Smart factories @ scale
Seizing the trillion-dollar prize through eﬃciency by design and closed-loop operations
Beyond labor productivity and asset-efficiency, the next performance leap in factories will be through end-to-end effectiveness of production systems:
•Efficiency by design: virtual design, simulation, and commissioning of factories before entering into physical operations to make processes more efficient throughout their life cycle.
•Effectiveness in operations: leveraging data and advanced analytics to reach “closed-loop” and ultimately self-optimizing operations.
•Deployment at scale: moving from an initial pilot to systematic deployment to realize the full value of smart factories.
With these issues shaping the future of manufacturing, the next challenge for organizations lies in scaling their smart factory initiatives. The key takeaways from our research include:
• Compared to two years ago, more organizations are progressing with their smart factory initiatives today and one-third of factories have already been transformed into smart facilities.
• They plan to make 40% more smart factories in the next five years and increase their annual investments by 1.7 times compared to the last three years.
• Organizations are focusing on both efficiency by design and achieving operational excellence through closed-loop operations.
The size of the smart factory prize is $2 trillion on average, higher than our 2017 estimate. Two-thirds of this overall value is still to be realized: efficiency by design and closed-loop operations will make equal contributions.
• There are a number of reasons for this uptick: higher penetration of smart factory initiatives, aggressive plans by organizations, and an increase in expected benefits. These benefits could be seen not just in productivity improvements but also in accelerated product-portfolio rotation and faster time to market which will further translate into an increased market share.
• 5G is set to become a key enabler of smart factory initiatives as its features would provide manufacturers the opportunity to introduce or enhance a variety of real-time and highly reliable applications.
• Organizations realize that success is hard to come by, with just 14% characterizing their existing initiatives as successful.
• The main issues with achieving scale are challenges with IT-OT convergence and the need to develop “hybrid” capabilities and soft skills.
– To ensure digital continuity1 and enable collaboration, effective IT-OT convergence will be critical, including digital platform deployment and integration, data readiness, and cybersecurity. Agnostic and secure multilayer architectures will allow a progressive convergence.