Sutton Tools

Industry 4.0

JourneyInformation Driven

Manufacturing:

Joining the dots in a disruptive landscape to bootstrap Innovation

& create the ‘smart enough’ factory

Dr Steve Dowey

‘Machining a special cutter at Sutton Tools’.B. Carroll, Australian made: success stories in Australian manufacturing since 1937.,Institution of Production Engineers Australian Council, 1987.Image Wolfgang Sievers 1960 – State Library of Victoria

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• Introduction to Sutton Tools

• Industry 4.0 and The ‘Smart Enough’ Factory

• A digital Strategy: The ‘Digital Triangle’

• Implementation: Smart Enough’ factory at Sutton Tools

• Summary, acknowledgements and questions

Overview

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Sutton Tools – about us

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Good at Cutting Tools. Not so good at Integrating

Systems…

Infor M3 Salesforce

QMS

WebsiteSharepoint/Product Design

Excel/CSV (manual)

• No real Integration*

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• The Goal (so simple…)

*in 2015. N.B If 20+ years ago we’d all learned Access & OLE…

INDUSTRY 4.0

Industry 4.0 and the Smart Enough Factory

Image Wolfgang Sievers – State Library of Victoria5

Industry 4.0 - Defined

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Problem:This imposes a view on us. It shows a stepwise progression on the industrial revolution, i.e an order. And implies it’s correct.

Q. Are the divisions really so clear cut?

R. – is complexity reallyincreasing?

S. Did the Industrial Revolution only affect manufacturing?

Industry 4.0 - Defined

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• The narrative: 1.0; mechanisation, 2.0; assembly lines, 3.0;

automation 4.0; digitisation

• ALL OF THEM WERE/ARE ABOUT LABOUR SAVING

& THEREFORE PRODUCTIVITY IMPROVEMENT

– Applied the (technical) tools of the day to:

• MAKE

• CONTROL

• MANAGE

– Things i.e. products, people, processes, factories, offices, businesses.

All three activities require insight and knowledge of the ‘thing’

Enabling ‘Industry 4.0 Thinking’

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Why is Industry 4.0 Attractive?

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From: Industry 4.0. The future of Productivity and Growth in Manufacturing Industries (BCG April 2015)

Germany & USA:

• lack of qualified employees (i.e. ones with STEM skills)

• data security

• excessive costs associated with implementation

• ‘‘Leaders’ biggest hurdles are data security (51%) and privacy

(39%), while the rest struggle with legacy systems (36%), inability to

do fast experiments and insufficient skills of IT staff (34%)’ *

Industry 4.0 Challenges

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*GE Digital and the Industrial Internet Consortium (IIC) survey by Genpact (2016)

Industry 4.0. The future of Productivity and Growth in Manufacturing Industries (2015)

• “Only about one in four enterprises has a clear strategy in

place for implementing IIoT”

• ‘‘Leader organizations are also three times as likely as their less

prepared counterparts to have effectively executed such a strategy”

Industry 4.0 Challenges

GE Digital and the Industrial Internet Consortium (IIC) survey by Genpact (2016) – Figure from ‘Transforming industrial businesses with the internet of things’

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National Differences

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Given the global challenges (cost, skills, security) and the need

for local solutions,

Smart Enough is:

• management data driven - enables transparency and immediacy of

processes.

• Lean.

• Leaves control and action to the experts and systems. Feedback

loop is closed by the operator / manager.

• Uses micro-service architecture. Complements but doesn’t need an

Enterprise Service Bus or SOA. Works with legacy systems.

• Applying a lightweight sensor network overlay onto existing

systems, leveraging web technology, RAD tools and open source.

What is ‘Smart Enough’ Industry 4.0 ?

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DIGITAL

STRATEGY

SME Tailored

Image Wolfgang Sievers – State Library of Victoria14

Why SMEs may lack a digital strategy

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Triangles!

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http://pscholtes.com/articles/total-quality-leadership.htm

The Joiner Triangle

(v management by control)

The Digital Triangle

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Principles for a Digital Strategy

Productivity and Compliance

One Source of Data

Accessed via Services and Systems

A single source of truth

Focus on business productivity and compliance to standards and processes

Web Services and ICT systems for C.R.U.D.

IMPLEMENTATION

IoT overviewBusiness Processes

18Image Wolfgang Sievers – State Library of Victoria

What are the dots?...

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• Business Process Re-engineering

– (1990s) + BPM, defined the technologies and therefore

the skill sets for Industry 4.0

• Information Driven Manufacturing.

