Collectively, these undertakings pave the way for the actual improvements of Industry 4.0, such as digital twins, machine cognition, and process self-optimization. Finally, due to the delimitations of the case study, the findings are but generalized for companies with similar characteristics, i.e. complex processes with low volumes.

Background – Through the progress in information and communication technology (ICT) new possibilities to connect smart objects via the internet arose. The number of connected devices had a strong growth in the past years and will continue rising fast in the next years as well. This new kind of smart and connected products (SCP) enables a lot of new product capabilities which have an impact on the creation of new customer value and competition on the market. Related to that, companies have to deal with digitisation and the affects for their products and manufacturing system. Purpose – The purpose of this thesis is to investigate changes in the manufacturing system when the products are getting smarter and connected. A special focus lays on the well-established Lean thinking approach. The results shall help to understand what new circumstances the decision to make the products smarter and connected will bring for a manufacturing department. Methodology – Relevant literature was reviewed to gain a theoretical framework. For gathering primary data, a qualitative case study was applied. Meetings with members of the case company’s management were arranged to conduct interviews. Additionally, observations were made during a guided tour through the production shop-floor and at a company presentation. The interview was recorded, transcribed and evaluated. Afterwards, the results from the case study were analysed and compared with theory based on the theoretical framework. Conclusions were made. Findings – The differences or changes in manufacturing because the products are getting smarter and connected are much more electronic components and software. Furthermore, new operating equipment is needed. The new circumstances require new knowledge and skills. Therefore, people have to be trained. New problems occur e.g. software problems. The use of Lean tools can be more difficult and time-consuming because of missing know-how and improvements itself are becoming more digital. Contribution – This thesis investigated the effects on the manufacturing system when the products get smarter and connected, which nobody did before. A practical case study with interviews, observations and secondary data from the company was applied. Limitations – The findings match reality based on data from the case company. Available time and access to data from the company’s side were limited. This means that the generalisation must be done with caution. However, it can be said that the findings may apply to many other industrial companies of similar size and similar products.

A Indústria 4.0, ou quarta revolução industrial, é o atual cenário industrial que estabelece um novo paradigma para os sistemas de produção. A indústria 4.0 é compreendida como a implementação da fábrica inteligente que opera de forma mais autônoma e com menor intervenção humana, cujo propósito é prover serviços e produtos inteligentes que atendam às necessidades individuais dos consumidores. A Indústria 4.0 está amparada nos sistemas ciber-físicos (CPS) e na Internet das Coisas (IoT). Neste cenário máquinas e produtos se comunicam entre si visando automatizar os processos industriais por meio de informações individuais obtidas em tempo real durante os processos de manufatura. No entanto, a Indústria 4.0 e as pesquisas em torno desse assunto ainda são muito recentes e requerem mais investigações no que diz respeito às arquiteturas que suportem a sua implementação, entre elas a comunicação entre produtos e máquinas. Neste quesito, recentemente foi proposto o modelo de arquitetura de referência para a Indústria 4.0 (RAMI 4.0) com o objetivo de nortear a implementação deste tipo de sistema. Contudo, o RAMI 4.0 ainda requer esforços no campo da pesquisa sob diferentes aspectos, entre eles a integração vertical de recursos do sistema de produção. Neste sentido, este trabalho objetiva apresentar uma arquitetura para a descoberta de equipamentos para processar operações conforme as necessidades dos produtos. A arquitetura foi projetada em camadas baseadas no RAMI 4.0 para prover componentes que permitam a comunicação entre equipamentos e produtos, e um mecanismo similar ao sistema de nomes de domínios (DNS - Domain Name System) para realizar a descoberta de equipamentos para processar uma determinada operação. Nessa arquitetura as informações dos equipamentos são armazenadas em uma estrutura organizada hierarquicamente para auxiliar o serviço de descoberta, e os produtos possuem informações das operações necessárias para o processo de manufatura. Para garantir a eficácia do funcionamento dos componentes e suas interações, é necessário a verificação e validação por meio de métodos formais. Neste trabalho a verificação e validação é realizada por meio da técnica PFS (Production Flow Schema)/RdP (Rede de Petri). Por fim, a arquitetura é aplicada em um sistema de produção modular para demonstrar a sistemática de implementação e a sua efetividade. / The Industry 4.0, also known as fourth industrial revolution, is the current industrial scenario that sets a new paradigm for production systems. The Industry 4.0 can be understood as the implementation of the smart factory that operates more autonomously and with less human intervention. The purposes of it is to provide smart products and services that meet the consumer individual needs. The Industry 4.0 is supported by cyber-physical systems (CPS) and Internet of Things (IoT). In this scenario machines and products communicate with each other to automate industrial processes through individual information that are obtained in real time during manufacturing processes. However, the researches around this issue are still very recent and require further investigations with regard of to the architectures that support its implementation, including communication between products and equipment. Taking into account this problem, a Reference Architectural Model for Industry 4.0 (RAMI 4.0) was recently proposed with the purpose to guide the implementation of this system type. However, the RAMI 4.0 still requires efforts in different aspects, including the vertical integration of resources of the production systems. In this sense, this work aims to present an architecture for the discovery of equipment to process operations according to the product needs. The architecture was designed based on layers of the RAMI 4.0 to provide components that allow communication between equipment and products and a Web Service that offer a mechanism similar to the Domain Name System (DNS) to locate equipment to process a required operation. In this architecture the capable operations supported by the equipment are stored in a structure organized hierarchically to aid the discovery service, and the products have information of the operation required for the manufacturing process. In order to guarantee the effectiveness of the component functionalities and their interactions it is necessary to verify and validate them by formal methods. In this work the Production Flow Schema (PFS)/Petri Net (PN) technique is used to develop the conceptual and functional modeling of the architecture. Finally the architecture is applied in a modular production system to demonstrate its implementation systematics and its effectiveness.

