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- Winners of 2018
Bosch Automotive Diesel Systems, Wuxi
The maker of automotive diesel systems like common rail injectors and high pressure pumps impressed the Jury with an outstanding level regarding the use of data to improve factory performance. In particular, a highly sophisticated model has been developed to find the sweet spot of operation which balances tool costs against machine wear & tear and equipment downtime, utilizing Big Data Analytics and improvement algorithms taking clues from artificial intelligence in the form of optimization algorithms.
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In addition to equipment being networked and monitored in real-time, Bosch stands out with multiple instances of condition monitoring, e.g. for spindle vibration and machine axis position deviation. This is remarkable evidence of their deep technical understanding, which is the foundation for making accurate predictions about a machines behavior.
IKD, Ningbo
The maker of high-precision aluminum die casting products for the automotive industry impressed the Jury with a self-developed information system, succinctly called the TouchNet. 450 of these terminals are present throughout the factory and allow users to access real-time operations information through a user-friendly interface. This system is build on a strong foundation data collection, with e.g. capturing 72 process parameter on one type of machine alone. Moreover, with the Award the Jury wants to recognize IKD for their remarkable combination of lean process design with technology capabilities from the fourth industrial revolution, e.g. by having set-up one-piece-flow machining cells with networked machinery, robotics, and real-time capturing of machine & performance data.
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Bosch Rexroth Beijing Factory
The maker of hydraulic pumps for industrial applications like in excavator and construction machinery impressed the Jury with a real-time utility monitoring system to optimize resource provision & consumption throughout the entire plant, in a precision which allows to drill down by machine. Build with network connected meters, real-time workload conditions are sensed and utility provision is regulated accordingly, e.g. for chilled water supply, compressed air, and electricity. The results of the efforts are an exceptionally efficient and clean factory footprint with minimized or even zero impact on the environment.
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Moreover, Bosch Rexroth is in the midst of executing a remarkably well put together industry 4.0 strategy & improvement roadmap which covers all aspects of operations, from product machine communication to RFID based material flow tracking, online spindle vibration monitoring, which is all pulled together in one user interface for data access and optimization called the Active Cockpit.
Beijing Benz
The maker of premium cars impressed the Jury with a comprehensive central maintenance which makes use of modern IT solutions for data gathering, analytics, reporting, and process improvement to increase equipment uptime.
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It covers a wide array of topics, from process & machine data collection, real-time monitoring of energy consumption, automatic leakage detection, to a collaboration system for topics & actions management, condition monitoring to predict component failure, and smart glasses for remote support.
Another highlight is that it is deeply embedded and building on a strong process foundation in the form of a custom-tailored total productive maintenance system. While the Award is accredited for outstanding achievements in digitalization in Maintenance, the Jury acknowledges both the Engine & Final Assembly plant for running on exceptionally high levels of operations performance.
Haitian, Ningbo
The maker of injection molding machinery impressed the Jury with an intelligent flexible manufacturing system for manifold production. It consists of an automated raw-material storage, high precision and multi-purpose CNC machinery, material transport on AGVs, and a strong IT system to provide real-time operations data to a control room with an array of 8 flat screen TVs.
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Furthermore, the machines are sensor-equipped to detect tool wear & tear, are capable of automatic changeovers, and therefore can run without human intervention for most of the time. Haitian also incorporated a cutting tool tracking & management system based on RFID tags for full and accurate recording of tool information over the entire lifetime.
JC Times, Taizhou
The maker of plastic extrusion dies like sheet/foil dies, hollow profile dies, and coating dies impressed the Jury with a strong vertical integration of its IT system, which is capable of providing a wide array of factory information in real-time, e.g. order information and machine status. It consists of a self-developed data capturing and provisioning platform with fully customizable views and a user-friendly interface.
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Furthermore, JC Times is recognized for its modern manufacturing site with state-of-the art infrastructure, for example with a geothermal energy system to provide heating and cooling for the factory.