SymphonyAI Case Studies Proactive and Mobile Maintenance: A Leap Towards Industry 4.0 for Philips Lighting

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	Proactive and Mobile Maintenance: A Leap Towards Industry 4.0 for Philips Lighting SymphonyAI

Proactive and Mobile Maintenance: A Leap Towards Industry 4.0 for Philips Lighting

SymphonyAI

Technology Category	Functional Applications - Computerized Maintenance Management Systems (CMMS) Sensors - Optical Sensors
Applicable Industries	Equipment & Machinery Recycling & Waste Management
Applicable Functions	Maintenance Quality Assurance
Use Cases	Manufacturing System Automation Smart Lighting
Services	Testing & Certification
Challenge	Philips Lighting (now Signify), a global leader in lighting solutions, aimed to become the world's only conventional lighting manufacturing plant network. However, its operations in Turnhout, Belgium, a high-wage country, needed to be as efficient as possible to realize this ambition and embrace the Industry 4.0 evolution. The company had already implemented Lean manufacturing, with employees constantly seeking ways to eliminate waste and improve processes. However, the old PDA used for monitoring and carrying out preventative maintenance tasks on up to 200 machines was slow, unwieldy, and difficult to manage. It was not adaptable to include new items or delete obsolete ones, could only record current measurements, and offered no historical data. The PDA was inadequate for the task at hand. Read More
About Customer	Philips Lighting, now known as Signify, is a global market leader in the development and production of lighting solutions. The company has a strong ambition to become the world's only conventional lighting manufacturing plant network. To achieve this, it has implemented Lean manufacturing principles in its operations, constantly seeking ways to eliminate waste and improve processes. Its operations in Turnhout, Belgium, are particularly crucial to this ambition, as they need to be as efficient as possible to help the company embrace the Industry 4.0 evolution. Read More
Solution	In collaboration with software developer Proceedix, PwC proposed a solution in the form of a smartphone and tablet app that allows Philips Lighting’s utility operators to carry out required preventative maintenance tasks. Rather than proposing a generic system, the three parties co-created the app to meet Philips Lighting’s specific needs. The solution aligns with the client’s Lean approach, contributing significantly to its efforts to increase quality and performance in its manufacturing operations. The app eliminates the need for reports to be created after machines have been monitored, saving time and reducing waste. The next step will be to extend the app to include maintenance activities, with step-by-step instructions enabling operators to carry out some maintenance tasks themselves. Strict authorization protocols will ensure that suppliers can only access data regarding their machinery. Read More Log in to view content
Contents

Technology Category

Functional Applications - Computerized Maintenance Management Systems (CMMS)

Sensors - Optical Sensors

Applicable Industries

Equipment & Machinery

Recycling & Waste Management

Applicable Functions

Maintenance

Quality Assurance

Use Cases

Manufacturing System Automation

Smart Lighting

Services

Testing & Certification

Challenge

Philips Lighting (now Signify), a global leader in lighting solutions, aimed to become the world's only conventional lighting manufacturing plant network. However, its operations in Turnhout, Belgium, a high-wage country, needed to be as efficient as possible to realize this ambition and embrace the Industry 4.0 evolution. The company had already implemented Lean manufacturing, with employees constantly seeking ways to eliminate waste and improve processes. However, the old PDA used for monitoring and carrying out preventative maintenance tasks on up to 200 machines was slow, unwieldy, and difficult to manage. It was not adaptable to include new items or delete obsolete ones, could only record current measurements, and offered no historical data. The PDA was inadequate for the task at hand.

About Customer

Philips Lighting, now known as Signify, is a global market leader in the development and production of lighting solutions. The company has a strong ambition to become the world's only conventional lighting manufacturing plant network. To achieve this, it has implemented Lean manufacturing principles in its operations, constantly seeking ways to eliminate waste and improve processes. Its operations in Turnhout, Belgium, are particularly crucial to this ambition, as they need to be as efficient as possible to help the company embrace the Industry 4.0 evolution.

Solution

In collaboration with software developer Proceedix, PwC proposed a solution in the form of a smartphone and tablet app that allows Philips Lighting’s utility operators to carry out required preventative maintenance tasks. Rather than proposing a generic system, the three parties co-created the app to meet Philips Lighting’s specific needs. The solution aligns with the client’s Lean approach, contributing significantly to its efforts to increase quality and performance in its manufacturing operations. The app eliminates the need for reports to be created after machines have been monitored, saving time and reducing waste. The next step will be to extend the app to include maintenance activities, with step-by-step instructions enabling operators to carry out some maintenance tasks themselves. Strict authorization protocols will ensure that suppliers can only access data regarding their machinery.

Impact #1	The new solution has significantly improved efficiency and lowered costs in a Lean way. It has eliminated the need for reports to be created after machines have been monitored, which is a significant area of waste that has been eradicated. The solution also allows operators to carry out some maintenance tasks themselves, reducing dependency on the machine supplier. The app may also be used for additional tasks such as analysing breakdowns and making improvements, as well as for areas close to maintenance, such as quality processes and operator procedures. Ultimately, this could lead to a paperless factory at Turnhout for Philips Lighting/Signify.

Impact #1

The new solution has significantly improved efficiency and lowered costs in a Lean way. It has eliminated the need for reports to be created after machines have been monitored, which is a significant area of waste that has been eradicated. The solution also allows operators to carry out some maintenance tasks themselves, reducing dependency on the machine supplier. The app may also be used for additional tasks such as analysing breakdowns and making improvements, as well as for areas close to maintenance, such as quality processes and operator procedures. Ultimately, this could lead to a paperless factory at Turnhout for Philips Lighting/Signify.

Benefit #1	Operators save up to an hour a day due to the new solution, freeing up time for more value-adding activities.
Benefit #2	The solution allows for the reduction of the maintenance service agreement with the machine supplier, leading to cost savings.

Benefit #1

Operators save up to an hour a day due to the new solution, freeing up time for more value-adding activities.

Benefit #2

The solution allows for the reduction of the maintenance service agreement with the machine supplier, leading to cost savings.

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Overview

Proactive and Mobile Maintenance: A Leap Towards Industry 4.0 for Philips Lighting

Operational Impact

Quantitative Benefit