iot: exposing the hidden factory - easyfairs · 1 week sprints shipped product 1 week sprint 24-48...

IOT: EXPOSING THE HIDDEN FACTORY

Advanced Engineering 201812:45 UK, 13:05 CET

Wednesday 31th October, 2018

2© 2018 PTC and InVMA All Rights Reserved

INTRODUCTION

Rob Dinsmore

Solutions Sales Manager

InVMA

▪ Digital Innovation Partner

▪ End to End Capability

▪ Industrial Heritage

▪ Partner Ecosystem

Transform

Consult

Design

Develop

Supply

Integrate

Support

5

THE HIDDEN FACTORY

WHAT IS THE HIDDEN FACTORY?

“Activities that reduce the quality or efficiency of a manufacturing operation or

business process, but are not initially known to managers or others seeking to

improve the process.”

Six Sigma and similar initiatives focus on identifying "hidden factory" activities in

order to eliminate sources of waste and error.

WHAT PROBLEMS AND OPPORTUNITIES? - FACTORY

OEE Scrap Energy

RFT Yield Waste

WIP Re-WorkMaintenanceNon Compliance

WHAT PROBLEMS AND OPPORTUNITIES? - EXTERNAL

Big Data

Social

Environmental

Economic

Supplier

Supply Chain

Out Bound

Deliveries

Knowledge

Best Practice

Performance

Reliability

Vendor Analysis

• Execute the plan with small steps in a controlled way

• Study the results

• Plan ahead for change

• Take action to standardise or improve the process

Act Plan

DoCheck

TO IMPROVE YOU NEED TO EXPOSE WHAT’S HIDDEN

TeamsData

Culture

THE CORE ARCHITECTURE AND ISA95 MODEL IS A CAUSE

Traditional System Landscape

Logistics SuppliersExternal

Business Systems

(ERP, CAD, PLM)

Level

4

Operational Control

(MES, MOM)

Level

3

Process Monitoring

(HMI, SCADA, Test Stands)

Level

2

Control Level & Data Acquisition

(PLC, CNC, Autoclave)

Level

1,0

Production Quality Inventory Mainten. EnergyQuality

Plant

Manager

Maintenance

Operator Process & Quality

Planners

Vendor Support

DISPARATE SYSTEMS ACROSS SITES ARE A CAUSE

12

TECHNOLOGIES

13

PHYSICALWORLD

DIGITALWORLD

PRODUCTS ARE CHANGINGSmart Connected Products

OPERATIONS ARE BECOMING MORE EFFICIENTSmart Operations |System of Systems

SERVICE IS TRANSFORMINGRemote Service | Product as a Service (PAAS)

HOW WE INTERACT WITH THINGS IS CHANGINGAUGMENTED REALITY | VIRTUAL REALITY

18

UNDERSTANDING INDUSTRIAL DIGITAL INNOVATION

“Smart, connected productsraise a new set of strategicchoices about how value

is created and captured, and how companies secure

competitive advantage as the new capabilities reshape industry

boundaries.”

“Smart connected products are not only redefining competition

but how we run companies across the value chain. New kinds of

cross functional integration and

coordination are necessary, and whole new organizational units are

being created.”

“There is a fundamental disconnect between the

wealth of digital data available to us and the physical world in

which we apply it. AR solves this

problem by putting information directly into the context in which

we’ll apply it.”

November 2014 October 2015 November 2017

Digital

World

Human

Physical

Experience

Human

Digital

Experience

Physical

World

1101

0101

WE EXPERIENCE PHYSICAL AND DIGITAL SEPARATELY

COPYRIGHT 2017 © MICHAEL E. PORTER AND JIM HEPPELMANN

20

PHYSICALThing

DIGITALTwin

AR IOT

IOT AND AR – UNLOCK THE VALUE OF INDUSTRIE 4.0

1101

0101

Digital

World

Human

Converged

Experience

Physical

World

Converged View of Physical / Digital World

CONVERGED EXPERIENCES ENABLE FASTER DECISIONS

COPYRIGHT 2017 © MICHAEL E. PORTER AND JIM HEPPELMANN

22

Connect the Physical World

OT IT

Understand the Context

Orchestrate the Response

Engage People using Digital on Physical

Analyze the Digital Data

UNITING DIGITAL AND PHYSICAL KEY CONCEPTS

PHYSICALWORLD

DIGITALWORLD

Traditional System Landscape

Logistics SuppliersExternal

Production Quality Inventory

Business Systems

(ERP, CAD, PLM)

