Industry 4.0:
Preparing Your Company
for Global Success
Radu Pavel, Ph.D.
Chief Technology Officer
Manufacturer’s Forum
October 6, 2016
TechSolve Overview
• Cincinnati-based Not-For-Profit
Corporation founded in 1982 by
Cincinnati Chamber of Commerce,
UC & City of Cincinnati
•
Core Competencies:
– Advanced Manufacturing & Machining
Technology
– Process Analysis & Improvement
© 2016 TechSolve Inc. All Rights Reserved.
•
40+ engineers, scientists and
business specialists
•
45+ contractors: technical and
industry experts
•
Fully instrumented on-site applied
development high-bay facility
(Heritage Metcut Research)
Fully-Instrumented Machining Laboratory
TechSolve’s M. Eugene Merchant Technology Development Center
(formerly MetCut Research Machining Laboratory, founded 1948)
Major Equipment List:
• Mazak Integrex i200S Mill Turn
• Makino V55 – 3 Axis VMC w/20K spindle
• DMG DMU-50 – 3+2 Axis VMC w/Siemens 840D
CNC & through-spindle coolant
• DMG DMU-70 eVo Linear – 5 Axis VMC w/
Siemens 840D & 580 psi through-spindle
coolant
• Hardinge Cobra 65 – 2 Axis turning center
w/Fanuc 21T & Bar Feed
• Milltronics HMC35 – 4 Axis HMC w/Fanuc 0iMC
• Chevalier Smart B1224II CNC Surface Grinder
• Sheffield Cordax D-8 CMM
• Kistler Turning, Milling, and Drilling
Dynamometers
• Keyence VHX Digital 3D Microscope
• Fluids Lab
© 2016 TechSolve Inc. All Rights Reserved.
Knowledge Is Power
“…recent conversations between Manufacturing
Leadership Council Global Vice President and
Editorial Director David Brousell and a group of small
and medium-sized enterprises in Ohio revealed that
very few, if any, had actually heard of the term, the
Internet of Things…”
- Manufacturing Leadership Council / Frost & Sullivan
© 2016 TechSolve Inc. All Rights Reserved.
INDUSTRY 4.0
Industrial Revolution
Industrial revolution - A rapid, major change in an economy
http://cdn.static-economist.com/sites/default/files/imagecache/full-width/images/print-edition/20120421_LDP001_0.jpg
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The Industrial Revolutions
First Industrial Revolution: 1700s – 1800s
• Water and steam powered production
Second Industrial Revolution: 1800s – 1900s
• Electric power used to create mass production
Third Industrial Revolution: 1900s – 2000s
• Production automatization through electronics and
information technology
Fourth Industrial Revolution – started
• Fusion of technologies that is blurring the lines
between the physical, digital, and biological spheres
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Industry 4.0
Autonomous
Robots
Big Data
and
Analytics
Modeling
and
Simulation
Augmented
Reality
Industry 4.0
Additive
Manufacturing
System
Integration
Internet
of
Things
Cloud
Computing
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Cybersecurity
Industry 4.0
http://thinkingaloud.aberdeen-asset.com/static_files/images/thinkingaloud/994x385_tbp_industry-4.0-the-fourth-industrial-revolution.jpg
Internet connectivity will enable products and machines
to communicate with each other, learn from each other,
and work directly with each other without human
intervention.
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Digitization, Connectivity, and Self-Awareness
http://vignette4.wikia.nocookie.net/matrix/images/1/12/Powerplant_fields2560-1600-178.jpg/revision/latest?cb=20140504002340
https://fsmedia.imgix.net/22/6c/06/1c/d24d/4a1f/b46f/836d61c5cfb2/image-20141215-24297-6jsbmpjpg.jpeg
http://vignette4.wikia.nocookie.net/starwars/images/a/a6/Droid_foundry.jpg/revision/latest?cb=20071004200659
Elements of Industry 4.0
•
The (Industrial) Internet of Things - IIoT
•
Digital Manufacturing
•
Big Data
•
Advanced Analytics
•
Augmented Reality
•
Cloud Computing
•
Cyber-physical Systems
•
Robotics and Automation
•
Systems Integration
•
Cybersecurity
© 2016 TechSolve Inc. All Rights Reserved.
