FUTURE MANUFACTURING :

IMPRESSIONS, INSIGHTS & IMPLICATIONS

S G DESHMUKH

ABV-INDIAN INSTITUTE OF INFORMATION TECHNOLOGY & MANAGEMENT,

GWALIOR

Natio al workshop o Ma ufa turi g “yste s

Under TEQIP MITS, 23 Oct 2016

Key talking points ..

• Today’s a ufa turi g – need /imperative

• Impressions • Connected world

• Device vis-à-vis human being

• Service oriented architecture

• Insights

• Various implications • Manufacturing & control

• Maintenance

• Workforce

Opening quote..

Disruptive technologies such as 3D Printing, Cloud Computing, Smart Sensors and ICT enabled logistics, are bringing a paradigm shift –from centralized mass production to distributed customized manufacturing, closer to end users. India now has an opportunity to achieve its aspiration of large‐scale employment generation by democratising manufacturing using smart technologies in an environmentally sustainable manner to leapfrog to the future.

Prof. Sir Mike Gregory, ‐ Ca ridge Univ., UK &

Dr. Baldev Raj, NIAS, Bangalore

My presentation based on Manufacturing the future: Mckinsey report (2012)

• http://www.mckinsey.com/business-functions/operations/our-insights/the-future-of-manufacturing

Industry Perspective (2014) ..

Industry 4.0 :

Challenges & solutions:

• Status paper by Deloitte (2014)

• http://www2.deloitte.com/content/dam/Deloitte/ch/Documents/manufacturing/ch-en-

manufacturing-industry-4-0-241

Academic Perspective (2016)

Future of Manufacturing Roundtable meeting at Bangalore

(21-22 Oct 2016)

Observations..

• Today’s customer- Hyper-demanding

• Today's world : Hyper-connected

• Today’s manufacturing- Hyper- Smart and Sustainable

• Internet of Things (IoT) : Network of physical objects—devices, vehicles, buildings and other items embedded with electronics, software, sensors, and network connectivity—that enables these objects to collect and exchange data.

source-https://en.wikipedia.org/wiki/Internet_of_Things

Insights ..1..

• Manufacturing – wealth generator

• Across the globe, governments, industrial federations, and corporations have recognized the significance of creating their own added value through production.

• One cannot compete unless manufacturing is strong !

• Ma ufa turi g syste s !

Manufacturing..

• Manufacturing matters. China, India & Indonesia are in the top 15 manufacturing nations by their share to world GDP.

• Manufacturing is not monolithic.

• Distinction between manufacturing & services has blurred.

• It needs new insights into new opportunities,

agilities, and capabilities !!

Impression 1: Ubiquitous Information Availability

• Global markets are demanding more flexibility and productivity

• Resour e o su ptio has to e i i ized. • Progress in in communication, sensor and production technologies

opens new sustainable and competitive ways of innovation, production and consumption

• More and faster information will optimize resource use, shorten lead times, increase productivity and allow the automated production of smart products for smart customers !

• Information in any form, any time, any device

Insights ..2..

• I for atio that drives the e t ce tur ’s structural strategic shift i a ufacturi g.

• Making real-time information available:

• when it is needed,

• where it is needed

• and in the form it is needed throughout the Manufacturing ecosystem

What is Industry 4.0

Synergistic combination of industry and the current Internet of Things (IoT) technology is Industry 4.0

An initiative for Smart Manufacturing !

Disruptive technologies behind Industry 4.0

• Analytics and Big Data

• Mobile technology

• AI & Robotics

• Cloud Computing

• Social networking

Four forces ?

• Digitalisation

• Personalization

• Localization

• Democratization

The traditional Factory

• Monolithic

• Hard wired

• Centralized

• Fixed locations

• Low skill set for labor

Smart factory ..at the heart of Industry 4.0 • Smart Intelligence

• Understanding of the manufacturing process through modeling and analysis

• Ability and agility to observe and take action on integrated patterns of operation through networked data, information, analytics, and metrics

• Dynamic management of energy and material resources

• Smart Practice

• Generating and coordinating use of sensor-based, data-driven manufacturing intelligence

• Applying integrated performance metrics based on real-time action

• Reusing, and scaling integrated practice using a common infrastructure (both cyber and physical)

• Smart Execution

• Real time Dynamic coordination of decision in heterogeneous environments without losing control of state

• Applications that can share data and data that can share applications and devices

Impression 2: Siemens view of Industry 4.0

• Industry 4.0 is an interesting initiative introduced by German companies such as Siemens with a motive of enhancing German competitiveness in manufacturing.

• http://www.totallyintegratedautomation.com/2014/07/smart-manufacturing-industry-4-0-whats

• https://www.youtube.com/watch?v=HPRURtORnis

Insights ..3..

• New organization of value chains.

• On the one hand through vertical network distribution, product development and services.

• On the other hand through horizontal network distribution between supplier, contractor and customer.

• Value chains generate hybrid products (Part material part service part knowledge)

• Manufacturing : Service orientation ?

18

Implications ..1.. Various connotations

• Smart materials

• Smart Controls

• Smart manufacturing processes

• Environment friendly operations

• Closer to customer and pulled by smart customer trigger

Implications ..2.. Networking

• It presents a big opportunity to have an enterprise view of suppliers, distributors and companies in the entire value chain where there will be a strong degree of coupling between Cyber and Physical world!.

• The entire manufacturing facility can be visualized and controlled through apps available on smart devices!- remotely controlled yet at the ground level .

• Benefits : Reduction in manufacturing cycle time and at the same time, the vision is to have mass customization affordable with intimate knowledge about customer!.

• The manufacturing will be smart, social and sustainable !

Implications For educational institutes • Institutes must develop strong linkages with industry to understand and

appreciate and gear themselves for meaningful R&D in collaboration with industry

• The discipline boundaries such as electrical, mechanical etc must vanish so as to appreciate and understand integrated solutions as desired by the industry

• Digital manufacturing is going to revolutionize our view of manufacturing and consequent need to develop trained manpower for the same. This calls for strong curriculum review.

• Mechanisms to upgrade skills need to be established in conjunction with industry. Online courses forums such as Mooc, need to be aggressively utilized.

Industry 4.0 in summarized form

• Digitalization and increased integration

» The horizontal value chain and vertical connectivity of a company

• Autonomous, self-organizing production units

• Intelligent products actively support the production process

• Creation of innovative business models

• Industry 4.0 provides the framework

Industry 4.0 on youtube

• Industry 4.0- Integrated industry reaches the next level (4.01 minutes )

• https://www.youtube.com/watch?v=ccB6e18VwsQ

• Furniture production on the way to Industry 4.0 (3.53 minutes)

• https://www.youtube.com/watch?v=KUKl-c5uWbM

• Industry 4.0 in the Volkswagen group (5.12 minutes)

• https://www.youtube.com/watch?v=JTl8w6yAjds

Acknowledgement

• Dr Kota Harinarayana (Chairman, BOG, IIITDM Jabalpur)

• Mr Baba Kalyani (CMD, Bharat Forge )

• Prof Puneet Tondon (IIITDM, Jabalpur)

• My special thanks to Prof Lajpat Rai, and Prof JP Subrahmanyam

Thank you

deshmukh.sg@gmail.com