Democratizing SMART MANUFACTURING - EIT Digital€¦ · Democratizing S MART M ANUFACTURING...

Copyright © 2018 CESMII - All Rights Reserved.

Democratizing

SMART MANUFACTURING

Democratizing SM KnowledgeWorkforce Development

Business Practices

Demystifying Smart Manufacturing & Industrie 4.0

Democratizing SM TechnologyPlatform Infrastructure

Models (Data, Analytics, Design)

1

Democratizing SM InnovationDe Facto Standards

Engaging the Whole Ecosystem


ManufacturingSystems

Challenges

CulturalComplexities

TechnologyComplexities

ApplicationComplexities

Corporate & AcademiaR&D Relevance

2


CORPORATE PLANT

Mfg

Op

sIT

Consolidate Disparate MFG Systems

Minimize (or Sanction) Shadow-IT

Integration with Enterprise Systems

Compliance

Security

System Integration

Infrastructure Support

Security

Revenue Improvements

Daily Production Schedule Attainment

Expanded Capacity

Supply Chain Visibility

Cost Improvements

Increased Labor Productivity

Lower Plant Expenses

Cash Generation

Reduced Inventory

Higher Return on Assets

BUSINESS PROCESS MGMT

Make Production Numbers

Exceed Quality, Productivity and

Cost Targets

Improve Safety

Current IT Sales & SI Comfort Zone Current OT Sales & SI Comfort Zone

Manufacturing Cultural Complexities

3

OT – Plants• OT Software Vendors

• OT System Integrators

• OEMs

• Government & Regulatory Bodies

• Buying Behavior / Selling Behavior

2 Distinct Ecosystems Serving 2 Distinct Groups of Manufacturing Stakeholders with Opposing Incentives

IT – Headquarters• IT Software Vendors

• Enterprise IT System Integrators

• Global Consulting Firms

• Industry Analysts

• Buying Behavior / Selling Behavior


900+ Clicks & Keystrokes

Configure the Same Tag in 4 Systems

Requires Proficiency in 6 OT Products

2 Unique Domains (Automation, Mfg IT)

Takes Several Days of Effort

Requires Proficiency in 3 OT Products

Requires Proficiency in 2 IT Systems

Requires Custom Code Development

4 Unique Domains (Automation, Mfg IT, EAI, Maintenance)

Takes Several Weeks of Effort

4

Manufacturing OT Scenario: Add a sensor in a typical OT environment (PLC, HMI, Historian, Portal)

Manufacturing IT Scenario: Open a maintenance W/O in SAP PM, Dynamics, Maximo based on a temp ‘rate of change’ event

Manufacturing Application Complexities

This COMPLEXITY Has Made it VERY Challenging to Become a Manufacturing IT Domain Expert


End-of-Shift Reports & Analytics

Analytics

Production Monitoring

Downtime Analysis

Production Counts

Constraint ID & Analysis

Schedule Execution/

Hit to Hit

Process Control Boards

Dock Inventory

Process Sheets

Manual Production Count

Cycle Time Analysis

Environmental Systems

Metrics (DTD, BTS)

