Digital Process Twin for Infusing Digital Adoption

I started my career working for the best global manufacturing companies after graduation. I take great pride in my firsthand manufacturing experience of product life cycle and process improvement methodologies like lean and six sigma. Luckily I got the opportunity to transition to the Digital/IT world later.  I have learnt and applied a few of these new technologies such as IoT, Predictive Analytics, AI, MES, Twins, Cloud, Big data, Industry 4.0 etc. for manufacturing customers. It has been an interesting journey so far…

CHALLENGES

The envisioned business impact from these new digital technologies can be transformational. However, pivoting to digital mindset and adoption has been difficult in manufacturing companies.  In a study done by NewVantage partners in 2019 on adoption of Big data and AI, it was reported that 95% of obstacles are due to cultural challenges and only 5% related to technology. Similar survey results are found from other research organizations. 

I believe four pillars are central to overcome these obstacles:

P1. A unique aspirational vision of digital transformation – focusing on why it is different and how it will change way of working [This clarity is not evident at plant levels]

P2.  Change management in regards to people excitement about use of digital data for improved decision making, at unit and company levels. [It is worthwhile and right time to create systematic digital adoption program with right type of talent team similar to successful global lean six sigma programs of 80s&90s]

 P3. In depth understanding of manufacturing problems – not just single use cases but also drawing the connection among system process mechanics. [Often touted benefits fail short of plant expectations due to narrow focus. Unlike Kaizen improvements, digital technologies should be able to demonstrate nonlinear impact for better buy-in]

 P4. Digital technologies need to be rightsized to manufacturing problems – solving them efficiently than traditional methods [Prediction accuracy, process entitlement achieved & their sustainability, impact on decision making or way of working. Total costs of implementing technology investments need to be optimized for desired specific business outcomes and to gain real competitive advantage]

SOLUTION APPROACH

A suggested approach to infuse digital adoption encompassing these pillars is to build a digital process twin of PDCA cycle in an organization. A PDCA process runs through the nervous system of established manufacturing system of people, process and technology.   A new product development process focusing on building quality products offers a useful PDCA cycle for this process twin.

Although manufacturing industry has made significant advancements in quality in the last two decades, opportunities still exist for achieving peak performance. A Quality 2020 study done by AIAG and Deloitte identified three top key challenges – concerns related to effectiveness of problem solving, product development and loss of experience. The composite impact is lower cost of quality.  

In my own experience of launching programs for automotive OEMs, common problems exist in all three phases i.e. Prelaunch, Production and Field as shown on the left side of this figure below. Ability to reduce costs is best possible in prelaunch phase, else high costs are incurred in production and field.  Right side of the figure, shows how process twin can address these issues.

DIGITAL ADOPTION VALUE

When implemented with optimal details, this type of process twin can be built quickly and at low cost.  It will drive digital adoption in following ways (Pillar impacted shown in brackets)

• Address real industry centric problems and offering results in three aspects as shown below. Everyone can see the forest for the trees. (P3)

• Provides a canvas for implementing digital technologies correctly. (P4)    Depending on digital maturity / current needs, some examples can be:

• It will facilitate cross collaboration in supply chain, builds digital competencies of people and creates sense of urgency and motivation of embracing digital mindset and its benefits (P1& P2)
• It will make the potpourri of digital technologies and their investments more lucid for decision makers and align business and IT teams for continual digital transformation journey. 

==========The contents of this article are strictly of my personal view=========