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Wenn sich die weltweiten Produktionsverantwortlichen von Kärcher, - dem Weltmarktführer für Reinigungssysteme, austauschen, geht es meist um drei Themen: Wie können wir die Produktion noch stärker auf den Kunden ausrichten, wie kann die Kosteneffizienz weiter gesteigert und die Nachhaltigkeit weiter verbessert werden? Auch wenn bei rund 3000 verschiedenen Produkten mit Stückzahlen von 100 bis 1 Million pro Jahr keine einfachen Antworten zu erwarten sind, so sind die Grundprinzipien klar. 100%ige Einhaltung der Kunden- und Lieferversprechen, konsequente Produktion in den jeweiligen Absatzmärkten bei kontinuierlicher Steigerung der Fertigungstiefe. Im weltweit größten und modernsten Kärcher-Werk Bühlertal wird die Strategie für uns Lernreisende greifbar: Eine hochautomatisierte Materiallogistik bespielt alle Vertriebswege vom Onlinehandel bis zum Handwerk, die Produkte werden überwiegend mit einer Region for Region-Produktion vom Grundmodell bis zum Premiumprodukt hochautomatisiert hergestellt. Durch zahlreiche Produkt- und Prozessinnovationen gelingt es zudem, den Co2-Footprint der Produkte von der Herstellung bis zum Gebrauch signifikant zu senken und der Idee einer abfallarmen Produktion immer näher zu kommen.
Produziert sie nur, wenn die Sonne scheint oder der Wind weht?
Bestes Beispiel hierzu ist der allgäuer Anlagenbauer Alois Müller mit seinem größten, nahezu energieautarken Produktions- und Bürogebäude der Welt. Tatsächlich bestimmt die tägliche Wetterprognose zu Arbeitsbeginn die Arbeitseinteilung und Maschinennutzung. Das betrifft besonders energieintensive Prozesse. Allerdings sorgen zahlreiche Speichersysteme für Wärme, Druckluft, Stickstoff und Strom an sieben Tagen in der Woche dafür, dass die Produktivität am Ende des Tages stimmt.
Jeden Montag beginnt die Morgenbesprechung im Bosch Werk Homburg mit mindestens einer guten Nachricht: 80% Energieeinsparung am Wochenende.
Dank konsequenter Abschaltplanung benötigen die Maschinen und Anlagen nur noch ein fünftel des normalen Wochenendbedarfs. Doch das ist nur ein Projekt von hunderten, mit dem das Bosch Leitwerk zur Energieeffizienz bewiesen hat, das in der Produktion 40% Energieeinsparung möglich sind.
Energiekosten sind heute ein wichtiger Standortfaktor. Bereits vor 17 Jahren hat Bosch in seinem Leitwerk für die klimaneutrale Produktion in Homburg begonnen, eine Vielzahl übertragbarer Ansätze zur Verbesserung der Energieeffizienz zu entwickeln und umzusetzen. Die Maßnahmen reichen dabei von A wie Abschaltmanagement bis Z wie Zustandsorientierte Wartung. Im Rahmen unserer Lernreise "Der Weg zu Net Zero" teilt das Bosch-Leitwerk seine Piloterfahrungen zur Erfassung der Verbräuche, zur Energieeinsparung und zur Nutzung CO2 freier Energieträger wie grünen Wasserstoff.
Gemeinsam mit verschiedenen Partnern, werden die Bausteine des Industrial Metaverse wie Digitale Zwillinge, Künstliche Intelligenz und Automatisierung in Kombination mit IT-Technologien Schritt für Schritt zum Einsatz kommen. Das Ziel: durch die vollständige Verschmelzung von realer und digitaler Welt nachhaltigen Mehrwert zu schaffen.
Fehler zu beseitigen, Downtime zu reduzieren und die Produktivität zu steigern sind einige der Vorteile, die das Industrial Metaverse bringen wird.
Die Reise der digitalen Transformation kann auch weiterhin nur mit der Motivation und der richtigen Mannschaft zum Erfolg führen.
Self-driving tables make their way to the next assembly station, workers are individually supported on screens to assemble the 14,000 pump types efficiently and error-free, excess solar power is stored in a huge hydrogen tank. The WiloPark in Dortmund is not only one of the largest industrial construction projects in Germany, but has also provided a unique opportunity to rethink all company and production processes on a greenfield site. The result is a multi-award-winning flagship project in terms of efficiency, digitalisation and sustainability.
Bosch's intelligent production of the future is located in the Allgäu region. And has been for 10 years. The Bosch plant in Blaichach/Immenstadt is the nucleus of Industry 4.0, with countless prizes and awards along the way. Despite all the technological expertise, leadership and employee involvement have always been at the centre of the company. This is certainly one reason for the sustainable success and the great opportunity to take the smart factory into the second generation.
Bosch Blaichach reports first-hand on its experiences and the new production concept, which for the first time provides a direct link between logistics and assembly.
Busch-Jaeger has built the world's first climate-neutral and cost-optimized production site for the ABB Group at its headquarters in Lüdenscheid. This reference project demonstrates how smart technologies can already change the way energy is generated and stored and how they can be implemented in efficient production and work processes.