Shipping

Container Track’g

Lot Tracking

Rack Tagging

Raw Mat Ordering & Inv

Dock Inventory

Schedule Optimization

Inventory Control

Line Side Replenishment

Part Consumption

Campaigns

Shipping – Error Proofing

External Metrics

Internal Metrics

Traceability

Error Proofing

Defect Tracking

SPC

Repair Bay OI

Quarantine

Scrap & Reject Reporting

Tool Monitoring

Predictive

Preventive

Crisis

Reliability & Maintenance

Downtime Analysis

Fluid Tracking

Programmable Dev Supp

Plant Design & Layout

Die Re-Chroming

Information Portal

Energy/Building Mgmt

Cost Management

Policy Deployment

Best Practice

Timekeeping

Metrics for Workforce

Issues Management

Production Log

Knowledge Management

Training

Birth History Sequencing

Logistics Quality Production Maintenance Management

Actual taxonomy

of mission-critical

manufacturing

systems for large

discrete

manufacturer

Actual ‘End-of-

Shift’ report board

to facilitate

production &

maintenance

hand-off to new

shift

5

Result : A Highly Fragmented Manufacturing Systems Legacy

Copyright © 2018 CESMII - All Rights Reserved. 6

Current Trajectory – More of the Same

All of these vendors – and many more – have great solutions for Manufacturing

All offering IIoT capabilities and Analytics

All able to help drive Smart Manufacturing

BUT…

All constrained by OT Complexity & Scarcity of Domain Expertise


This Legacy Will

Severely Constrain

Smart Manufacturing

Industrie 4.0

Digital Transformation

Initiatives

7

Predictive AnalyticsPlant Floor Assets: Largely relegated to high-value, high-volume assetsOps Mgmt & Supply Chain: Severely constrained by lack of data access

Security: Many unique security risks for each point solution in that application taxonomy

Supply Chain: Data access to Operations is COMPLEX and HIGH RISK

IIoT: Creates significant value but adds to the messy taxonomy of plant floor systems

Automation Vendors building PlatformsIndustrial IoT Vendor PlatformsSensor Vendor PlatformsRobot Vendor PlatformsMachine Tool Vendor PlatformsMachine Builder/OEM Platforms

Academia will continue to struggle to engage & stay relevant

IT constrained in their ability to access the plants & create value


The Manufacturing Challenge – Current State

8

IdentifyStrategicInitiative

DevelopHigh-Level

Justification

DefineSuccess

AssessYour State of

Readiness

CreateRFP

EngagePotentialVendors

EvaluateRFP

Submissions

IdentifyVendor

DevelopSolution

ROI

BecomeInformed

IdentifySystems

Integrator

ProjectKickOff

SM Objective: Reduce Waste by XX%, Energy Footprint by XX%

Scope: 8 Packaging Lines

Each Line: 2 Unscramblers, Filler, Sealer, Labeler, Form-Fill-Sealer, Cartoner, Palletizer, Robot, Conveyance

Automation: 5 PLCs, 1 Robot, 18 VFDs, 145 Sensors (times 8)

Available Data Points: ~2.5 Million (times 8) = 20,000,000


The Manufacturing Challenge – Current State• Translate the desired outcomes (DO) to technology and architecture

• Deep understanding of each piece of equipment, the process, the workflows…

• Ensure all machines and data sources are accessible (86% are not)

• Determine which data is necessary to achieve the DO (which of those 20,000,000 tags need to be collected)

• Then comes the hard part… create context - build a data model

• The success of your solution (how it scales, how it integrates to the enterprise) is a function of how well the data model is designed

• THE CHALLENGE: your data model is a blank slate – EVERY VENDOR, EVERY PRODUCT, EVERY TIME

9

65 – 80% of Solution Time/Cost Spent on Building the Data Collection & Contextualization Platform - not Value Creation

$100k in SW licenses

$300K & 6 months to implement

4 Months before value creation begins


SMART MANUFACTURING

RIGHT INFORMATION –AT THE RIGHT TIME –IN THE RIGHT FORM –AT THE RIGHT PLACE –

WITH THE RIGHT TECHNOLOGY –

FOR THE RIGHT PEOPLE –TO ENABLE SMART

DECISIONS

SMART MANUFACTURERS

REPRESENT A DATA-DRIVEN CULTURE;

LEVERAGE TECHNOLOGY AND KNOWLEDGE MORE EFFECTIVELY THAN THEIR

PEERS

THE SM JOURNEY

A CATALYST TO INVEST IN DIGITAL TRANSFORMATION

AND BECOME A DATA-DRIVEN MANUFACTURER

WITH THE RIGHT EMPHASISON PEOPLE, PROCESS &

TECHNOLOGY

THE SM INSTITUTE

DEMOCRATIZEFOUNDATIONAL

❶ TECHNOLOGIES,❷ KNOWLEDGE &

❸ INNOVATION FOR MANUFACTURERS OF ALL

SIZES AND ALL INDUSTRIES

10


SM Platform

SM Marketplace™(Profiles & Apps)

