1.
VCST’S SMART FACTORY IMPERATIVE:
DELIVERING HIGHER PRECISION,
QUALITY AND EFFICIENCY
JOURNEY OF A DIGITAL TRANSFORMATION
Tim POLLEUNIS
Dirk LUWAERT
Jordan CHAISSON
27th July, 2020
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2.
VCST’S SMART FACTORY IMPERATIVE:
DELIVERING HIGHER PRECISION,
QUALITY AND EFFICIENCY
JOURNEY OF A DIGITAL TRANSFORMATION
Tim POLLEUNIS
Dirk LUWAERT
Jordan CHAISSON
27th July, 2020

3.
3
SPEAKERS
Tim POLLEUNIS
Manager Smart Factory
VCST Industrial Products
Dirk LUWAERT
Enterprise Solution Architect
Manufacturing Industry
AdUltima Group
Jordan CHAISSON
Senior Manager, Connected
Operations Solutions
PTC

4.
AGENDA
What’s Next?
Solution &
Results
VCST &
AdUltima
introduction
Digital
Transformation
with PTC

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5
INDUSTRIAL COMPANIES LOOK TO US TO MAXIMIZE THE USE
OF TECHNOLOGIES TO BOOST THEIR EFFICIENCY, PROMOTE
THEIR BUSINESS AND MAKE THEIR COMPANY SUSTAINABLE
Data
transformation
and enrichment
Collaboration
on same data
Data
Synchronization
Data quality
Data
associativity
and traceability
WHILE FACING THE FOLLOWING CHALLENGES
ON THEIR ENTERPRISE DATA

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VCST & AD ULTIMA

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Oostkamp
Sint-Truiden*
Zanesville
Léon
Iasi Alba
Reichenbach
Brno
Suzhou
Changzhou
Pune
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
FTE: 162
TO: € 21,8m
FTE: 1024
TO: €26.7m
FTE: 207
TO: € 44.7m
OVERVIEW BMT DRIVE SOLUTIONS

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OVERVIEW AD ULTIMA GROUP
+350
employees
20y
experience
+ 500
Satisfied
customers
Local
Presence
Trusted
Advisor
Industry
Experts
Faster to
value
AGILE

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SOLUTION & RESULTS

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• Automotive Industry – Innovative, very high quality standards and
extreme cost pressures
• Cost and the Efficiency of the shop floor – Supporting departments
need to be stronger/automated
• New strict NVH requirements – High Product & process requirements
• Cost of poor quality – Automotive: High volume. Instability = Risk for
high costs
• Time to market - Non-automated workflows in different systems.
Time consuming to determine impact of request/change.
CHALLENGES

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Objectives of the digital transformation initiative
• Improve OEE - Improvement in supporting functions like logistics,
quality & maintenance
• Reduce the costs of poor quality – run the system in a more stable
way, reduce risk. Introduce closed-loop system
• Improve Competitiveness/Revenue – Reduce NVH- Capture line
parameters for customers – more data, the greater the chance
of finding correlations
• Improve Time to Market - Reduce the time it takes to implement
a change by 25%
• Scalable – Integrate in BMT-IT structure
OBJECTIVES

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PROJECT TIMELINE POC - PILOT
April
2019
January
2020
January
2020
Smart Factory
Show Case (part 2)
GO-LIVE
Breakthrough with
Marposs to Create
Q-Digibox
Blueprints Systems
Integration Available
July
2018
Approval
POC Project
Concept
workshop
November
2018
Start POC
Thingworx
Planning Full Roll-out
Upgrade IT-landscape
Smart Factory
Show Case
September
2019
New Smart
Factory Manager
June
2020
September
2020
Visit
Event
POC PILOT
GO
First CNC from
machine connected

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SNAPSHOT OF THE SOLUTION
Production Planning
OEE
NVH Optimization
Material tracebility
Closed loop Quality
Plan for optimal efficiency with integrated visual planning
from order intake to shopfloor
A constant accurate view on efficiency
by a (nearly) fully automated logging of events
Towards Machine Learning in action …
Overall material traceability by a complete digital chain,
assuring compliance demand
From PLM managed Control plan, over event-drive quality
measurements enabling extended process control
What is the approach taken and technology used for the Smart Factory platform at VCST?