Factory of the Future
Industrial Internet of Things
•
The concept of the “Internet of Things” dates back to 1999 and
was coined by British technology pioneer Kevin Ashton
•
“[IOT is]…the intelligent connectivity of smart devices by which
objectS can sense one another and communicate, thus
changing how, where, and by whom decisions about our
physical world are made.” - Bryce Barnes, Cisco's Senior
Manager of Machine and Robot Segment
© 2016 TechSolve Inc. All Rights Reserved.
Digital Manufacturing
• In the late 1980s, >1% of the world's technologically
stored information was in digital format, while it was
94% in 2007, and more than 99% by 2014.
• 2002 was estimated to be the year when human kind
was able to store more information in digital format,
than in analog format – this noted the beginning of
the Digital Age.
© 2016 TechSolve Inc. All Rights Reserved.
The Digital Thread
• “Digital manufacturing and design is the ability to
connect different parts of the manufacturing life-cycle
through data, and to utilize that information to make
smarter, more efficient business decisions” - DMDII
• Digital technologies are now in the process of
transforming the way parts, components and complete
systems can be designed and manufactured.
© 2016 TechSolve Inc. All Rights Reserved.
Big Data
MESA Library,
www.mesa.org, 2009
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Big Data and Advanced Analytics
Data
Data
Data
Actionable
Acquisition
Warehousing
Analytics
Information
Structured
Data
A set of
Dashboards /
and
management,
statistical and
Visualization /
unstructured
storage, cleaning,
mathematical
Automatic
synchronization
methods for
feedbacks
etc.
data processing
© 2016 TechSolve Inc. All Rights Reserved.
16
Advanced Analytics
The autonomous or semi-autonomous examination of data or content using
sophisticated techniques and tools, typically beyond those of traditional
business intelligence, to discover deeper insights, make predictions, or
generate actionable information.
“The extensive use of data,
statistical and quantitative
analysis, explanatory and
predictive models, and fact-based
management to drive decisions
and actions.”
[Davenport, T. H., Harris, J. G., “Competing on
Analytics”, Harvard Business School Press, Boston,
Massachusetts, 2007.]
http://www.dunnsolutions.com/content/predictive-analytics
© 2016 TechSolve Inc. All Rights Reserved.
Advanced Analytics - Components
Physics/engineering-based modeling
• Needs less data
• Powerful but difficult to scale
Empirical, heuristic rules and insights
• Easy to understand
• Captures accumulated knowledge of your experts
Data-driven techniques such as machine learning, statistics,
visualization, etc.
• Easiest to maintain and scale
• Need significant amounts of data
• Limited to regions of parameter space
© 2016 TechSolve Inc. All Rights Reserved.
Cybersecurity
http://i.imgur.com/RIN87.jpg
© 2016 TechSolve Inc. All Rights Reserved.
Cybersecurity
“Security waits for no one, so don’t wait for security.
78% of security officials expect a successful attack on
their ICS/SCADA systems within the next two years.
IoT security is one of the top three challenges that
businesses face when integrating their assets with the
Industrial Internet.”
–GE’s Perspective on Cybersecurity
© 2016 TechSolve Inc. All Rights Reserved.
In the Factory of the Future…
• All internal and external activities will be connected
through an information platform
• All value added business divisions and of the entire value
added chain will be integrated with the aid of digitalization
• Information, communication, and automation
technologies will be fully integrated
• All subsystems( including non-producing ones) are
networked and consolidated into one system
• The entire process can be considered and managed in
real time in its entirety from the very first step
© 2016 TechSolve Inc. All Rights Reserved.
Factory of the Future
• Rapid adaptable production lines
• High-level of customization and quality
• Focused on zero defects
• Interconnectivity, communication & data storage via cloud
• Energy and resource efficient
• Innovative Small and Medium-size Enterprises
• Continuous skills improvements – multi-skilled jobs
• Doing more with less
© 2016 TechSolve Inc. All Rights Reserved.