SM Edge

CPM Designer™(Contextualizer)

Common Profile Model™Enable SME’s to Digitizetheir Domain Expertise

CESMII Strategy: Common Manufacturing IT Infrastructure

11

CESMII MembersIndustry thought leaders & SME’s

Device Vendors

System Vendors (OEMs…)

App Vendors

System Integrators

Academia

Man

ufac

ture

rs

Objective: Create a Plug & Play experience for all Manufacturers, from Discrete to Continuous Process1. A seamless experience based on

Hyperscale infrastructure and vital technology contributions from CESMII• CPM Designer (Contextualizer)• Common Data Model definitions (extend OPC)• A data store construct that integrates time

series, relational and unstructured data

2. CESMII will invest aggressively to encourage (fund) the manufacturing ecosystem to build Profiles & Apps• Device Vendors• Machine Builders• System Integrators• IT App Vendors• OT App Vendors

SM InfrastructureA well-orchestrated

experience

EH Profile Fanuc Profile P/C Profile


Smart Solutions™Vendor 1

AssetPerformance

HomegrownCustom

App

Customer’sIoT Edge

Customer’sSM Platform™

SM Marketplace™

The Smart Manufacturing Challenge - 5 Minutes to Value

1. Access the SM Marketplace™ and establish your credentials

2. Select, purchase and provision your SM Platform™, choosing…

• Your existing cloud environment• Multi-tenant SM cloud environment

3. Deploy IoT Edge on secure HW that’s connected to your control system

4. Search for and instantiate SM Profiles™ that match the devices and equipment you’re connected to

5. Hit the SM Easy-Button™• Assemble SM Profiles™ into Data Model• Data collection initiated• Value creation starts

6. Identify SM Insight App(s)• O365, Power BI, Dynamics365, Flow…• Savigent Workflow, Honeywell App…• Model-based integration with SAP…• Watson…

12

Manufacturing Plug & Play Environment That Requires NO Domain Expertise to Begin Creating Value

Small or Large


CESMII Imperative: Smart Manufacturing Platform

13


CESMII Imperative: Shrink the SM R&D Innovation Lifecycle

14

Systems IntegratorApp Vendor(s) AcademiaFaculty & Student

Machine Builder

Manufacturer

Bringing Academia and Industry together to solve difficult Analytics problems

SM Innovation ProjectIDEA to Deliverable in 6 months

• CESMII creates a Structured Agile R&D Framework

• CESMII facilitates SM Team (Manufacturer, OEM, Vendor, Academia & SI)

• Each member of the SM IP signs the Agile R&D Framework SLA

• Outcome: The SM IP Team builds a “Profile” for the Asset/Process

• Outcome: The SM IP Team builds, trains, refines predictive model(s)

14


CESMII Imperative: Democratizing SM Knowledge

15


CESMII’s Mission, Strategy and RoleImprove Energy Efficiency through Sensing, Control, Modeling, Analytics & Platform Technologies

• Founded & funded by the US .gov in 2017

• Private/public partnership - $210M over 5 years

• Invest in technology & learning aligned with our mandate

• Projects, platform development, applications, workforce development

• We represent the ‘Voice of Manufacturing’

• NOT a Vendor, NO product to sell

• We engage the SM Ecosystem through a membership model• Manufacturers on a digital transformation journey

• Vendors looking to innovate

• Academia looking to drive relevance

• SI’s looking to build their digital portfolio

• Provide access to manufacturers, labs & industrial facilities to pressure test innovative technologies across diverse use cases

Smart Manufacturing Ecosystem

16


SMART DECISIONSSMART ASSETS OPERATIONS & SUPPLY CHAIN VISIBILITY

DemocratizingSMART MANUFACTURING

17

www.cesmii.org

Engage With Us!

EDUCATED, DATA-DRIVEN CULTURE

[email protected]

Democratizing SMART MANUFACTURING - EIT Digital€¦ · Democratizing S MART M ANUFACTURING...

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