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PRODUCTION PLANNING

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15
OEE

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NVH OPTIMIZATION

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NVH OPTIMIZATION
Reishauer Argus
• Partner: Reishauer
• Goal: Process, Machine & Component
Monitoring
• Remark: Extra features available on
Reishauer platform
Digibox
• Partner: Siemens WCC
• Goal: Access to PLC & NC Data
• Remark: 110 parameters traced every 1-3
seconds.
Measurement Data
• Partner: Marposs – AdUltima
• Goal: Risk-Based Measurements
• Remark: No solution on the market.
Prototype developed together with
Marposs
Tools
• Partner: AdUltima – Delaware
• Goal: Minimize Risk Critical Tools
• Remark: Incoming inspection on tools (ex.
Dresser) combined with performance
monitoring on serialized tool level.
Shopfloor Monitoring - OEE
• Partner: AdUltima
• Goal: Link Events from the Shop Floor
• Remark: Give insight to the events that
happened linked to the process
VIBMON
• Partner: Enginity – Flanders Make
• Goal: Predict Gear Quality
• Remark: Measuring
vibrations/accelerations on the
grinding head with accelerometer
Waviness
• Partner: (Self-Development)
• Goal: Predict NVH Behaviour
• Remark: In-house developed GEWA
software re-engineered to make it future
proof
Machine
Monitoring
Tool Monitoring
Part Monitoring
Environment Monitoring
NDA

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SNAPSHOT OF THE SOLUTION
Production Planning
OEE
NVH Optimization
Material tracebility
Closed loop Quality
Plan for optimal efficiency with integrated visual planning
from order intake to shopfloor
A constant accurate view on efficiency
by a (nearly) fully automated logging of events
Towards Machine Learning in action …
Overall material traceability by a complete digital chain,
assuring compliance demand
From PLM managed Control plan, over event-drive quality
measurements enabling extended process control
What is the approach taken and technology used for the Smart Factory platform at VCST?

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APPROACH TAKEN TO BUILD A SMART FACTORY
PLATFORM AT VCST
IT-OT convergence
Data-driven operations
Operator Advisor
ISA-95 datamodel
Translate backend processes
using industry standard
ThingModel
Hybrid capabilities close to
the ground and the events

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EXTENDED INDUSTRY 4.0 ARCHITECTURE AT VCST
Production Devices
Maintenance
Execution
Guided
instructions
Siemens
Legacy ERP
Equipment
monitoring
Phase 1
Transport
Personnel
Time registrations
Maintenance,
Transport, HRM, ...
Resources
Production Order
Materials & BOM
Inspection Lot
Production Status
Actuals
Inspection Results
mBOM
Process Plan
Control Plan
ECN
Product Definition
and Information
Tool Definition and
Information
Process Definition
en Information
Shop Floor
Execution &
Monitoring
Production
Scheduling
Quality Planning
Demand Mgmt and
Forecasting
Warehouse
Phase 2
Measuring Devices
Quality Control /
Capture
Inspection
Reporting
Quality Analysis
Inspection
Results
VCST &
AdUltima
Actual Time/Cost
Discrepancies
Corrective Actions
Process Plan
Instructions
Transport Devices
Wearables

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SNAPSHOT OF THE SOLUTION
Production Planning
OEE
NVH Optimization
Material tracebility
Closed loop Quality
Plan for optimal efficiency with integrated visual planning
from order intake to shopfloor
A constant accurate view on efficiency
by a (nearly) fully automated logging of events
Towards Machine Learning in action …
Overall material traceability by a complete digital chain,
assuring compliance demand
From PLM managed Control plan, over event-drive quality
measurements enabling extended process control
What is the approach taken and technology used for the Smart Factory platform at VCST?

