Date post: | 08-Aug-2015 |
Category: |
Documents |
Upload: | harish-pant |
View: | 40 times |
Download: | 1 times |
1
Intelligent Manufacturing System Integration
Harish PantManaging Director
2
97% of Indians find themselves in the bottom 60% of the world’s population when ranked according to incomes.
Irony of our country being a low cost country….
Labor is cheap so keep it Not Intelligent and without system – only short pulses of Jugad!
3
• Who is Not Intelligent ?
• What should be intelligent and how much?
• What an intelligent device does? e.g. The Best Smart Phone vs Ordinary Phone
Why Intelligent?
4
Why Intelligent?
To achieve better
• Quality, Cost, Delivery, Safety, Security, Reliability
• Environment, Sustainability, Comfort, Convenience
• Seamless / Integrated Service
• Futuristic Products and services: Quantum Research
>> Innovations to meet Uncertain, Volatile and ever Changing World
.. Return on investment (ROI) vs Survive on Investment (SOI)
Human
Can do Can’t do
Machine
Phase 1 - Human and MachinePhase 2 - Human Vs. Machine Phase 3 - Machine to MachinePhase 4 - Internet of ThingsPhase 5 – Intelligence to Intelligence
InformationIntelligenceIntegrationIOT
Capacity and Capability
Can do Can’t do
1. Principles of Motion Economy
2. Motion Study
3. Workstation Design
4. Application of Ergonomics
5. Fatigue Studies
6. Productivity/Safety/Comfort Device Design
7. Standardization of Operator Methods
8. Operator training
9. Incentive Systems
10. Job Evaluation
11. Learning effect capture
12. Work Measurement - Time Study
1. Process/op Analysis/OR
2. Six Sigma
3. Value engineering
4. Statistical quality control ,
5. Statistical inventory control and ABC
6. Variety reduction
7. Standardization
8. Waste reduction or elimination
9. Activity based management
10. Business process improvement
11. Learning effect capture and continuous
12. 5S, SMED, Lean system
Techniques
Value
Human Motion Method
Productivity
Traditional
X In Built
IE FrameworkInnovation/Disruption
Context
TechnologyCompetitionSustenanceEnvironmentSocialEconomic
Integration
SeamlessWhole / TotalEnd to EndUser controlled
Value
• Disruptive Impact• Beyond “As desired” or “perceived”• Authentic / Real
The last mile/end changes are changing the structure / base creating multiple disruptions
>>>>>>
Value - Increasing Envelop
New Value Preposition
Chapati Making
Prepare DoughRollBake in oven
Prepare DoughPress and Bake
Fill Flour and WaterSelect roti thickness
• The next…..Grains Fill and auto operate…auto recognition….• Disruptive Change in Human Motion and Method: everything changed• Skill and knowledge required – a disruptive change!
EliminationsWastes (Muda) >>> Variations (Mura) >>> Strain (Muri)
ImprovementsQuality, Cost, Delivery…..)
Disruptions Mobility and scalability, Internet of things, Free
of Cost – Knowledge/Info/across the globe
Innovation Unique, New, Different
• The roti maker has to become expert in many dimensions• Streamlining processes and cutting cost is just 18th century• Complexity is managed by simple rules and constraints actually spur the
innovation
Changing Change @
10
Manufacturing System Elements Interplay
Interplay of 5M’s
Man – Attendance, Attention, Availability
Machine
Idle timeChangeoversReduced lot size
Money
Cash FlowMargins
Material
Lead timeAvailabilityGlobal Supply chain
Method
Changing requirementsImprovements disruptions
11
Systems System
• Quality System, EHS System• Customers requirements• CAD/CAM• Machine Programing software• Machine controllers• ERP• DOC Management System• Quality Lab Management• Out Source – In Source Interface• Individual Hardware / software/App• Social Media • Search engines
System Issues
• Standards• Compatibility• Availability• Affordability
Manufacturing System
12
Information Technology (IT) Operational Technology (OT)
Internet of Things (IOT)
Internet of Things (IOT) as Service
Industry Era – 4.0
A world in which digital technologies are deeply embedded and in abundance.
The Future Factories
• The Internet of Things on the Plant Floor• 3D Printing and Emerging Production Technologies• Digital Manufacturing
13
A future for manufacturing in which
• Pervasive connectivity, • Sensor networks, • Cyber-physical systems, and• Increased production flexibility
promise to drive the creation of ever-more customized and smarter products.
A new levels of digitization, automation, and integration within an enterprise, and many new areas of technical and software innovation.
http://www.gilcommunity.com/blog/hannover-highlights
The mantra of Industry 4.0
14
• Dramatically change the products we manufacture and use, making them smart, connected, and, ultimately, more autonomous.
• The IoT era will require much tighter and more agile collaboration between what historically have been stove-piped organizational functions such as IT, engineering, R&D, service, and manufacturing.