製造業是台灣經濟發展的重點產業，科技快速的發展加速工業技術的革新，面對全球的競爭，我國製造業需透過持續的創新來維持其在國際上的競爭地位。工業4.0下的技術創新即是製造業在尋求發展與成長的最佳動能。近年來的文獻多半針對工業4.0的概念進行介紹，較少研究工業4.0這個新興的議題，亦較少談論企業如何進行工業4.0的技術創新活動。本研究藉由個案訪談了解我國企業在面對工業技術快速變化之下，推動工業4.0技術創新活動的實際作為，並以「組織方式」與「知識管理」兩大構面為主軸，針對我國三家在不同產業中具優異表現的公司進行研究，得到了以下的結論： 結論一：企業在推動工業4.0下的技術創新活動時，會從公司內部原有業務內容進行延伸，依產業類別的不同而有不同的發展方向。 結論二：企業推動工業4.0技術創新活動的團隊，會具有較高的權力層級及跨功 能整合程度，且團隊領導者特別強調溝通與整合的能力。 結論三：企業在整合工業4.0相關知識時，會同時強調整合的廣度與深度。 最後，本研究提出對於產業實務上以及後續學術研究上的建議。 / Manufacturing industry is one of the backbones of Taiwanese economy. As the rapid development of technology accelerates the innovation of industry, Taiwan’s manufacturing should be more aggressive in innovation in order to maintain its competitiveness in the global world. “Industry 4.0” provides the best opportunity for manufacturing companies for growth. In the past few years, the research and studies of Industry 4.0 focused more on providing an overall preliminary introduce and rarely mention how companies can apply it to the innovation activities. This study aims to investigate the actual responses of companies while doing technology innovation activities in "Industry 4.0". A framework with two major constructs: organizing, knowledge management is adopted for this study. And three leading companies in different industry are selected. Three conclusions from this study are as follows: 1. Enterprises that promote Industry 4.0 technology innovation activities will be usually extended from their existing business, and have different direction for business development according to their industry types. 2. Enterprises that promote Industry 4.0 technology innovation activities will require the responsible teams to have higher level of authority and cross functional integration. The ability to communicate and integrate will be also emphasized by the team leaders. 3. The breadth and depth of integration will be emphasized when the enterprises try to integrate the related knowledge of Industry 4.0. Finally, there are some recommendations for industry and follow-up researcher.

