Client carousel during our 'Phygital' even (24/10/2019), where Tim Polleunis (Manager Smart Factory VCST) & Jan Coekaerts (Business Consultant bluecrux) showed how VCST is moving towards the next generation, towards a smart factory.

1. LET’S GET
PHYGITAL
WITH

2. Industry 4.0 & the next
generation:
Towards a smart factory

3. Nice to meet you
Tim Polleunis Jan Coekaerts
Manager Smart
Factory
Business
consultant

4. The agenda?
1
2
3
About VCST
Smart Factory @ VCST
Round-up

5. About VCST1

6. STRUCTURE OF THE DIVISION
Markets
Business lines
Brands
Division
Automotive Industrial Rail

7. THE BMT GROUP
12 Companies in 8 countries
3728 People
Industrial & automotive
gears & gearboxes
9 companies in 8 countries
1568 People
Glass moulds
3 companies
in 3 countries
190 People
Glass engineering
5 Companies in 5 countries
419 People
Aerospace gears &
gearboxes

8. GLOBAL FOOTPRINT
OostkampSint-Truiden*
Zanesville
Léon
Iasi Alba
Reichenbach
Brno
Suzhou
ChangzhouPune
Distribution centre for NAFTA
market & gearbox assy for rail.
Manufacturing & assy site for
railway gearboxes, overhaul and
distribution centre for China.
Manufacturing site for gears (up
to  0.5m), shafts, subassemblies
& gearbox assy.
HQ BLR & manufacturing & assy
site for railway gearboxes,
overhaul service, R&D.
Manufacturing site for gears &
shafts.
HQ BLA & manufacturing site for
gears, shafts incl. heat treatment,
R&D.
Manufacturing site for gears &
shafts incl. heat treatment.
Manufacturing site for gears,
shafts incl. heat treatment.
Manufacturing site for aluminium
components for brake systems.
Manufacturing site for gears (up
to  1m), shafts & spiral bevel
gears incl. heat treatment.
HQ BLI & manufacturing site for
gears (up to  2m), shafts,
aluminium components &
castings incl. heat treatment.
FTE: 443
TO: € 65m (incl. € 7m BLI)
FTE: 13
TO: € 31.1m
FTE: 420
TO: € 27.3m
(incl. € 8.8m BLI)
FTE: 467
TO: € 12.7m
FTE: 343
TO: € 17.4m
FTE: 173
TO: € 19m
FTE: 315
TO: € 33.8m
FTE: 161
TO: € 38.3m
TO: only sales to thirds (no interco)
FTE: 162
TO: € 21,8m
FTE: 1024
TO: €26.7m
*STC included
FTE: 207
TO: € 44.7m

9. Smart Factory
@ VCST2

10. INTRODUCING SMART FACTORY @ VCST & OUR PILOT
July 1st
2018
October 1st
2019
October 1st
2018
July 1st
2019
January 1st
2019
April 1st
2019
Approval
Pilot Project
Start Support
Bluecrux
Kick-off focus teams
(brainstorm)
Decision on high-level
system architecture
First CNC from
machine connected
New Smart
Factory Manager
Start POC
Thingworx
Smart Factory Show
Case
Planning Full Roll-outConcept
workshop

11. 1111
KEYLEARNINGS
Look at your company
from an E2E perspective
Assign a dedicated
business owner
Start small but keep
scalability in mind

12. SMART
PRODUCTS
CONNECTIVITY
DIGITIZATION
SMART
FACTORY

13. SMART
FACTORY
SMART
PRODUCTS
CONNECTIVITY
DIGITIZATION

14. “The sky is the limit.
Technology is not a limiting
factor anymore!”

