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NACFAM:Speeding Up Manufacturing through Greater Connectivity
Michelle PastelManager Measurements, Controls &Systems Innovation
April 9th, 2015
Revised 2/2/2015
© 2015 Corning Incorporated 2
Corning Incorporated
Founded:1851
Headquarters:Corning, New York
Employees:34,800 worldwide
2014 Sales:10 billion
Fortune 500 Rank (2014): 343
• Corning is one of the world’s leading innovators in materials science. For more than160 years, Corning has applied its unparalleled expertise in specialty glass, ceramics, and optical physics to develop products that have created new industries and transformed people’s lives.
• Corning succeeds through sustained investment in R&D, a unique combination of material and process innovation, and close collaboration with customers to solve tough technology challenges.
© 2015 Corning Incorporated 3
Corning Market Segments and Additional Operations
• Optical Fiber and Cable
• Hardware and Equipment– Fiber optic
connectivity products
SpecialtyMaterials
OtherProducts
and Services
LifeSciences
Optical Communications
DisplayTechnology
EnvironmentalTechnologies
• Cell Culture and Bioprocess
• Drug Discovery• ADME/Tox• Genomics• Chemistry• Microbiology• General
Laboratory Products
• Emissions Control Products– Light-duty gasoline
vehicles– Light-duty and
heavy-duty on-road diesel vehicles
– Heavy-duty non-road diesel vehicles
– Stationary
• Corning® Gorilla® Glass
• Display Optics and Components
• Optical Materials• Optical Systems
• LCD Glass Substrates
• Glass Substrates for OLED and high-performance LCD platforms
• Optical Fiber and Cable
• Optical Connectivity Solutions
• Wireless Distributed Antenna Systems
• Optical Cables for Consumer Networks
• Copper Connectivity Components
• Emerging Innovations
• Equity Companies– Cormetech, Inc.– Dow Corning Corp. – Eurokera, S.N.C.– Samsung Corning
Advanced Glass, LLC (SCG)
© 2015 Corning Incorporated 4
Processes for mass
producing the television
bulb
Glass envelope for Thomas Edison’s light bulb
Heat-resistant PYREX® glass
Dow Corning
silicones
Innovation Timeline
Fusion overflowprocess
Ceramic substrates for automotive catalytic converters
Label-free screening platform for drug discovery
Environmentally consciousLCD glass
First low-loss optical fiber
Active matrix liquid crystal display (LCD) glass
Glass ceramics
Ultra-bendable fiber
Thin, lightweight cover glass with
exceptional damage
resistance
Ultra-slim, flexible glass for thin and lightweight applications
First EPA-registered antimicrobial cover glass
First all-optical
converged cellular
and Wi-Fi solution
1879
1934
1952
1970
1982
2007
2012
1915
1947
1964
1972 2006
2013
© 2015 Corning Incorporated 5
Growth Through Innovation
• Our culture of innovation is built on the foundation of research and development
• Our near-term growth will be fueled by several opportunities
– Glass substrates for LCD and OLED displays
– Ceramic substrates and filters for mobile emissions control systems
– Optical fiber, cable, and connectivity solutions for the world’s leading carrier, enterprise, wireless, and consumer networks
– Drug discovery tools and solutions
– Chemically strengthened, damage-resistant glass
– Other advanced optics and specialty glass solutions for the semiconductor, aerospace, defense, astronomy, and metrology industries
© 2015 Corning Incorporated 6
Research and Development (R&D)
• Our growth is fueled by a commitment to innovation and a passion for conquering complex material and technology challenges
• We invest approximately 10% of our sales in R&D
• We maximize the results of our R&D by engaging cross-functional teams and senior leadership at all stages of innovation
• Our technology leadership and R&D environment attract and enable the best scientific minds in the world
© 2015 Corning Incorporated 7
Deep Core Technology Capabilities – Science & Engineering
Corning’s strength is based on a broad portfolio of core technologies…
… and the ability to integrate
them.