Industry 4.0 is the current trend of automation and increasing digitalization of wide range of processes. This trend brings about a revolution in manufacturing technologies, but also has its challenges that influence the labor market. The thesis introduces the fourth industrial revolution (Industry 4.0) and provides the most important information for its understanding. It also allows to understand the specific characteristics of business models in the digital society and it clarifies the theory of maturity models. These serve as a basis for assessing the company's level of maturity in relation to Industry 4.0. The next section contains a proposal for improvement of the business model in food manufacturing company. For this purpose, the production process and related processes are analysed and the current situation is evaluated according to the Industry 4.0 requirements. Based on this evaluation, the problematic areas are selected and their specific improvements are proposed. In addition, the work includes a proposal of specific steps that a company must take to be prepared and take advantage of the era of Industry 4.0.

本研究的進行期間，正處於台灣電腦代工業的成長趨緩時期，然而隨著中國逐漸承接起「世界工廠」的角色，兩岸早已由垂直分工進入水平競合的階段，且競爭的比重愈來愈高。過去我國製造業能夠迅速崛起，主要是因為勞動力成本、原材料成本以及土地取得成本等資源所構成的比較成本優勢，然而這些成本優勢卻逐漸在消失中。 本研究探討之問題為總體環境變化對代工企業的影響?以及代工企業對環境變化的回應對策？主要是希望能夠擺脫傳統製造思維，從核心資源的角度來探討台灣電子代工廠面對工業4.0的浪潮，該如何調整營運模式，找尋最合適的轉型策略。 透過案例分析，本研究針對代工廠的轉型策略提出以下幾點建議：一、導入自動化生產，進一步提高生產效率以及降低生產成本。二、全球製造板塊移動，代工企業從生產製造走向技術服務，善用以人為中心的技術與服務，致力於發展關鍵技術。三、轉型勢在必行，調整策略符合市場需求，將技術導向的研發轉向消費者導向的創新，開創產業的新價值。 / The timing of conducting this study is that EMS providers in Taiwan encounter the slow growth of market demand as well as China’s taking over the leading role of the world factory gradually. Moreover, the conventionally vertical Taiwan-China collaboration turns out horizontal competition increasingly. Over decades, thanks to competitive advantages of relatively low labor cost, raw material cost and land acquired cost, Taiwan PC manufacturing providers dominated in the market. However, the previously-mentioned advantages are approximately disappearing. The objectives of this study are to discuss the potential impact of macro-environment change to electronic manufacturers and their counter actions to the impact. Hopefully, these players can not only cask off conventional manufacturing stereotype but also search optimal transformational strategies through core resource approach to embrace the waves of Industry 4.0. By demonstrating some cases, the suggestions of transformational strategy for Taiwan EMS providers are as follows: firstly, the introduction of manufacturing automation and then the improvement of manufacturing efficiency and cost reduction; secondly, turning past-manufacturing-centered toward human-centered technologies and services, dedicated to developing critical technologies; lastly, initiating meeting market-needed strategies, shifting technology-driven research and development to customer-driven innovation and creating values of the industry.

「台灣的代工製造產業應該如何發展」的問題，是困擾PC產業的管理難題，特別是在公司面臨產品成熟、訂單驟減、毛利下滑的時刻。所有台灣的代工製造產業亟思轉型的方法和方向，但是轉型到的新的產品市場或產品也是非常複雜、動態、多重因素多相互依存及影響。屬於複雜難解的問題(Wicked Problem)、問題本身都還需要定義及釐清。本論文將列出想解決的議題並定義為服務設計的議題。 因此本研究的服務設計議題(Service Design Challenge)可定義如下:「以服務設計思維建構專業代工緯創的未來」。本論文經由訪談傳統PC產業的品牌公司、IC供應商、作業系統公司和工業PC的公司，研究過程藉由運用服務設計(Service Design)手法並發掘洞見(Insights)與價值，據此將真正符合客戶需求，在找出表面及深層需求後、設計新的服務模式，得到其反饋之後再修正設計；接著結合最新科技趨勢，例如：物聯網、工業4.0、感測器和機器手臂，以提供客戶安心的代工服務；最後希望藉由改變運營模式，達到緯創成功轉型的目標。 雖然新的科技尚未成熟，只要方向正確，這些模式或能力成熟後，可以快速讓公司保持彈性，能充分利用的資源，進行個別化差異設計。 / “How to develop the ODM (Original Design Manufacturer) industry in Taiwan” is plagued by PC industry management problems, especially for those companies facing product maturity, orders plummeted and the decline in gross margin. The ODM in Taiwan is trying to change the way and direction, but the transition to the new product market or product is very complex, dynamic and involves multiple inter-dependent factors. It is a complex problem (Wicked Problem), and the problem itself also needs to be defined and clarified. The aim of this thesis is to address and define the issues through the lens of service design. Therefore, our Service Design Challenge Problems can be defined as: “The Future of Wistron through the Service Design Lens". This thesis, through interviews with traditional PC industry brand companies, IC suppliers, operating systems companies and industrial PC companies, adopts the research process of the service design approach and explores the insights and value, which will truly meet Customer needs, identify the surface and deep demand, attain the design of new service model, and integrate the latest technology trends, such as Internet of things, industry 4.0, the sensor and the robot arm, in order to provide customers with reliable and assured ODM services. Our final hope is to change the operating mode and achieve a successful Enterprise Transformation of Wistron. Although the new technology is not yet mature, as long as the direction is correct in light of these models or abilities to mature, the company can remain flexible, make full use of resources, and create individualized design differences.