Level

4

Operational Control

(MES, MOM)

Level

3

Process Monitoring

(HMI, SCADA, Test Stands)

Level

2

Control Level & Data Acquisition

(PLC, CNC, Autoclave)

Level

1,0

An Industrial Innovation Platform

complements and brings

• Unified visibility across systems,

assets, devices and people

• Wrap and extend existing systems

• Actionable and comprehensive

operational intelligence

• Real-time, social, mobile

• Rapid application developmentMainten. Energy

USE NEW TECHNOLOGY TO WRAP AND EXTEND

SOURCE CONTEXTUALIZE SYNTHESIZE ORCHESTRATE ENGAGE

AN INDUSTRIAL INNOVATION PLATFORM

25

THE EXPERIENCE OF OTHERS

© Howden Group 2018

Howden Data Driven Advantage

Uptime

© Howden Group 2018 27

This is what we do:

Howden Digital TransformationData Driven Advantage


Why are we discussing Digital Transformation?

• Global uptake of the digitization trend

• More about the service than about the product

– Every type of commodity today is moving

towards a “as a service” model

What is our Data Driven Advantage strategy?

• Howden is not a Big Data organisation

• We are committed to leveraging the data around our operations and equipment to

– Enhance the customer value through the service around our equipment

– Optimize our operations

– Create a new business model

Howden Digital Transformation

Product

Service

Data Driven Advantage


Howden Data Driven AdvantageUptime

Uptime

Unique digital solution building on

• Howden digital twins

• Artificial Intelligence (AI)

• Machine Learning

• Augmented Reality

• Our expert guidance to realise full

customer value

Our foundational block

Highly differentiated Digital Twin approach,

first of its kind in most air and gas handling

applications

Our technology stack is completed by our

strategic partners, Microsoft and PTC

Over 160 years experience in designing and

manufacturing rotating equipment

The Howden Digital Twin

Our design data is used to model theoretical performance and

compared with actual in-field data from the sensors

Connected machines

We work with all industrial connectivity protocols, we can integrate

with existing control logics or operate completely remotely, our

connectivity block is completely customizable to our customers’

needs

Data storage solution: Microsoft Azure

Integrated solution that lives in the cloud

We take our customers' data very seriously and with Azure we have

further fortified our approach to security and data protection

ThingWorx: purpose-built industrial innovation platform

to streamline our approach

Combine the industrial experience of ThingWorx - world leading IIoT

platform - with OEM differentiated analytics to deliver predictive/

prescriptive maintenance and performance optimization on demand

Full customer solution

Ai powered Machine Learning

Smart analytics powered by the Howden Digital Twin

Complete AR experiences and HoloLens integration

24/7 support and direct access to Howden AFM


UptimeThe service around the customer’s equipment

OEM differentiated digital solution that delivers optimized equipment and plant performance

Current state

• Complex customer need

• Unplanned downtime around critical assets

• Howden equipment operating away from best efficiency point

Future state

• Predictive maintenance as a service to avoid the unplanned downtime of critical assets

• Performance Optimization on Demand around our customers’ equipment/process

• Direct link to Howden service and support

Understanding Machine Health

& Their DNA

Important FactTypically it is often stated that the profit generated by:-

Sustainable long term savings are key, not short term

savings.

World Class OEE – 90% and a 2010 Aberdeen Study

suggested the best in class was 89%.

Typically most US & West European companies operate at

50%!!!

