Future Manufacturing 4.0: Toyota innovation, robotics, AI, Big Data. Futurist keynote speaker



I'm here in Sweden at Toyota where I've been giving a lecture on the future of manufacturing manufacturing 4.0 digital artificial intelligence different aspects of the future but at the end of the day it's all about teams of people working together in very precise ways integrated fully with the very best of technology to do amazing things about 80,000 of these things a year and you can see them behind me they're very precisely engineered very heavy-duty you might be shocked at the sheer thickness and weight of the pieces of steel here this is not building cars this is building industrial machines that make other machines so they're tough they are they're let they're built like tanks and here behind me is a laser cutting components out of Steel this thing and the laser is cutting it at around 2 or 3 centimeters every second so here we have sheet steel that has been laser-cut to produce large numbers so they can be pasted assembled into other parts and so on and now they're being bent with colossal force very thick steel in a very very precise way I'm absolutely astonished at how quiet this place is considering the stamping huge amounts of steel at a very great thickness we are laser cutting we're bending but the noise level is just a few decibels very picked well decision so this is what the robots are welding and if we come close we could just see that the sheer size and strength this is like it's like like a military vehicle it's just incredibly strong it's made to withstand huge impact and massive stresses so behind me we've got robots that are spraying powder onto metal and this power there will there be baked in the oven at the temperature of several hundred degrees centigrade which means that these powers of particles coalesce together form a liquid and then when it sets if the juices is very very hard industrial quality coating so Bob me we got trains these are modern rails and they're traveling relatively slowly carrying components on hooks from one process into another in this case they're covered in black powder and they're heading for the oven so this is the buff for the factory because some of these pieces are only made one and a half hours before they're needed on the assembly line so this is lean lean lean manufacturing you are running an operation literally hour by hour making fitting making fitting out out out salt dispatched all over the world and what's going on is a combination of the genius and good ideas and the common sense of every single worker who's working on the assembly line together with those that are controlling the robots in different parts of what we're going to see you later at all with one purpose in mind to make sure that we have the minimum amount of waste the minimum minimum amount of wasted effort and the minimum amount it's fine to do things really really well it's a low level environment it's er easy to work in and every person is on the floor is encouraged to contribute their own ideas about ways to speed processes up and make things more efficient now although it doesn't look like it there are hundreds of robots working around here but they're unobtrusive they literally got a low profile and may be driving a platform around with the particular components from one place to another or maybe supplying new boxes to one set of people who are assembling on the line they may be pods as we'll see in a moment moving slowly down the assembly line come Tessa so this little fella is the partner of a virtual conveyer belt is not on any railroad lines or anything that he knows where he is in the factory who knows what he's carrying and preparing all kinds of components here but you're going to be used elsewhere on the rest of this assembly line behind me we're now on the main assembly line one with five lines down here and these are going to produce 80,000 trucks this year 120,000 in a couple of years time and each of these people is working on a platform and the platform itself if we have a look doesn't look like it but it's moving very slowly and the precise speed at which these different platforms move across the factory determines the number of vehicles that comes out and each group of workers has precisely the same amount of time to do their own set of tasks so we have many different stations and then each point they move on and each worker will change the station they work at several times a day to keep the work more interesting and over appeared at two or four years they will work their way right through the whole factory so behind this we're assembling the vertical part of the mast of a forklift truck that's that big black thing going up and down and these are the seats being turned it's on the assembly line assembly line itself it's a big conveyor belt and it's moving maybe slowly in the track time here land at the time that takes each station is about eight minutes and every worker they got a a number of tasks they have to do and the whole thing is about optimization about being incredibly lean and efficient it's all about learning where the spanner is located where are the components are with it and at the top left on the bottom right these things all really matter because you want workers to be able to do these things almost in their sleep just automatically very easy no strain on the back safe environment now obviously if you've got a tack time of 8 minutes you've got teams at each sector working flat out to make sure they complete their tasks but what if you something runs out or your drills broken or and something's gone wrong the answer is you've got two things you can press one is that this yanking this yellow thing here tells the rest of the line that you need an assistant the second is the red one that's an emergency stop that means I'm out I can't continue start start start this whole lines got to stop and everything immediately halts everyone down stalls the supervisor will come sort out what the problem is and try and get the line back up and running in hopefully seconds if not in minutes so it's a highly precise environment and the efficiency of the factory depends more than anything on how many stops you're going to get in a day and how long each one actually is we have a minor incident here so we got an orange light which means the the fact is still running but that's we can't say continue for much longer we've got literally minutes to sort this out or we're going to have to close the whole line for a minute or for a little while so the engineers on site tried to resolve the problem we're on the phone getting expertise and so on to repair the line gets it back up and running and then we'll be flown again this is what it's all about it's about response time reliability anticipating and finding workarounds that enables a line to continue without halting the whole factory now important thing about products is learning from your own customers well how about being your own customer since all yota uses sixty thousand five hundred of its own fault lift trucks in its own factories and that data is absolutely vital in terms of reliability our ease of use and so on to help shape the next generation of fourpence obviously whenever there's a break for any human being everyone has to stop because the whole line is halted and that's the time when the maintenance crews come in sort things out and prepare the line for full operation very soon I think the take-home message is this that you can have all kinds of brilliant engineering and the best designs and so on but when it actually comes to making things it's a different matter but we're looking at predictive analytics we're looking at combining a lots of big data about failures about problems we're talking about optimizations particular fine-tuning things which may be very very small to your eye but will be mission-critical in terms of the overall factor efficiency over the next year or two we're talking about problem solving and the speed at which you can diagnose something that's about to happen and prevent it and make you intervention to keep that line up and running without any interruption and above all this the human element when we look around the factory we need to make sure that every single person here is comfortable in what they're doing they're safe they're properly supervised they're well trained but they're also satisfied and enjoying the challenge because only when all of those things work together that you have a happy environment and that means you get reliability the sky-high