Thin Filmsand
SurfaceSciences
BiochemicalSciences
andProcesses
OrganicMaterials
andProcesses
Engineering: - Materials - Optical - Process - Chemical - Electrical - Mechanical
Core Capabilities
NetworkIntegration
andConnectivity
Research
InorganicMaterials
andProcesses
MaterialsCharacterization
andProcesses
Modelingand
Simulation
OpticalPhysics
andNetwork
Technologies
© 2015 Corning Incorporated 8
Awards and Recognitions
• Four-time National Medal of Technology winner
• Institute of Electrical and Electronics Engineers (IEEE) Milestone Award for the invention of low-loss optical fiber (2012)
• Edison Award gold medal in Materials Science for Corning® Gorilla® Glass (2012)
• Thomson Reuters Top 100 Global Innovatorsm (2013, 2012, 2011)
• Massachusetts Institute of Technology’s list of disruptive innovators (2013)
• “Most Innovative Companies” (2013) and “Innovation All-Star” (2010) by Fast Company magazine
• The American Ceramic Society Corporate Technical Achievement Award (2010)
• One of Fortune magazine’s most admired companies (2010, 2009)
© 2015 Corning Incorporated 9
The Corning Values
Our Values are the historic strength of our company, guide our every move, and continue to set us apart from others.
All seven, All around the world. All the time.
© 2015 Corning Incorporated 10
Corning Summary Remarks
• We’ve succeeded for 160 years … few other U.S. companies have
• How have we done it?– Successive waves of innovation
– Deep understanding of glass and ceramic materials
– Strong process and manufacturing capabilities
– Collaboration with customers and partners
– An exceptionally talented and dedicated workforce
– A conservative financial structure and patient capital
`
Smart Manufacturing Leadership Coalition
www.smartmanufacturingcoalition.org
Smart Manufacturing Leadership Coalition
www.smartmanufacturingcoalition.org
NACFAM - Speeding Up Manufacturing through Greater Connectivity
Michelle Pastel - Corning, Inc.
Smart Manufacturing Leadership Coalition
www.smartmanufacturingcoalition.org
An Industry-Driven Open Architecture
Shared InfrastructureSMLC Partnerships
“Information that drives the next century’s structural shift in manufacturing.”
Smart Manufacturing
Smart Manufacturing Leadership Coalition (SMLC) – 501c (6)
Making real-time info available:•when it is needed, •where it is needed•and in the form it is needed throughout the Manufacturingecosystem
American Council for an Energy _Efficient Economy (ACEEE)AMP SocalAlcoaAmerican Institute of Chemical Engineers (AIChE)American Society of Quality ARCAssociation of State Energy Research and Technology Transfer Institutions (ASERTTI)CorningDepartment of Energy (DOE)EmersonElectric Power Research Institute General DynamicsGeneral Electric General MillsGeneral MotorsManufacturing Enterprise Solutions Association (MESA)MT ConnectNational Association of State Energy Officials (NASEO)North Carolina State University
Nimbis ServicesNISTNational Science Foundation (NSF)OSISoftOwens CorningPacific Northwest National LaboratoryPfizer Inc.PraxairPurdue UniversityRensselaer Polytechnic InstituteRockwell AutomationSavigent SoftwareSchneider ElectricSociety of Manufacturing Engineers Southwest Research Institute - SWRISustainable SolutionsTexas A&M Engineering Experiment Station (TEES - TAMU)Tulane - PolyRMCUniversity of California, BerkeleyUniversity of California, Los AngelesUniversity of Texas - AustinWest Virginia University
Smart Manufacturing Leadership Coalition
www.smartmanufacturingcoalition.org
SMLC’s Industry-Driven Strategy
Roadmap: Operations & Technology for SM systems
Establish Work Groups: Identify & Drive Priority areas• Test Bed• Platform• People• Business
Infrastructure Specification: Increasing SM Platform Definition& Development
Action Plan: Implementing 21st Century Smart Manufacturing
SMLC Incorporates as 501c6:Building Capacity & Resources; Leveraging Resources; Advocacy for SM
DOE, NSF, NIST Awards: $13 million in Project Work to develop SM Platform Prototype
Implementation Plan: Review & Refine Collaboration Roles & Alignment
Membership Expansion Spin-off parallel activities
AMTechACCELERATE
DOE Workshop
SMLC Forum WorkshopNSF
Workshop
AIChE Workshop
Technical Meetings
Board Meetings, Calls, Advisory Groups, Focused Workshops, etc.