The site is energy self-sufficient for many days and saves around 630 tons of CO2 every year thanks to its solar power plant and an adaptive energy management system.
#Lernreise #FabrikderZukunft
Special prize for new factory construction at the Lean & Green Management Award 2022
The new NExT Factory from Schaltbau GmbH proves that with renewable energy, electrical and thermal energy storage and a direct current grid, it is possible to achieve long-term CO2-free production economically. It is undoubtedly a prototype for the factory of tomorrow that sets standards for the entire industry and can also react very quickly and flexibly to customer requirements thanks to automated production and high-performance logistics.
Increasing performance while downsizing at the same time. This is the recipe of Voith Turbo in Garching, which was awarded in the "Factory of the Year" benchmarking for exemplary digitalization and sustainability of its production. With its digitalization turbo, the plant network achieves the efficiency of a large plant by bundling information, knowledge and production data. At the same time, CO2 is being downsized. In the last seven years, the CO2 footprint has been reduced by 61%.
#Lernreise #ProduktionderZukunft
In fact, factories must learn to react highly flexibly to fluctuations in demand, but also to supply bottlenecks. Plant manufacturer ASMPT shows how this can be achieved: consistent process organization with end-to-end responsibility, full transparency in real time and a global production network that can manufacture any product at any location. This organization has not only earned the industrial equipment supplier ASMPT the hat trick in the "Factory of the Year" factory benchmarking, but also guides the company remarkably resiliently through its extremely volatile business field.
#Lernreise #ProduktionderZukunft
Our "Factory of the Future" learning journey has shared the knowledge of the best factories over the past two years. The buzzwords lean / green / digital have summed up the challenges of production well. When we were guests at Fraunhofer IPA on October 17-18, 2023, we were naturally curious about the trends of the day after tomorrow. Ultra-efficient factory, biointelligence or digital ecosystems for the factory will be buzzwords that the researchers will make tangible for us.
#Lernreise #FabrikderZukunft
The production of the future must face up to new realities. Achieving more and more with less is the goal for the coming years. And this is where the innovation drivers of lean and digitalization open up great opportunities. The best example at the Siemens plant is matrix production. It combines the flexibility of workshop production with the economic advantages of flow production. Experts are already talking about the lean of the 21st century.
#Lernreise #ProduktionderZukunft
A production that makes every heart beat faster. Our learning journey to the factory of the future is looking forward to a visit to Porsche in Leipzig. Under the motto Production 4.0 - smart / lean / green, Porsche shares the production experiences of one of the best automotive plants, from the first experiences as a lean pioneer, to the use of smart tools such as the Porsche Performance Board, to the path to the Zero Impact Factory.
#Lernreise #FabrikderZukunft
Using tomorrow's technology today is the claim of Technologiefabrik Scharnhausen. The first collaborative robot was used here in the valve factory, and artificial intelligence is already in productive use here today. Digitalization, networking and sustainability were already important cornerstones when the Festo main plant was redesigned around 10 years ago. Lean is now being practiced by the third generation. This change can only succeed together with all employees. And this is the real secret of the technology factory.
#Lernreise #FabrikderZukunft
Our factories are pushing the boundaries of what is feasible. Reduction of climate-damaging CO2 emissions by over 90%, reduction of throughput times in production to pure processing time and even unmanned shifts at weekends in the future. This vision is already within reach at connector manufacturer Harting. Join us live when we get to know this factory of the future on site as part of our learning journey on May 24 and 25, 2023.
#Lernreise #FabrikderZukunft
The machine tool manufacturer Trumpf has repeatedly set milestones in the field of production. Back in the late 1990s, the company succeeded in revolutionising assembly with the lean production system SYNCHRO and making the machine tool "flow" for the first time. With a delivery time of just one day for customised tools, the company is now the "Amazon" of smart tool production. The company is now also rethinking its core expertise in machining and has opened a new plant that is pointing the way to the future in the areas of lean, green and digital.
#Lernreise #FabrikderZukunft
Under the motto "Everyone, every day, everywhere a little better", Deutsche Post DHL Group is implementing a continuous improvement program with its FIRST CHOICE corporate program with over 500,000 employees in 220 countries and territories around the world. Thanks to professional program management and close integration with the Group strategy, we have succeeded in anchoring continuous improvement as part of the Group's DNA and corporate culture. Today, the programme is making a significant contribution to shaping the agile transformation towards digitalization and sustainability together with all employees.
#Lernreise #FabrikderZukunft
Together we get to know the largest truck production facility in the world - the Mercedes-Benz plant in Wörth. Variance and transformation at your fingertips, no two trucks are alike and alternative drive systems are already within reach. Together we will discuss the implementation of the Daimler Truck Strategy, which focuses on first-class plants, committed employees, efficient processes and reliable products. In addition, the Mercedes-Benz plant in Wörth is becoming the centre for emission-free transport within the Mercedes-Benz truck production network. In the transformation towards CO2-neutral transport, Daimler Truck is consistently relying on two fully electric drive technologies: Battery and hydrogen-based fuel cell.
