Reducing and Eliminating Downtime in Robots Using Predictive Analytics

Scott Melton

FANUC AMERICA Corporation

Transformation

“Transformation is not from new technologies but transforming your organization to take advantage of the possibilities…”

- MIT Center for Digital Business

What is IoT ? The Internet of Things (IoT) is the network of physical devices and other items

embedded with electronics, software, sensors, actuators, and connectivity, which

enables these things to connect and exchange data creating opportunities for more

direct integration of the physical world into computer-based systems, resulting in

efficiency improvements, economic benefits, and reduced human exertions”. Source: Wikipedia

How / Why did we get here ?

Four Phases of Industrialization

Where is the IoT?

Smart Phones – Proximity

ads, traffic patterns, fuel

prices, etc.

Wearable Tech – Apple

watch, Fitbit, Google

glass, Nike+, etc.

Home Automation – Nest,

Echo, Wink, Arlo, Z-

Wave, etc.

Medical Devices –

Glucometers, blood

pressure, etc.

Agriculture – Smart

irrigation, optimized

seeding, etc.

Smart Cities –

Parking apps,

Intelligent lighting

Connected Logistics

Systems

Professional

Sports

Wildlife Tracking

Jet Engine

Monitoring

Here are some examples of the IoT outside of manufacturing…

And companies are investing in it… PWC surveyed 2,000 senior executives in 26 countries:

• Industrial companies around the world are expected to invest more than 900 billion dollars per year in Industry 4.0 through 2020.

Reference: pwc 2016 Global Industry 4.0 Survey

And why are companies are investing in it…

http://www.forbes.com/sites/louiscolumbus/2018/03/18/where-iot-can-deliver-the-most-value-in-2018/

• Harley Davidson – reduced BTO ratio by factor of 36

• Rolls Royce – 1% reduction in fuel usage – savings of 250K per plane, per year

• Royal Dutch Shell - $1M return on $87K investment.

IIoT = Industrial Internet of Things The IoT and IIoT both rely on sharing and using data to provide value, but…

• IIoT targets Industry - producers of goods and services

• The IIoT is expected to revolutionize manufacturing by creating new value streams through the collection, analysis and sharing of data to improve uptime, reduce scrap, optimize processes, etc.

• IIoT solutions require long term support and rugged design considerations

• IIoT solutions need to work with existing (legacy) equipment

• IIoT solutions MUST BE SECURE

IIoT

Why is connectivity so important?

Because Connectivity

Enables Access to

Data & Data Drives Value

Creation

Some Facts about Data Collection

Data storage is growing 4X FASTER THAN THE WORLD ECONOMY

Increasing quantity of data allows for

MORE QUALITATIVE APPROACH

EVERY DAY WE CREATE

2,500,000,000,000, 000,000 (2.5 QUINTILLION) BYTES OF DATA

That is enough data to Fill 10 million Blu-ray discs, the height of which when stacked, would measure the height of 4 Eiffel Towers one on top of another.

Source: Adient / Adient Industry 4.0/ May 11, 2017

Alphabet Soup… Industry Terminology

• IoT = Internet of Things

• IIoT = Industrial Internet of Things

• SCM (Supply Chain Management) = software to execute supply chain transactions, manage supplier relationships, and control associated business processes.

• MES (Manufacturing Execution System) = software to understand how current conditions on the plant floor can be optimized to improve production output.

• ERP (Enterprise Resource Planning) = business management software that tracks resources (cash, raw materials, production capacity) and the status of business commitments (orders, purchase orders and payroll).

Industry 4.0

• Digital to Physical Conversion

• Reconfigurable Mfg Systems

• Cyber-Physical Systems

• ICT (Info & Comm Technology)

• “Smart” Products

Industry 4.0

• Interoperability

• Connectivity

• Human-Machine Collaboration

• Additive Machining

Connecting Smart Manufacturing FANUC has been investing in connectivity and Smart Manufacturing for many years.

Connecting Smart Manufacturing We have been creating features that produce useful data at the Robot & Machine tool

• Maintenance Reminder

• Process Logger

• Operation Logbook & History

• I/O Signal Information Operation

History

Signal and CNC

information

Connecting Smart Manufacturing

Today we have smart phone apps to view data outside plants

• Data produced on CNC & Robots using existing software.