At Sutton Tools this means:

– Collaboration• Web 2.0 tools (PaaS) – Platform as a Service –

e.g. Confluence

– Integration• Web tools + Web Service technologies + RAD tools

– e.g. create data management middleware &

supply data direct to external business systems (at

low cost)

– Digitization• Web Tools + Web Services + ‘tech’ (Sensor

Networks + SBCs + micro-controllers) = IoT, e.g.

the ‘Smart Enough’ Factory

– Compliance & Productivity (emerging)• BPMN – Process Engines, DMN – Modelling

business decisions, CMMN –Case Management

Shared Databases, Expert systems, Telecoms networksDecision support tools, Wireless data comms and portable PCs, Automatic identification and tracking. NEW – The Internet!Web services, IoT NEW – High Level languages and configuration –enabling the ‘Citizen Developer’Business Process Model and Notation.LATEST NEWS – The enabling technology hardware & software is very low cost

MQTT Message. Follow the string…

29/06/2016,

10:30:284d14d2ce.ab5c84Thomastown/plant1/drillLine/1984 :

msg.payload : string [23][1984,10,1467160195208]

29/06/2016,

10:30:304d14d2ce.ab5c84Thomastown/plant1/drillLine/1234 :

msg.payload : string [22][1234,0,1467160197457]

[1984,10,146…78]

String Theory:

JSON ArrayNotation

Sensor Address16bit Hex

The data 2bit binary

Epoch time stamp -ms since 1 Jan 1970

10The ‘machine state’ bit The ‘ignore machine state’ bit

Thomastown/plant1/drillLine/1984MQTT msg address:

MQTT msg payload:

(see model)What does it enable you to do?

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IoT

It just takes persistence…

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• Industry 4.0 covers a huge range of ICT related activities.

• The ‘problems’ –Cost, Security and Skills can be engineered out (or

at least mitigated against) . Think Smart enough!

• When identifying projects, focus on a business need first; not a

technology first approach. Be guided by a simple Strategy.

• STEM skills are vital:

– You may be creating ‘big data’

– If only to know what you don’t know, so to scope projects and activities to

integrators and developers in this space effectively!

• However, cost of entry is low and the (STEM) skill set requirements

have converged and shrunk significantly since the 1990s and BPR.

• Collaboration, Integration, & Digitization enhance Compliance and

Productivity at any scale.

Summary

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Capability through

collaboration

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This work was partly conducted within the Defence Materials Technology Centre, which was established and is supported by the Australian Government’s Defence Future Capability Technology Centre (DFCTC) initiative

Acknowledgements

• IIoT is not easy - without a strategy – doubly so. Why? It requires

nit-pickingly detailed attention and an overview of the ‘big picture’

• The last digital 100m – is a real challenge (Charlie Peters -

Emerson)

• IIoT also has the potential to be incredibly disruptive both positively

and negatively at the same time!

– It provides TRANSPARENCY, IMMEDIACY and PRODUCTIVITY

– Immense visibility of processes. Friction of time – eliminated with near

realtime. Productivity (value add – often comes for free)

– Zero cost has problems – profitability reduced to a commodity level

What’s the problem again?

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http://industrialinternet.co.uk/solution-stack/

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• Charlie Peters nails why IoT is not ramping as expected it’s the last wireless mile/Km/yard/room Listen from 25.52 min in this podcast from Gigaom.

• https://soundcloud.com/gigaom-internet-of-things/the-internet-of-things-will-rock-your-business-and-heres-how

• The internet of things will disrupt the hell out of your business and you best start preparing your business to meet that change by preparing to deal in information as opposed to physical goods, according to Charlie Peters, an executive senior vice president at Emerson. This may be surprising coming from a top executive at a company know from process manufacturing and old-line systems, but Peters, laid down several hard truths in this week's podcast about how the internet of things will change enterprises in his conversation with me.

• He covered the three ways that IoT changes business, the hurdles that companies face from a technical perspective (and why that hurdle is driven in part by a business rationale on the part of companies responsible for driving the technical innovations we need.) Before Peters and I chat, my colleague David Mayer joined my on the show to share his thoughts on the connected home and how he thinks manufacturers might gain consumer trust when it comes to privacy and security. Tune in for his delightful accent and stay for some compelling content about Mobile World Congress and more.

• Guests: Charlie Peters Senior Executive Vice President and director at Emerson

• A european perspective on the smart home and privacyDoes the internet of things need a Trust-E or other seal of approval for privacy to communicate to the consumer?The internet of things changes your business in three ways. Here they are.The result of more information will be a few large successes and several mediocre businessesWhy wireless connectivity is a last hurdle for IoT that still isn't solved.

http://industrialinternet.co.uk/solution-stack/

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INNOVATION

Compliance & Productivity

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Image Wolfgang Sievers – State Library of Victoria

APC Magazine Feb 2017 (borrowed from a public library)

AI?30

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BPMN - The BP Diagram is run

by the Process Engine

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