The Journey to a...Implement optimization schemes that leverage acquired data, advanced analytics,...

Advancing. Manufacturing. IT.

The Journey to a Smart Manufacturing Future

Conrad Leiva

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MESA International

MESA International:Building bridges‐of‐understanding from plant to the enterprise

Speaking wit the voice of the industry’s practitioners

Peer‐to‐peer

Point‐of‐view

Globaleducationprogram

• MESA – Founded in 1992– Manufacturers/producers,

analysts, education members – System integrators and software

vendors– + 800 members– 45 countries

• MESA published:– Over 500 pieces of content– 60++ White Papers & Guidebooks– More to come soon

Copyright 2017 | iBASEt 3

The Journey to a Smart Manufacturing Future

Agenda What is Smart Manufacturing and Why? Building blocks to Smart Manufacturing: IIoT, Digital Manufacturing, … The Roadmap to Smart Manufacturing A new Manufacturing IT Platform Framework is shaping up Getting Started on the Journey to Smart Manufacturing

Copyright 2017 | iBASEt

Technologies Fueling new Smart Manufacturing

Source: McKinsey Global Institute, May 2014

Smart Manufacturing

Auto ID


What is Smart Manufacturing?


The IoT will connect our Smart Homes and Smart Devices


We see Smart at Home…


The IoT paving the way to the IIoT

IoT Industrial IoT - IIoT


The IIoT will connect Smart Machines in the Smart FactoryManufacturing Plant Global Facility

Insight

Monitor production flow in real-time to eliminate wasted time and reduce in-process inventory

Manage equipment remotely using sensors and limits to conserve energy and reduce costs

RFID sensors identify product and materialsAggregate product

and process data, analyze, identify constraints and improvement areas

Production line triggers autonomous material handling vehicles

Implement condition-based maintenance alerts to reduce downtime and increase throughput

More intelligent, autonomous and connected machines


IIoT and Digital Mfg are enablers for Smart Manufacturing


Smart Manufacturing is…

Key concepts: “intelligent”

“orchestration”

“business, physical, digital processes”

“optimization” optimization - leverage the digital version of the physical process, use simulations and mathematical models to do what-if analysis and optimize decisions. For instance, maximizing the use of resources to deliver as soon as possible to the customer, adjusting schedules to work around issues while minimizing overtime, minimizing energy use, or selecting the quickest cheapest route to expedite raw materials or delivery to the customer

intelligent - active intelligence versus passive systems that just collect and report data. Routine decisions are made by automated smart systems based on high-level constraints. This leaves managers to manage the more important issues we need to manage every day.

orchestration - coordinating the flow of business processes through resources across the manufacturing value chain so they are in-sync and data flows smoothly. This is the next level of synchronization between business, physical, digital processes.

business, physical, digital processes - covers people, physical equipment and digital IT processes all together--not just inside each factory, we need to orchestrate business processes in the entire value chain including everyone involved from design of the product, packaging, and processing to partners, suppliers, and services we might be delivering along with our products.

“Smart Manufacturing – The intelligent, real-time orchestration and optimization of business, physical and digital processes within factories and across the

entire value chain.”MESA Smart Manufacturing Working Group


Goals and Guidelines for Smart Manufacturing Minimize manual data entry, translation, or transformation at each process step. Processes should hand over structured parsable data (like XML or JSON web services) as output to

successor processes to facilitate publish/subscribe mechanisms to systems within company and into the value chain. Establish distributed nodes of autonomous diagnostic and decision support at the machine, factory, and enterprise

levels. These nodes should roll up transaction information for each machine, factory, and each product unit as needed Allow ubiquitous use of mined information throughout the product value chain including end-to-end value chain

visibility for each product line connecting manufacturer to customers and supplier network. Automate routine tasks and decisions but include people in the process loop wherever needed to handle nonroutine

situations, manual adjustments, and complex decisions assisted by the analytical insights. Implement optimization schemes that leverage acquired data, advanced analytics, and machine learning algorithms

to recommend process adjustments at different levels of the enterprise from controls, to operations, to value chain. Adopt machine-to-machine (M2M), application-to-application (A2A), and business-to-business (B2B)

integrations standards that will enable multi-vendor hardware and software plug and play solutions with open integrations platforms to the internet. Learn about organizations including ISO, IEC, NIST, OAGi, MESA, IIC, DMDII, and CESMII which are establishing and promoting standards.

Develop a collaborative culture and new workforce skills that encourage projects that cross old functional boundaries like engineering, production, automation, and information technology (IT). Manufacturing automation personnel needs to understand IT and vice versa. Workers will need to learn to configure and maintain smarter machines and robots.


What to do on the Journey to Smart Manufacturing?