#Lernreise #FabrikderZukunft
B/S/H Hausgeräte GmbH and its award-winning dust masonry plant in Bad Neustadt impressively prove it: economic production at the German location is possible even in highly competitive consumer markets. However, this is only possible if change is actively shaped and the potential of digitalisation and sustainability is fully exploited.
Digital process chains from ordering raw materials to networked production of blower motors to fully automated plastic injection moulding on the one hand, and sustainability and energy management on the product and process side on the other, point the way to the future in exemplary fashion.
#Lernreise #FabrikderZukunft
Are digital production platforms, virtual twins and Plug&Produce apps the new shining lights for tomorrow's production? In fact, pioneers like the automotive supplier ZF in Saarbrücken see a new steep development on the way to more productivity even in existing factories.
#Lernreise #FabrikderZukunft
How does a 60-year-old factory manage the transformation into the here and now? The OSRAM factory relies on lean processes, a culture of cooperation and the use of advanced IOT technologies. In our view, the plant is representative of many factories in Germany and shows that transformation from a brownfield can succeed.
#Lernreise #FabrikderZukunft
What concrete added value does digital data offer in the production sector? Let's ask one of the global thought leaders! Under the motto "Think tank for industrial transformation" Microsoft shares its implementation experiences
#Lernreise #FabrikderZukunft
What does it look like, the path to the future? Digitization and cultural change will certainly play a very decisive role. "Our path to becoming a lifetime partner" is how the insurance group Generali and its digital subsidiary CosmosDirekt describe their own transformation.
#Lernreise #TransformationLive
Starting with a lean implementation in production, Schaeffler Special Machinery has undergone a fundamental transformation of its processes, culture, and business models over the last few years. The outward sign of the change is a completely redesigned working environment, which was intended to significantly improve collaboration and communication along the entire value stream.
#Lernreise #TransformationLive
Be inspired by how the Bosch Homburg plant is realising its idea of a factory of the future. The Saarland plant is not only one of the pioneers in the implementation of Industry 4.0, but also in Energy Management 4.0. Here, essential prerequisites were created for Bosch to become the world's first global industrial company to have climate-neutral production since 2020.
#Lernreise #FabrikderZukunft
How can artificial intelligence technologies, image processing or even new operating systems for production ensure the competitiveness of our factories?
#Lernreise #Industrie4.0
In Haiger, Hesse, Rittal has made the largest total investment in the company's history at 250 million euros and created an end-to-end digital value chain. Thus, a digital product twin extends from engineering through production and distribution deep into the customer's value creation processes.
#Lernreise #Industrie4.0
The ING learned from Spotify, Netflix and Google and was the first bank to implement "The Agile Way of Working".
#Lernreise #TransformationLive
Under the motto " Flexibility Factory - Future made in Rohrbach " we take a look behind the scenes of the largest FESTO plant in Europe. Festo describes itself as a learning company. Our host Jürgen Otto puts it in a nutshell: "Good qualification ensures good processes and good performance". Thus, the Learning Factory I 4.0 impressively demonstrates how to actively involve employees in the digital transformation. The second common thread is the topic of flexibility. How can you react quickly and cost-effectively to customer wishes and produce batch size 1 with zero set-up time automatically?
#Lernreise #Industrie4.0
Schwan Cosmetics has set up a "Digital Studio" to quickly develop digital ideas and solutions. Familiar processes were successfully turned upside down. In order to avoid an organisation of two worlds with its own culture and speed, organisational integration was also driven forward at an early stage. Because the same applies here: Technology can only be a catalyst. People make the difference.
#Lernreise #TransformationLive
In the future, BSH Hausgeräte GmbH is to be not just a hardware company, but a "hardware+" company. But how will this change take shape? What opportunities and challenges need to be considered and what role do PLM and I4.0 play in this?
#Lernreise #TransformationLive #Industrie4.0
Die letzten Monate haben eine ungeahnte Dynamik in das Thema „New Work“ gebracht. Die Arbeitswelt von morgen wird schneller, effizienter und flexibler sein.
Wir müssen Umdenken bei der Gestaltung unserer Arbeitsumgebung. Aber genauso bei unseren Regeln der Zusammenarbeit sei es mir den Mitarbeitern als auch mit den Kunden.
Die Digitalisierung kann diesen Wandel begleiten. Die Technologie steht aber nicht im Vordergrund. Microsoft und Steelcase, - beide Pioniere einer neuen Arbeitswelt, zeigen neuste Möglichkeiten bei der Gestaltung der Arbeitsumgebung und der Digitalisierung, so dass eine neue Art des Arbeitens entstehen kann.
#Lernreise #TransformationLive #Arbeit4.0
How will production be fit for the digital age? What happens to the existing machinery? And how do you deal with individual customer needs that could previously only be met by a single manufactory? The connector technology manufacturer HARTING is facing precisely these challenges and will be demonstrating its implementation status live in production.
Industry 4.0, networking, logistics, batch size 1
#Lernreise #Industrie4.0