16. CONNECTIVITY
OLD WAY OF WORKING
Operator monitors process to his best ability
Slow problem solving (search for data) – ad
hoc monitoring by maintenance
INTERESTING DATA CONTENT IN STANDARD CNC MACHINE
PLC
Basic NC (multiple channels)
Extended
• Status of the lamps (simplified
version of status of machine)
• Counters
• Status of sensors
• Failure codes
• …
• Age machines: 2000-2019
• Brand of Control
• Siemens (80% for VCST)
• Fanuc
• Others
VCST
• Motor currents, temperature, voltage,
…
• Tool data (total & remaining toollife)
• Failure codes/ alarms
• CNC cutting programs incl actual
program
• …

17. CONNECTIVITY
IIOT (Database)
Machine 1 Machine nMachine 2 Machine n-1
PLC
CNC
HMI
ONE-STOP-SHOP- DATA
SUBLAYER
DATA AGGREGATION
SUBLAYER
MACHINE CONNECTION
SUBLAYER
PLC
CNC
HMI

18. FULL CONNECTIVITY
CAD
PLM
AR
IIOT

19. FULL CONNECTIVITY
CAD
PLM
AR
IIOT

20. 2020
KEYLEARNINGS
Machine connection can
be complex depending on
data requirements
The machine supplier’s
business model matters
Set up POC together with
key-users

21. SMART
FACTORY
DIGITIZATION
SMART
PRODUCTS
CONNECTIVITY

22. “Don’t digitize
processes with
waste!”

23. CONNECTIVITY – MEASURING DEVICES
ERP legacy
Example Process steering measurement assignment:
Paper assignment
30+ custom made
Fully integrated system (Q, Log, Eng,
Fin, Maint,…
Monitoring?
Evaluation time-consuming
Dim M: 109,789+/-0,03mm
Frequency
A)1/50
B)Every Tool change
Context?

24. PLM – Product Masterdata
IIOT-Trigger
IIOT - Datalake
IIOT - Analytical Engine
CONNECTIVITY – MEASURING DEVICES
Trigger/Event definition
Assignment & reaction plan definition
Dim M: 109,789+/-0,03mm
A)1/50
B)Every change of Tool X
C)Additional info (e.g. Spindel C1 & C2)
Trigger/Event scanner
Request Assignment def. from PLM
Machine counter
450 prod/500 Target
Notification to Operator
Assignment towards Measuring
equipment (incl Trigger/Event, order,…)
Take part from Spindel C1
Select correct part
Start measurement
Measuring task “456789”
Evaluate Value
Start reaction plan if required
Dim M: 109,789+/-0,03mm
Value: 109,793 => OK
IIOT - Evaluation
Operator
IIOT-Assignment
L3: Store value with context
Value: 109,793 => OK
Spindel C1
450/500 from Tool X
L4: Check for
optimizations: risk
analysis
Analytical tools - Analysis
L5: Monitor process long term
(set alarms)
VCST = Automotive (IATF
16949)
• Level 4 & 5
available
• Manual charts
Analytical tools - Alarm
L6: Work towards dynamic
inspection plans: Make every
measurement count
Need “contextualized data” to
reach level 6

25. 2525
KEYLEARNINGS
Define a
“single source of truth”
for master data
Make every
measurement count
Look for a win-win:
WIIFM vs. WIOM

26. SMART
PRODUCTS
CONNECTIVITY
SMART
FACTORY
DIGITIZATION

27. “Search for value creation for
your customers!”

28. LINK OWN DATA TO CUSTOMER DATA
NVH
Noise
Vibration
Harshness
=> NOK: Engine to be
replaced & reworked
CUSTOMER: ENGINE & CAR ASSEMBLY
TORQUE
Customer Partnumber
Date
Operator last check
Torque value
Sequence number
WAVINESS LEVEL 5 SOLUTION: Big data analysis – risk indication
LEVEL 6 SOLUTION: not found yet
BIAS GEAR TORQUE IS CRITICAL
RISK FOR MIXING PARTS: DMC code, Torque known for every engine

29. KEYLEARNINGS
Finding the right
“level 6” solution is not
always easy
It is possible to make
your product smart
Focus on value creation
for your customer

30. Round-up3

32. Thank you!
Tim Polleunis Jan Coekaerts
Manager Smart Factory Business consultant

34. LET’S GET
PHYGITAL
WITH