Durant les dix dernières années, l'infrastructure informatique et l'infrastructure industrielle ont évolué de manière à passer de systèmes monolithiques à des systèmes hétérogènes, autonomes et largement distribués. Tous les systèmes ne peuvent pas coexister de manière isolée et exigent que leurs données soient partagées de manière à accroître la productivité de l'entreprise. En fait, nous progressons vers des systèmes complexes plus vastes où des millions des systèmes doivent être intégrés. Ainsi, l'exigence d'une solution d'interopérabilité peu coûteuse et rapide devient un besoin essentiel. Aujourd'hui, les solutions imposent les normes ou les middlewares pour gérer cette problématique. Cependant, ces solutions ne sont pas suffisantes et nécessitent souvent des développements ad-hoc spécifiques. Ainsi, ce travail propose l'étude et le développement d'une architecture d'interopérabilité générique, modulaire, agnostique et extensible basée sur des principes de l'architecture dirigée par les modèles et les concepts de la séparation de préoccupations. Il vise à promouvoir l'interopérabilité et l'échange de données entre les systèmes hétérogènes en temps réels sans obliger les systèmes à se conformer à des normes ou technologies spécifiques. La proposition s'applique à des cas d'usages industriels dans le contexte de réseau de distribution de gaz français. La validation théorique et empirique de notre proposition corrobore note hypothèses que l'interopérabilité entre les systèmes hétérogènes peut être atteinte en utilisant les concepts de la séparation de préoccupations et de l'ingénierie dirigée par les modèles et que le coût et le temps pour promouvoir l'interopérabilité est réduit en favorisant les caractéristiques de la réutilisabilité et de l'extensibilité. / Over the last decade, the information technology and industrial infrastructures have evolved from containing monolithic systems to heterogeneous, autonomous, and widely distributed systems. Most systems cannot coexist while completely isolated and need to share their data in order to increase business productivity. In fact, we are moving towards larger complex systems where millions of systems and applications need to be integrated. Thus, the requirement of an inexpensive and fast interoperability solution becomes an essential need. The existing solutions today impose standards or middleware to handle this issue. However, these solutions are not sufficient and often require specific ad-hoc developments. Thus, this work proposes the study and the development of a generic, modular, agnostic and extensible interoperability architecture based on modeling principles and software engineering aspects. It aims to promote interoperability and data exchange between heterogeneous systems in real time without requiring systems to comply with specific standards or technologies. The industrial use cases for this work takes place in the context of the French gas distribution network. The theoretical and empirical validation of our proposal corroborates assumptions that the interoperability between heterogeneous systems can be achieved by using the aspects of separation of concerns and model-driven engineering. The cost and time to promote the interoperability are also reduced by promoting the characteristics of re-usability and extensibility.