• Manufacturing companies create what he called “Unified Data Groups,” led by Chief Data Officers, that would be tasked with turning the mountains of data generated by IoT infrastructure into competitive assets that could truly be exploited by existing business units
• Whether manufacturers decide to graft the data management function onto their existing organizational structures, set up new centers of excellence, or partner for expertise, the structural changes forced by IoT are likely to be, at least for a time, a source of conflict or a source of Collaboration.
• Require a new generation of manufacturing employees with a unique combination of not just mechanical and software engineering skills but also data science skills and knowledge of domains such as post-sales product service and support.
Internet of Things
Excerpts from M.Poter
15
• Deep Learning : Hardware's designed for the Machine Learning Techniques
• Many gadgets will be able to understand images and video thanks to chips designed to run powerful artificial-intelligence algorithms."
• Companies like Google have made breakthroughs in image and face recognition through deep learning, using giant data sets and powerful computers...\
• Quantum Computing Algorithm for advanced Artificial Intelligence• The Dutch government, research institute TNO* and other organisations have agreed to
invest Euro 135 m• New design recognized speed-limit signs in footage from a car.
• A home security camera could start sending data over the Internet only when a human entered the frame.
• Being able to do things like analyze images on a device without connecting to the Internet can make apps faster and more energy-efficient because it isn’t necessary to send data to and fro
New Advances in Artificial Intelligence
16
To offer a range of services including
• A new IOT platform-as-a-service offering, that will allow developers to integrate IOT-generated data with existing business applications such as enterprise asset management;
• A cloud-based service that IBM, its customers, and its partners can use to design and deliver analytics applications that are focused on specific vertical industries; and
• An ecosystem of partners that will deliver IOT solutions based on IBM’s platforms.
• Working with Cummins and Pratt & Whitney, to create IOT solutions that monitor the functioning and health in the field of products such as engines.
• Partnering with the University of South Carolina to create IOT-enabled analytics tools and skills that can enhance predictive maintenance.
- See more at: http://www.gilcommunity.com/discussion/ibm-will-invest-3-billion-internet-things-initiative/#sthash.5EQlNY1N.dpuf
IBM Will Invest $3 Billion in Internet of Things
17
Futuristic Festo R&D program, the partially 3D-printed BionicANTS communicate with each other to coordinate both their actions and their movements to achieve cooperative tasks. Each ant takes autonomous decisions but is always subordinate to the common objective
http://www.gilcommunity.com/blog/hannover-highlights
The electro-mechanical e-Motion Butterflies, meanwhile, autonomously coordinate their flying patterns using indoor GPS, a collection of spatial infrared cameras and controller, plus on-board guidance and monitoring systems so they never collide.
New Developments
ABB --- YuMi – combines a vision system, grippers, touch-sensitive sensors, software, and integrated safety components in a form factor that weighs 38 Kg and consumes one square foot of space. YuMi is designed for consumer product manufacturing applications such as electronics, phones, and various small parts
18
SmartFactory’s Plug and Produce ApproachPioneering German research initiative, SmartFactory KL e.V., and the German Center for Artificial Intelligence demonstrated how the Industry 4.0 concept can be integrated into existing industrial applications.
Harting’s Customized Production LineThough still in development, Germany’s Harting Technology Group is showcasing a prototype modular factory line able to create individually customizable products with the speed and efficiency of mass production volumes. Called the Harting Integrated Industry 4 You (HIIA4YOU) project, it connects an eShop customer selection system, with an SAP ERP network, and finally the production and assembly machinery in a three-cell production line.
Volkswagen’s e-Golf and Factory PowerwallThe digital networking will become an essential part of the auto industry in the future, featuredA number of digitally-driven production and product developments, including augmented reality systems that show where specific parts are installed in the body of a car, the e-Golf electric vehicle which features wireless charging and a digital key that can be operated by smartphone, and what it calls the Powerwall – a virtual wall screen, adapted from a similar technology used earlier in vehicle design and engineering, that now allows factory teams to simulate a plant and plan and refine an entire production process for a new product in a virtual world before any physical changes are made to the factory itself.
- See more at: http://www.gilcommunity.com/blog/hannover-highlights-day-1-industry-40-clever-collaborations-and-plug-and-produce/#sthash.DejGlQbr.dpuf
New Developments…
19
Impact on Education System
• CS/IT/Analytics to be embedded in all courses
• Projects to be done with across the branches of various discipline
• Create infrastructure throughout the campus to facilitate cutting edge research
• Very active involvement of Industry – Academia – Research and Development
• Content no more important and to be made available online – application is important
• Create similar experience in running the Education Institute
• Create a platform for Intelligent Manufacturing System for active participant of Faculties, Students and various Research scholars
• Carry out an India specific research on where IOT will bring immense benefits to industry and society
• More collaborate and then compete
• Be a Role Model