THE-ONGOING-MANUFACTURING.ppt

Editor's Notes

• #5: Manufacturing Industry is currently experiencing a Revolution It is commonly referred to as Industry 4.0, meaning this is 4th version of the industrial revolution The first industrial revolution happened towards the end of 18th century when water and stream powered mechanical loom was invented The second revolution happened towards the end of 19th century when electricity was discovered and was used in mass manufacturing production lines (Electricity driven Conveyors etc.) The third revolution happened in Q4 of 20th century (1960s & 1970s) when Electronics, Programmable Logic Controller devices along with Robots were introduced to automate manufacturing production lines The fourth or current revolution started in early 21st century with the introduction of Cyber Physical Systems enabled by IoT, Augmented Reality and 3D printing etc. IoT is at the core of the 4th revolution
• #6: Multifaceted innovations in multiple complementary technology & business disciplines are enabling the rise of IoT For example, there are innovations in readily usable intelligent devices such as Sensors, Actuators, ServoMotors etc. Engineering fields such as Mechatronics & Nano Technology are driving miniaturization of such intelligent devices Likewise, advancements in Embedded systems, Robotics, Augmented reality are enabling Internet connected Smart Electro-Mechanical systems commonly referred to as Cyber-Physical Systems While cloud computing has been around for a while, the notions of Edge & Fog computing are being evolved thereby enabling IoT in manufacturing In turn, IoT or otherwise, IIOT in the context of manufacturing is enabling factories transform into SMART factories
• #9: Airbus revolutionized their manufacturing on many fronts. The Challenge: Manufacturing & assembly of Aircraft involves tens of thousands of steps and a single mistake in the process could cost hundreds of thousands of dollars to fix, makes the room for error very small MiRA: cross between a tablet and sensor pack Captures video from real environment Generates a 3D model of the aircraft that can be manipulated and accessed for production work Smart tools smart tools understand the actions that the operator must perform next and automatically adjusts the tools to the proper settings, which simplifies the task for the operator Once the action is completed, the smart tools can also monitor and log the results; For example, a smart tightening tool understands which task the operator is about to perform using vision to process its surroundings and automatically sets the torque. The tool would record task data in a central database. With such information, production managers can precisely pinpoint the procedures and processes for QA certification In addition, Operators are given a smart Mobile App enabled with Augmented Reality driven instructional & educational tutorials The sensors on smart tools can transmit alerts to the operator's smart mobile App letting operator know when the device to be operated upon is close by. The smart App would then display AR driven instructions about performing the right operations on the target device
• #10: Siemens is one of the early adopters of IoT in their Manufacturing The Challenge: Separate production lines were needed for filling and labeling each variant of Shampoo and this was hugely inefficient in simultaneous mass production of different Shampoo types Multi-format capable carriers were introduced that can transport different types of Shampoo containers through production line Each carrier is equipped with an RFID tag that contains the specific Shampoo variant information The ingredients dispenser machine would read RFID tag on the carrier and determine what quantity and which Shampoo variant to dispense After dispensing right quantity of Shampoo variant, the dispenser machine would update the status info on the RFID tag Next in the line is the packaging and labeling machine that would read the RFID tag on the carrier Labeling machine first would ensure that the container has been filled by the dispenser machine by reading RFID tag status and then would determine which label to assign based on the Shampoo variant info found on the carrier’s RFID tag Eliminates the need for human input in the dispensing and labeling process Eliminates the need for a separate production line for each type of shampoo Information is then collected and engineers can review to improve the process
• #11: Continental AG is one of the first who transformed their factories into SMART factories They introduced SMART manufacturing techniques on many fronts The Challenge: Physically finding input components for tire manufacturing in a massive facility was causing considerable loss of productivity. Employees knew what components are in the inventory but could not track them in the facility. If a component remained unused, it could pass its shelf life & expire RFIDs are attached to containers that contain tire components In-Facility Geolocation services are used to locate the specific components needed and alert forklift drivers to have them move the components quickly from current location to target location RFID enabled components are also integrated with Inventory systems so that inventories are updated in real-time Collaborative Robots collaborative robots are able to work conveniently, quickly and precisely. Inherent errors are avoided and processes executed extremely dependably. This, in turn, results in quality improvements and cost savings. This also reduces employee injuries Deployment of collaborative Robots also reduces the need for additional assisting employees Moreover, Many factory workers are working longer so it helps aging workers continue to do their job. http://www.roi-international.com/fileadmin/ROI_DIALOG/ab_DIALOG_44/EN-ROI-DIALOG-49_web.pdf
• #13: Many manufacturing companies are streamlining their factories by deploying IoT Solutions
• #15: Another critical area where IoT driven SMART solutions are being deployed is Factory inventory management Challenge – If not proactively monitored, components can run out or run low Loss of productivity could be because of unavailability of required parts On the other hand, costs can sky-rocket if surplus parts are procured quickly Moreover, some of the parts have short shelf life and hence can expire if not used Hence smart optimal inventory management become mandatory
• #16: Challenge – If not proactively monitored, components can run out or run low Increased costs can be from not producing or have to pay more to get parts quickly)
• #17: Quality Control is another area where SMART solutions are being deployed
• #18: - Smart manufacturing is much more than mere usage of Sensors. - The entire value chain starting from inbound logistics through production, through outbound logistics including sales, marketing and post sales services are being electronically tracked and key assets are connected to the internet (Essentially IoT enabled) There is both vertical and horizontal integration of smart production systems Vertical integration refers to IoT enablement of production systems starting from inbound logistics to outbound logistics including sales & marketing Horizontal integration refers to IoT enablement of raw material suppliers, finished products consuming business partners, post sales services to product end-users (customers) etc. The vision of Industry 4.0 is that in the future, industrial businesses will build global networks to connect their machinery, factories, and warehousing facilities as cyber-physical systems, which will connect and control each other intelligently by sharing information that triggers actions. These cyber-physical systems will take the shape of smart factories, smart machines, smart storage facilities, and smart supply chains. This will bring about improvements in the industrial processes within manufacturing as a whole, through engineering, material usage, supply chains, and product lifecycle management.
• #20: Entrigna is a provider of Real-Time Cognitive & Prescriptive decisions software that can play a key role in the Information and Operations domains as depicted in the reference architecture. Entrigna’s product Real Time Expert System (RTES) can be leveraged both in Edge Gateway as a Fog Computing brain and also as a real-time cognitive and prescriptive decisions in cloud computing within information and operations domain
• #21: Entrigna’s RTES is a software platform that seamlessly combines many decisioning techniques under one technology; techniques that are critically needed for IoT Fog and Cloud cognitive computing For more information, visit entrigna.com