A 10% saving

in maintenance

costs

A 40% increase

in sales &

turnover

Machinery DNA

Each machine / asset has it’s own unique DNA / finger

print. The variables associated with this unique DNA are

numerous:-

• Temperature

• Vibration (velocity, acceleration, time waveform, etc)

• Ultrasound (dB(A), distress, etc)

• Oil Condition & Oil Temperature

• Motor Load

Applications monitored include:-

Fans Compressors Conveyors Pumps Mixers

Classifiers Gearboxes Extruders Vibratory Screens

Crushers Motors Blowers Turbines

Continuous Monitoring Systems

2005

• MachineGuard

• Wireless Comms & Stand Alone Software

2011

• MachineGuard II

• iMATS Web Portal Software & Alerts

2017

• MachineGuard III

• Asset Minder Web Platform

2018

• MachineGuard Blue Tooth Sensors

• Asset Minder II Web Platform

Web Portal

Continuous Monitoring SystemsNew spiral bevel pinion

fitted on Friday /

Saturday. On Sunday

they ran up the system

and it was apparently

very noisy. A set of

readings were taken

and as you can see

from the vibration

spectra, a problem was

identified. We

diagnosed that the

spiral bevel gears were

not mating correctly

(620Hz – 25T @ input

speed).

© Tan Delta Systems Limited 2017

MachineGuard III – The Future!

View trends

View spectra

Blue Tooth

accelerometer

Gateway &

enclosure

Asset

39

Examples of outcoes achieved with PTC Digital Transformation Journeys

MANY COMPANIES ARE VERY SUCCESSFUL WITH PTC

53

A GLOBAL FOOD LEADER INCREASES PRODUCTIVITY

5 to 8% improvement in productivity

HEALTH

20105

Alarms

4,700/25,500 lbs/min

50,0000

WasteOEE

68%Fair

M T W FT

TOPWEEKLY

GOAL 77%complete

Operat or Keyser Ar ea 18 March 25, 2015

Keyser_SözeGE Proficy

Shift Events Start Time 05/25/2014 22:30:00 End Time 05/26/2014 06:30:00

22:30:00 23:30:00 24:30:00 1:30:00 2:30:00 3:30:00 4:30:00 5:30:00

Alarms

0301,500/1,000

lbs/min

3,5000

Waste

2,050 / 2,100 lbs/min

3,0000

Speed

6467 / 70,000 units

11%

Complet eOrder 2501879

RUNNING

05/25/2014 22:30:00 / 05/25/2014 22:27:00

05/26/2014 05:30:00 / PENDING

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DOWNTIME

WASTE

69

Use Remote Service to monitor equipment performance.

Reduce on-site visits by 42%.

Save $2,000 for each on-site visit avoided.

73

React and respond to customer service needs 3X faster than competition.

Improve first-time fix rate from 88% to mid 90% (industry average 60%).


BUILD A BACKLOG

Business Planning

SelectionDesign and

Product BacklogExecution of

Approved Sprints

Innovation, Ideas, Opportunities, Needs

Screening Process

Agile Project Management

1 2 3

Highest value

items prioritised

Low value items de-prioritised

New requirements prioritised and added to the stack

4

Hold a design and prioritisation session you to explore your detailed requirements and develop them in to a series of user stories which we will

prioritise into a “work stack”


1 WEEK SPRINTS

Shipped Product

1 week

sprint

24-48 Hours

Regular Scrum MeetingProduct

Backlog

Sprint Backlog

1week sprints delivering value from the customers perspective

All managed through a shared portal

We will take the back-log and deliver elements of it in 1 week sprints.

As ThingWorx is extremely flexible with large pre-built elements this enables

you to focus on the parts that you value.


USEABLE PRODUCT EARLY

Sprint 1 Sprint 2 Sprint 3 Sprint 4

ActualResource

Resource

Time

Value

Prioritise

Design

BuildTest

Deploy

Prioritise

Design

BuildTest

Deploy

Prioritise

Design

BuildTest

Deploy

Prioritise

Design

BuildTest

Deploy

Prioritise

Design

BuildTest

Deploy

Small dedicatedteams delivering

value early

The approach also enables you to decide what gets delivered first allowing for user

feedback before further investments are made


THANK YOU

Rob Dinsmore

Sales solution Manager

[email protected]

InVMA

invma.co.uk

@InVMA_IoT

www.linkedin.com/company/invma-limited/

http://www.linkedin.com/company/invma-limited/

iot: exposing the hidden factory - easyfairs · 1 week sprints shipped product 1 week sprint 24-48...

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