The Smart ManufacturingRoadmap…


To Do List on Journey to Smart Manufacturing

1. Review Business Structure for Future Market Strategy2. Establish Evolution Milestones for the Journey3. Nurture New Culture around New Vision4. Address Skills Gap for Knowledge Workers5. Build Partnerships to Support the New Vision6. Evolve the Information Technology Infrastructure



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Gartner 2016 Survey of Top Business Priorities

Drivers:1. Market Growth Share2. Business Digitalization3. Technology Adoption4. Customer Focus5. New Product Introduction


Manufacturers planningnew business value with Smart Manufacturing

Source: Microsoft blog, 2015


Manufacturers planning new business value with Smart Manufacturing and Smart Products

Source: “The Rise of the Smart Product Economy”, Cognizant, 2015


To Do List on Journey to Smart Manufacturing

1. Review Business Structure for Future Market Strategy2. Establish Evolution Milestones for the Journey3. Nurture New Culture around New Vision4. Address Skills Gap for Knowledge Workers5. Build Partnerships to Support the New Vision6. Evolve the Information Technology Infrastructure



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Evolve IT Infrastructure


Old Tiers of IT and OT

ERP

Enterprise Information Technology

Manufacturing Operations Technology

PLM MES

GPS

SSO

BI

SCADA

Energy Mgt OEE

PLC

Sensors

Meters



Next: Start some projects…

Pilot, small steps, learn,plan to evolve…


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Example: UAV Incident Repair DemoFrom SOLUMINA Work Dispatch – Create Service Order

End

Analyze consumption rates, failure rates

Update As Maintained

Perform part replacement

Execute maintenance on Asset

Plan parts availability

Create work order/schedule

Investigate failure condition

Monitor asset health

Start


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Example: UAV Incident Repair Demo

End









Start


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Example: UAV Incident Repair DemoSOLUMINA As-Maintained

End









Start


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Example: R&D Project at UK’s MTC (Manufacturing Technology Center)


Example: R&D Project at UK’s MTC (Manufacturing Technology Center)

Dashboard

Multiple vendors involved in solution

Siemens’ WinCCSCADA

iBASEt’s MES

UbisenseRFID sensors ATS’s MSB


R&D Project found we still have significant connectivity gaps


The Smart Manufacturing Roadmap…

Streamline, orchestrate and optimize processes

across the value chain

A2A, B2B

Business Processes, Workflow

Digital Thread


The Product Value Chain extends into Suppliers and Customers

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Enterprise Business Process Management (BPM)includes Manufacturing

Source: NIST, 2014

Enterprise

Enterprise

Service Prov

ider

Hardware

Vend

or


Over 50% of communication with suppliers is unstructured

Make sure that parts are inspected this way, okay?

Have you told your supplier about the new

revision?

Have you got the new revision of the

component?

OEM talking with Tier 1 Supplier

Make sure you don’t subcontract that

component, it is ITAR protected.

Did your supplier make design change? Why

didn’t you tell me about that? You did? I have no

record about it.

Source: OAGi ppt, 2014


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Cloud Services are also an enabler…

The Cloud facilitates communication across the

Product Value Chain

How much will be in the cloud?


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M2M, IIoT

A2A, B2B

Integration Services

Connective technologies and integration standards

for multi‐vendor solutions


Institutes and consortia are leading the way

Goals for Institutes and Consortia– Drive innovation through shared cost and risk– Promote guidance for connectivity and standards– Provide test beds

Examples: – Industrial Internet Consortium (IIC) - IIoT– Industrie 4.0 - Cyber-Physical Systems, Smart Factory– Smart Manufacturing Leadership Coalition (SMLC) - Open Platform – CEMII - Smart Manufacturing for Cleaner Energy – Digital Manufacturing and Design Innovation Institute (DMDII) - Digital

Manufacturing, Digital Thread– NIST - promote measurement science, standards and technology


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Institutes and consortia are leading the way

MESA International

Get Involved!


Integration standards: participate, use, promote for better ecosystem


The Smart Manufacturing Roadmap…

New workforce Skills,

new Apps

BusinessIntel

Function Specific

AppsUser

Interface


Multi-discipline Collaboration Culture and Technical Skills

The World Bank Studies estimate that 220,000 new engineers are required every year from 2014 to 2022 to connect the unconnected.

For the next two decades, a large generation of workers will be reaching retirement age and ready to leave the workforce.

IT and OT convergence requires collaboration among these traditionally siloeddepartments

Social online collaboration across disciplines with remote people in the value chain New IT skills needed on integration standards, reference architectures, logical

topologies, protocols, switching and routing infrastructure, physical cabling and wireless technologies

New manufacturing skills on advanced equipment installation, configuration and maintenance

We must attract young people to these jobs and prepare them with the required collaboration, science, math, engineering, and technology skills


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Summary: To Do List on Journey to Smart Manufacturing

Manufacturers should get started on the journey1. Review Business Structure for Future Market Strategy

2. Establish Evolution Milestones for the Journey

3. Nurture New Culture around New Vision

4. Address Skills Gap for Knowledge Workers

5. Build Partnerships to Support the New Vision

6. Evolve the Information Technology Infrastructure


With the right focus … opportunities can be significant

… but about creating value using an enhanced set of technologies

… but leveraging the information with judgement and expertise

… rather they enable business to evolve their model to serve, orchestrate, and optimize better

Digital transformation is not just about technology …

Success is not all about data and analytics …

Smarter machines do not make a business smarter …

Source: Krishnamurty, Industru of Things USA, San Diego 2016

Smart Manufacturing is not about smarter machines,but about business transformation


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The Future of Smart Manufacturing is Exciting!


www.MESA.org


www.iBASEt.com ResourcesQuestions?

Advancing. Manufacturing. IT.

Thank You

Conrad [email protected]

The Journey to a...Implement optimization schemes that leverage acquired data, advanced analytics,...

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