Det här examensarbetet har utförts på Scania CV AB:s motorbearbetningsavdelning i Södertälje. I dagsläget pågår en omställning av tillverkningsprocessen på avdelningen där två nya tillverkningslinor, en för cylinderblock och en för cylinderhuvud, är under uppbyggnad. Linorna kommer styras med hjälp av ett Manufacturing Execution System. Ett Manufacturing Execution System har i uppgift att samla in data och information från tillverkningsprocessen, som sedan kan presenteras i ett gränssnitt. Vilken information som kommer finnas tillgänglig att presentera i systemet styrs utifrån en intern kravspecifikation som ska spegla International Society of Automation:s standard, även känd som ISA-95. Den kravspecifikation som finns för systemet är framtagen av IT-avdelningen i samråd med avdelningschefer. För närvarande är det osäkert om kravspecifikationen som finns på systemet stämmer överens med vad medarbetarna behöver för att kunna arbeta på ett effektivt sätt. Det här arbetet kartlägger behovet hos medarbetarna och jämför det med den befintliga kravspecifikationen. Genom intervjuer och enkäter har den befintliga kravspecifikationen för systemet jämförts med vad medarbetarna anser vara önskvärda funktioner i systemet. Resultatet av den första omgången intervjuer och enkätutskick var att kravspecifikationen och behovet hos medarbetarna stämmer väl överens. Det mynnade ut i att ytterligare en enkät skickades ut där medarbetarna istället skulle rangordna den information som kommer finnas tillgänglig i systemet utefter en prioriteringsskala i tre nivåer. Resultatet från den enkäten gav en bild av vilken information medarbetarna tycker är viktigast för att kunna arbeta på ett effektivt sätt. / This bachelor thesis has been done at Scania CV AB’s department for engine manufacturing in Södertälje. The manufacturing process at the department is currently under development, where two new lines are being added, one for cylinder head and one for cylinder blocks. These two new manufacturing lines are going to be controlled with the help of a Manufacturing Execution System. The Manufacturing Execution Systems task is to collect data and information from the manufacturing process, which later can be presented in an interface. There is a specification at Scania that presents what information will be available in the system. That specification is in line with what the International Society of Automation has specified in ISA-95. The specification for the system was set by the IT-department in consultation with department managers. There is currently an uncertainty if the specification meets the requirement that the workers has, to be able to work efficiently with the system. This thesis will identify the requirement that the workers has on the system, and compare it with the current specification. What the workers deems is necessary information has been identified and mapped through interviews and a survey. The result of these interviews and the survey made it clear that the specification was well in line with the requirement from the workers. This information led to the decision to send out another survey that asked the workers to prioritize how important the information in the system is, in three different priority levels. This resulted in an overview of what the workers consider is the most important information in the system.

A major issue within automotive Sheet Metal Forming (SMF) concerns ensuring desired output product quality and consistent process performance. This is fueled by complex physical phenomena, process fluctuations and complicated parameter correlations governing the dynamics of the production processes. The aim of the thesis is to provide a deeper understanding of the challenges and opportunities in this regard within automotive SMF. The research is conducted in collaboration with a global automotive manufacturer.  The research shows that systematic investigations using process simulation models allow exploration of the product-process parameter interdependencies and their influence on the output product quality. Furthermore, it is shown that incorporating in-line measured data within process simulation models enhance model prediction accuracy. In this regard, automating the data processing and model configuration tasks reduces the overall modelling effort. However, utilization of results from process simulations within a production line requires real-time computational performance. The research hence proposes the use of reduced process models derived from process simulations in combination with production data, i.e. a hybrid data- and model-based approach. Such a hybrid approach would benefit process performance by capturing the deviations present in the real process while also incorporating the enhanced process knowledge derived from process simulations. Bringing monitoring and control realms within the production process to interact synergistically would facilitate the realization of such a hybrid approach. The thesis presents a procedure for exploring the causal relationship between the product-process parameters and their influence on output product quality in addition to proposing an automated approach to process and configure in-line measured data for incorporation within process simulations. Furthermore, a framework for enhancing output product quality within automotive SMF is proposed. Based on the thesis findings, it can be concluded that in-line measured data combined with process simulations hold the potential to unveil the convoluted interplay of process parameters on the output product quality parameters. / <p>Related work:</p><p>1) http://urn.kb.se/resolve?urn=urn:nbn:se:bth-14412</p><p>2) http://urn.kb.se/resolve?urn=urn:nbn:se:bth-14388</p><p>3) http://urn.kb.se/resolve?urn=urn:nbn:se:bth-18935</p>