• Live updated information in real-time

• Data sent via e-mail messages to an in plant mail server

Cisco Security

ZDT Service Center Portal Alert Monitoring, Schedule Parts and Maintenance, Enhanced Customer Service Tools

ZDT Customer Portal Track alerts, View ZDT network status, Access ZDT reports, Authorize users, etc.

Web Services

Business Intelligence/

Reporting Area

Plant 1 Plant 2 Plant X Data

Receive

FANUC CLOUD

Persistent, Secure Encrypted

ZDT D/C Customer

Cisco Customer Security

Data Analytics

Machine Learning

Data Visualization

ZD

T D

ata

C

olle

ctor

@

Challenge

Solution

Business Outcomes

Save estimated $40M in machine downtime Provide visibility on machines are utilized and increased the Overall Equipment Effectiveness (OEE)

No visibility on how machines are utilized Machine downtime cost millions Data collection and edge compute Cloud managed service across plants

ZDT data collector with UCS on-premises Streaming machine data to Cisco Cloud service and perform data analytic with Cloudera cluster

We have cases where downtime is costing over

$20,000 per minute. With Cisco, I saw a

potential for the solution that could change our

entire go to market strategy… This has the

potential to have the biggest impact of anything

I’ve seen in my 35-year career.

--- Rick Schneider, former North America CEO

”

“

ZDT – A Transformational Tool • Started from 10 robots in 10 factories • Grown to 17,200 robots around the

world

• Already detected and avoided 360 failures

• Estimate $40M+ saved by avoiding downtime

Component changed during weekend

-ZERO DOWN TIME-

Replacement component automatically sent to customer

ZD

T

Data analysis detects failing component from historical data and notifies customer.

-Action Required-

ZDT Data Storage

FANUC Analytics

ZDT Data Collector

Alert message sent to customer and FANUC Service team Partnered with Cisco for Network

Security and Reliable Cloud Services

ZDT - The Big Picture

ZDT is deployed on more than 17,200 robots

Global Installed Base

Europe 1,570 Canada 1,789

China

Europe

Africa

USA

Brazil 698

Japan 64

USA 10,700

Mexico 1,850 Taiwan 48

Australia

India 13

S. Korea 205

China 8

Thailand 51

If downtime costs $500/minute, the total savings is $47,370,000

Total # of robots : 17,252 Total # of plants : 71 Total # of countries : 17 Total # of alerts confirmed : 363 Total downtime avoided: 1,579 hours In production since : May, 2015

Downtime Avoided by ZDT Notifications:

Downtime Avoided by ZDT

• Even though FANUC robots are highly reliable, we are not always kept up to date on how they are used or applied.

• With ZDT we can continually monitor the use and performance of our robots to predict failures before they happen.

• ZDT and FIELD System enhance our support strategy from ‘improving our ability to quickly react’ to ‘predicting and addressing issues before they occur.’

Drive Replaced

Normal

Alert

DOWN TIME PREVENTED BY

ZDT

ZDT is Re-Defining Robot Support Strategy

ZDT Provides Additional Value

Advantages of Cloud Connectivity • Increases awareness of how our

products are being used after shipment

• Connects our service team to our robots for improved response time

• Speeds the deployment of new and refined analytic functions

• Enhances technical support capabilities

• Provides a foundation for future value added services

SECURE

Cisco IE-4000 Hosts FANUC Adapter and MTConnect Agent

Cisco & FANUC IoT Machine Integration 1) IOT Fog Node hosts Adapter + Agent 2) Extracts Machine Data Securely 3) Managed at Scale 4) IOT Ready Machine 5) Factory integration that IT Supports 6) POE+ for Sensor support

IOT Fog Node

MTConnect with FANUC’s CNC (FOCAS)

adapter

FIELD system

Edge Heavy

Open Platform

An open platform that links

all devices at the edge of

the network to make their

data available to intelligent

applications that drive

Smart Manufacturing

systems.

FANUC Intelligent Edge Link and Drive

How ”Open” is FIELD system? Connect Any Device • FIELD system is designed so network

enabled devices from FANUC or any other company can connect, including competitor products.

3rd Party App Development • FIELD system is designed so Apps can

be written and sold by FANUC or any company that wants to be a FIELD system App development partner.

How does FIELD system work? Key Components… • FIELD system Server • Device Converters • FANUC FIELD Apps • 3rd Party FIELD Apps • FIELD system Manager

& Store

Edge Heavy

Open Platform

FANUC FIELD Base Pro

Cisco UCS Server

Thank You