Gartner’s Hype Cycle for Emerging Technologies 2013
Internet
of Things
Expectations
Predictive Analytics
Big
Data
Enterprise 3D Printing
Cloud Computing
Time
http://na2.www.gartner.com/imagesrv/newsroom/images/hype-cycle-pr.png;wada20fd4bd7891509
© 2016 TechSolve Inc. All Rights Reserved.
Gartner’s Hype Cycle for Emerging Technologies 2015
Expectations
Internet of Things
Machine Learning
Enterprise 3D Printing
Smart
Robots
Digital Security
Time
http://blogs.gartner.com/smarterwithgartner/files/2015/10/EmergingTech_Graphic.png
© 2016 TechSolve Inc. All Rights Reserved.
Industry 4.0 – Opportunity
• Unlock unprecedented efficiency and factory
optimization
• Predict, adapt, and react more quickly and effectively
than ever before
• Real-time visibility, insights, and optimization
• Reduce operational expenses
• Optimize asset utilization
© 2016 TechSolve Inc. All Rights Reserved.
Cincinnati – Demonstration City
© 2016 TechSolve Inc. All Rights Reserved.
Smart Machine Platform Initiative
Machine tool integrating technologies that recognize the goal of
“First Part Correct” manufacturing.
© 2016 TechSolve Inc. All Rights Reserved.
TECHSOLVE’S IOT ENABLING
TECHNOLOGIES
Machine Monitoring
Brings the Factory into the IoT,
enabling:
• Asset Management
• Shop Floor Awareness and Control
• OEE - Utilization/Efficiency
• Maintenance Insight
• Simulation & Verification
• Supplier Visibility
• Risk Analysis, Contingency Planning
© 2016 TechSolve Inc. All Rights Reserved.
The “WIN” For Manufacturers
Quickly identify underperforming manufacturing
assets and reduce downtime by:
• Uncovering the root cause of
machining issues and disruptions
• Validating process improvement
initiatives
• Promote productivity by revealing
machine performance to all
© 2016 TechSolve Inc. All Rights Reserved.
Choices For Manufacturers
1.
Do Nothing
2.
Traditional (Manual) Data Collection
3.
Automated System (Cloud or Local)
© 2016 TechSolve Inc. All Rights Reserved.
MTConnect®
VERSION 1.0 RELEASED DECEMBER, 2008
TechSolve partnered with AMT to
establish the MTConnect Institute as part
of the SMPI Project
Institute developed MTConnect as open
standard that addresses the needs for
compatibility, interoperability, and plugand-play capability for the machine tool
industry
Standard vocabulary, syntax, and
communication protocol for devices
© 2016 TechSolve Inc. All Rights Reserved.
How Automated Monitoring Works
Use
Store
Aggregate
CNC Machine
CNC Machine
Power Monitor
Extract
CNCs: FANUC, Siemens, Mazak, Okuma, DMG,
Makino, Haas, and more…
© 2016 TechSolve Inc. All Rights Reserved.
Non-CNC
equipment of all
types
Sensors, Digital
& Analog
Signals
Pressure, flow,
temperature,
pH, etc.
HID
Data
Barcode, keyboard, ERP, MES, etc.
measuring device
TechSolve MTConnect VizProducts™
ShopViz®
• Enterprise level monitoring
• Live dashboards, historical reporting, event
notification
• Cloud or local deployment
MiniViz®
• Introductory level monitoring
• Quick and simple – single .exe file
• Live dashboards and data logging
VizProducts®
• MTConnect Adapters, data collection
infrastructure, consulting services
© 2016 TechSolve Inc. All Rights Reserved.
Conclusion
•
The exponential increase in data and new computing capabilities,
along with advances in other areas such as artificial intelligence,
automation and robotics, and human-machine interaction, will
change the nature of manufacturing itself.
•
Data will only grow bigger. Technology reached a level that allows
conducting big data analytics with reasonable speed and
efficiency.
•
There is a need for culture change and experts to fill the gap
between IT capabilities and the realities of the industry.
•
Every manufacturer has to make choices and start somewhere on
the journey to the future.
© 2016 TechSolve Inc. All Rights Reserved.
Thank You!