the journey to a...implement optimization schemes that leverage acquired data, advanced analytics,...
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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
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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
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Technologies Fueling new Smart Manufacturing
Source: McKinsey Global Institute, May 2014
Smart Manufacturing
Auto ID
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What is Smart Manufacturing?
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The IoT will connect our Smart Homes and Smart Devices
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We see Smart at Home…
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The IoT paving the way to the IIoT
IoT Industrial IoT - IIoT
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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
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IIoT and Digital Mfg are enablers for Smart Manufacturing
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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
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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.
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What to do on the Journey to Smart Manufacturing?
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The Smart ManufacturingRoadmap…
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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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The Smart ManufacturingRoadmap…
?
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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
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Manufacturers planningnew business value with Smart Manufacturing
Source: Microsoft blog, 2015
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Manufacturers planning new business value with Smart Manufacturing and Smart Products
Source: “The Rise of the Smart Product Economy”, Cognizant, 2015
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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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The Smart ManufacturingRoadmap…
?
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The Smart ManufacturingRoadmap…
Evolve IT Infrastructure
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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
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The Smart ManufacturingRoadmap…
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
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 DemoSOLUMINA As-Maintained
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: R&D Project at UK’s MTC (Manufacturing Technology Center)
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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
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R&D Project found we still have significant connectivity gaps
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The Smart Manufacturing Roadmap…
Streamline, orchestrate and optimize processes
across the value chain
A2A, B2B
Business Processes, Workflow
Digital Thread
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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
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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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The Smart ManufacturingRoadmap…
M2M, IIoT
A2A, B2B
Integration Services
Connective technologies and integration standards
for multi‐vendor solutions
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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!
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Integration standards: participate, use, promote for better ecosystem
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The Smart Manufacturing Roadmap…
New workforce Skills,
new Apps
BusinessIntel
Function Specific
AppsUser
Interface
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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
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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!
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www.MESA.org
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