效率竞赛_工业40及其对电子组装的影响英文版_20页_2mb

Roland Berger Focus - The Race for Efficiency

Core Content

The electronics assembly industry, valued at around EUR 1.5 trillion, is undergoing a transformation driven by Industry 4.0. This new industrial revolution combines technologies like the Industrial Internet of Things (IIoT), 3D printing, and cyber-physical systems such as augmented reality, to enhance efficiency, flexibility, and profitability.

The race for efficiency is intensifying due to declining sales prices, increased customer and product numbers, shorter innovation cycles, and faster time-to-market demands. Companies are under pressure to adopt Industry 4.0 technologies to stay competitive, and the potential for improvement is significant—up to 9 percentage points on EBIT and 20 percentage points on ROCE.

Main Points

1. Industry 4.0 and the Electronics Assembly Industry

• Industry 4.0 is a broader concept than just production systems, encompassing digital transformation across the entire value chain.
• The semiconductor industry is more mature in implementing Industry 4.0 than electronics assembly.
• Electronics manufacturers (OEMs, EMS providers, ODMs) and suppliers (equipment and software) can all benefit from Industry 4.0.
• Technology blocks are key to understanding and implementing Industry 4.0. The report outlines 20 technology blocks, divided into hardware-centric and software-centric categories.

2. Maturity Levels of Electronics Manufacturers

• Even leading players are only halfway through the full implementation of Industry 4.0.
• LVHM (Low-Volume, High-Mix), HVLM (High-Volume, Low-Mix), and MVMM (Medium-Volume, Medium-Mix) are three distinct operating models that influence the choice of technology blocks.
• LVHM players (e.g., aerospace, medical) benefit most from flexible workshop-based production systems, production scheduling optimization systems, and process master control systems.
• HVLM players (e.g., consumer electronics) focus on further equipment automation, predictive maintenance, and machine and line performance optimization systems.
• MVMM players (e.g., automotive electronics) combine elements from both LVHM and HVLM models.

3. Strategic Implementation

• LVHM players can increase EBIT by 6% and ROCE by 20%.
• HVLM players can add 2% to EBIT and 6% to ROCE.
• MVMM players can achieve 3% to EBIT and 9% to ROCE.
• Companies must prioritize technology blocks based on their operating model, product mix, and volume.
• Internal development and external partnerships are essential to implementing Industry 4.0.

Key Technology Blocks and Their Impact

Key Information for Equipment and Software Providers

• Machine suppliers are focused on hardware and machine-related software. They need to expand into software-based technology blocks like process master control and predictive maintenance.
• Automation providers can develop customized solutions for workshop-based production and automated material handling. They should proactively market these solutions.
• MES providers offer software-based solutions for many Industry 4.0 technology blocks. They must integrate with legacy equipment and form partnerships with machine suppliers.
• Specific software players should identify their market niche and build competitive advantages. They can also partner with automation and machine suppliers to offer combined solutions.

Conclusion

• There is no one-size-fits-all solution for Industry 4.0 implementation.
• Strategic alignment with the operating model of the company and its customers is essential.
• Transparency in understanding the value chain and operating models is key to prioritizing technology blocks.
• Collaboration with the right partners is crucial for successful implementation and maximizing the benefits of Industry 4.0.

Recommendations

• Electronics manufacturers should:

  • Identify their operating model.
  • Prioritize relevant technology blocks.
  • Build internal software capabilities.
  • Partner with specialized firms for implementation.

• Equipment and software providers should:

  • Understand the operating models of their customers.
  • Offer customized and integrated solutions.
  • Expand into software-based technology blocks.
  • Form strategic partnerships to enhance value delivery.

By focusing on these areas, all players in the electronics assembly industry can leverage Industry 4.0 to boost efficiency, increase profitability, and secure their position in the market.