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Proactive and Mobile Maintenance: A Leap Towards Industry 4.0 for Philips Lighting
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
The 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 The 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.
The 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.
Operational Impact
Quantitative Benefit
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