29 Comments

  1. Shoikot Mahmood said:

    Don’t Much of the machinery. Rather see your face the whole time. Next time try to do a better job

    June 28, 2019
    Reply
  2. Xubair Ahmed said:

    scorpion from Mortal Kombat 20

    June 28, 2019
    Reply
  3. Francisco Cevallos said:

    Is Toyota into manufacturing electric cars and self driving cars already?

    June 28, 2019
    Reply
  4. Francisco Cevallos said:

    They should improve more everyday,Kaizen-Japanese work ethic about everyday development

    June 28, 2019
    Reply
  5. Łøvē Ÿøū said:

    Hello brother I'm from Cambodia 🇰🇭
    You know Cambodia 🇰🇭?
    TOYOTA Prius 2004-2009 price $20000
    TOYOTA Prius 2017 price $50000
    It price in Cambodia it very expensive for me,
    Some workers get paid $ 177 a month. So they can not afford to go to the car

    June 28, 2019
    Reply
  6. Rotten Brainz said:

    bah ill beat em out my own backyard and garage. MAXIMUM EFFICIENCY! BLOW THE WORLD UP WITH OVERPRODUCTION! NNNOOOWWW!!!!

    June 28, 2019
    Reply
  7. boermaone said:

    This has absolutely nothing to do with industry 4.0. This is just another factory tour talking about lean manufacturing and simple systems like robotics, AGVs, laser cutting and welding and andon. These have been around for decades. This is just a good example of how to put the basics together. Industry 4.0 is all about device level communications and how machine interact. However, if you are not up to speed with the manufacturing practices here (done pretty well), you should be focusing on Lean Manufacturing and not Industry 4.0.

    June 28, 2019
    Reply
  8. Savaliya Mahesh my mo 7567209892 said:

    Yes u India Gujarat Name mahesh Patel my WhatsApp mo 7567209892 kaim business yes

    June 28, 2019
    Reply
  9. Yahootube chanel auto generate video said:

    คนทั้งนั้น เลือกก่อน กดดู ใครๆก็รู้

    June 28, 2019
    Reply
  10. Takut Dosa said:

    Pake Helm tolol… kejatuhan benda bocor langsung pala lu

    June 28, 2019
    Reply
  11. Kiran Mahindrakar said:

    Wear the helmet

    June 28, 2019
    Reply
  12. gerry said:

    factory of robots building other robots

    June 28, 2019
    Reply
  13. Kal BEN said:

    This’s more about lean manufacturing and have nothing to do with industry 4.0.

    June 28, 2019
    Reply
  14. David said:

    Great video! "They're built like tanks."

    June 28, 2019
    Reply
  15. gibbetify said:

    This is not industry 4.0

    June 28, 2019
    Reply
  16. Michael Smith said:

    You have trumpf brand…..

    June 28, 2019
    Reply
  17. aleksander suur said:

    Let me get this right, you have a line going with 8 mins cycle time and you have only few hours of buffer on some parts? Yeah, there's being lean for the sake of efficiency and then there is being lean for the sake of management wanting to feel they have done great work. That's where all your line stoppages are coming from, non-existent buffers and lack of backups, everything you need to run efficiently has been "optimized" away.

    June 28, 2019
    Reply
  18. Andi Y sobandi said:

    Banyak ngomong Lo

    June 28, 2019
    Reply
  19. Diego Piscoya said:

    I would love to work in a place like that, sir what do you think would prepare me better for it electrical or computer engineering? Ty

    June 28, 2019
    Reply
  20. Kevin Jongte said:

    Thr art of science. Brilliant!

    June 28, 2019
    Reply
  21. Limitless 1 said:

    This feels more like an add for Toyota than anything else ….

    June 28, 2019
    Reply
  22. Vladan Markovic said:

    Do you really think we have to see your head in every single frame?

    June 28, 2019
    Reply
  23. MrWalker1000 said:

    is manufacturing 4.0 pioneered by japanese or german?

    June 28, 2019
    Reply
  24. Muhammad Andri Alfian said:

    You should use safety helmet actually hhe 😁

    June 28, 2019
    Reply
  25. thomas lambrecht said:

    Now do Tesla Motors

    June 28, 2019
    Reply
  26. mm tindaro said:

    not sure what do you really have to celebrate .

    June 28, 2019
    Reply
  27. Bear Humphrey said:

    yes it very impresive but with only a few people working how can you sell produtes with people out of work

    June 28, 2019
    Reply
  28. Quantum Information said:

    Nice work ma man!

    June 28, 2019
    Reply
  29. Alex Cristopoulous said:

    Trumpf brand

    June 28, 2019
    Reply

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