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MATERIAL TRACEABILITY

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MATERIAL GENEALOGY
RAW
Component A
(Semi) Finished
Component B Material
Supplier Batch
Boxnr

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CLOSED LOOP QUALITY

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AD ULTIMA’S PROJECT DRIVERS
❑ Introduced MVP approach
❑ Trained VCST to secure
upscaling
❑ PLM/ERP/MES experience
linked to MDM
❑ Match requests to ISA-95
model and MES “light”
“Agile”
Bring instant value
in the Factory
“Future proof”
Build platform based on
industry standards
“Smart”
Continuously designed
“Smart Factory” proof
❑ Process design starting from
Machine data
❑ “Closed loop” thinking

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WHICH APPROACH TO CHOOSE?
MES Application Industrial IOT Platform
Works well for “greenfield” implementation
and when processes will not change much
over time
Brownfield implementation requires
flexibility to fully support mature shopfloor
processes
Transactions based logic focusses on
optimal processes
Data (“Thing”) centric allows for a “Smart”
approach linking in to processes
Integration is often tied to specific
limitations (data and UX level) depending
on vendors product strategy
Easy integration to business systems like
ERP, PLM, … Easy access to UX devices
(handhelds, wearables, …)
Customization can be time and cost
consuming. Risk of lock-in.
Low-code platform allows for balanced
level of ownership

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• Increase overall efficiency in the organization by E2E approach and de-
”Silo”…
• Reduce operational costs by tracing the behavior of the machines and
tools real-time.
• Reduce MTTR and OEE losses
• Time to implement a change – 25% anticipated
• Scalable – VCST / Division / Group
TARGETED BENEFITS

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WHAT’S NEXT?

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• Further develop machine & Q-device connectivity
• Use power of PTC suite
– Creo: 3D models with MBD
– Windchill “full”: optimize engineering process
– Vuforia: Expert capture
– Chalk: remote support plants (accelerated through COVID-19)
• Connect to the Smart Factory platform
– Automated warehouse
– AMR/AGV
– Customer/ Supplier data
WHAT’S NEXT

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DIGITAL TRANSFORMATION
WITH PTC

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ENTERPRISE EFFICIENCY WITH DIGITAL TRANSFORMATION
CREATE A COMPREHENSIVE DIGITAL THREAD WITH PTC
Unlock double digit value from digital engineering, to smart manufacturing with
connected solutions that deliver impact, speed, and scale

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A CONNECTED ENTERPRISE WITH PTC
CLOUD | HYBRID | ON-PREM
Requirements,
Systems
& Software
SIMULATION MFG SUPPLIERS CUSTOMERS
Source Data
MBSE Authoring Tools
REQ
& TEST
Lifecycle Management including
XBOMs, Documents, Variability,
Change & Configuration
Management, 3D Mockup, RAMS,
Technical Documentation
Spare Part
Management
Test and
Validations
Device Cloud
Physical Product
ERP MES MRO CRM …
…
Crosscutting Link & Context
Extended PLM
ROLE & TASK BASED
APPLICATIONS
Enterprise Roles
Engineering Manufacturing
Procurement
Configuration
Manager
PLM Expert Sales
Service
Others…
Sourcing
ENTERPRISE
DOMAIN
APPLICATIONS
PLATFORM Extend the PLM: Source - Contextualize - Synthesize - Orchestrate - Engage

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WANT TO LEARN MORE?
CHECK OUT THESE GREAT RESOURCES:
LNS Research Spotlight: Transforming Frontline Operations with
Augmented Reality
The PLM Deployment Handbook
Report: Increase the Asset & Machine Efficiency of your Hidden
Factory

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QUESTIONS?
Tim POLLEUNIS
Manager Smart Factory
VCST Industrial Products
Dirk LUWAERT
Enterprise Solution Architect
Manufacturing Industry
AdUltima Group
Jordan CHAISSON
Senior Manager, Connected
Operations Solutions
PTC

35.
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