Smart Manufacturing Leadership Coalition
www.smartmanufacturingcoalition.org
General Mills Networked-Based Manufacturing
Supply ChainDistribution Center
Customer
Business Systems, ERP
Smart Grid
Smart Factory
Recipe ManagementMapping formula into operatingrecipes
EDI transaction& qualitycertifications
FDA Tracking &traceabilityGreen Light
Analyze - to put into productionMake – right ingredients – confirmation on recipeRelease – meet requirements to release
Mapping SAP informationInto operation
Graphics courtesy of Rockwell Automation
Smart Manufacturing Leadership Coalition
www.smartmanufacturingcoalition.org
Core Systems
Data Input
Core Functions
MQISMQIS MESMES SAP ERPSAP ERP Red PrairieRed PrairieSAP APOSAP APO SAP PLMSAP PLMSAP MRPSAP MRP
Value Creation
Business Applications
GMI’s ECO System of “STUFF”
Smart Manufacturing Leadership Coalition
www.smartmanufacturingcoalition.org
EERE DOE “Project Smart Manufacturing”
Smart Manufacturing Leadership Coalition
www.smartmanufacturingcoalition.org
Achievable Meaningful Use Goals and Magnitude of Impact
• Demand-driven efficient use of resources and supplies in more highly optimized plants and supply
– 25% reduction in safety incidents– 25% improvement in energy efficiency– 10% improvement in overall operating efficiency– 40% reduction in cycle times– 40% reduction in water usage
• Product safety – Product tracking and traceability throughout the supply
• Sustainable production processes for current and future critical industries
– 10x improvement in time to market in target industries– 25% reduction in consumer packaging
• Maintain and grow existing U.S. industrial base– Environment for broad innovation– 25% revenue in adjacent industries– 25% revenue in new products and services– 2x current SME’s addressing total market– More highly skilled sustainable jobs created
• ROI constrained or prohibitive- Requires broader infrastructure investment to scale- Incremental investment difficult- Requires IT investment with 70% of cost non-value- Depends on other companies - supply chain- Need 80% lower cost implement modeling/simulation- 10x reduction in cost of sensors/sensor infrastructure
• ROI opportunity comprehensive– Multiple systems– Integrated global performance metrics– Aggregating data
• Installed base of serviceable manufacturing facilities– $60 B in IT investment– Retrofit
• Risk– Major change & New business model– Uncertain about technology, security & IP
• Organization– IT capability lacking or IT not talking to operations– Workforce skills – Collaboration
Issues Beyond Individual Company
Technical and Business Drivers for Shared Infrastructure
Smart Manufacturing Leadership Coalition
www.smartmanufacturingcoalition.org
Manufacturing Health & Sustainability
Smart Manufacturing Leadership Coalition
www.smartmanufacturingcoalition.org
What is SMARTTest Bed Smart Systems
Smart Machine Line
Operations
In-Production High Fidelity
ModelingDynamic Decisions
Enterprise & Supply Chain
Decisions
Design, Planning & Model
Development
Machine product management
Better management complex behaviors
Performance management global integrated decisions
Variability reduction
Design models in production
Benchmarking machine-product interactions
Rapid qualification components products materials
Untapped enterprise degrees of freedom in efficiency, performance time
Risk and compliance management
Product/material in-production ability
Machine-power manage management
Integrated computational materials engineering
Business operational tradeoff decisions
Tracking traceability genealogy
New product, material technology insertion
Adaptable machine configurations
External partner integration into business process
Configurable data and analyses for rapid analytics and model development
Smart Manufacturing Leadership Coalition
www.smartmanufacturingcoalition.org
Smart Manufacturing: Multi-Layered Seams, Time, Data & Action - Materials
Dynamic Manufacturing Ecosystem
Product Manufacturing
Materials & Process TechPrototype Qualification In
Service
Macro Layer
Meso Layer
Micro Layer1000s control loopsTime - minutes
100s control loopsTime -hours
10scontrol loopsTime – days
Focus: 10x Multiple Pass Variability
Reduction; Supply Chain Information
Busi
ness
Sys
tem
sBu
sine
ss S
yste
ms
Cont
rol &
Aut
omati
onCo
ntro
l & A
utom
ation
Focus: 100x Event Variability/Tradeoff
Adjustment; Dynamic Performance Mgmt.;
Integrated Metrics
Focus: Insertion, Qualification, ICME, High
Fidelity Dynamic Operations
DesignData
Smart Manufacturing Leadership Coalition
www.smartmanufacturingcoalition.org
ApplicationsApplications
ContextContext
DataData
Calibration &Maintenance
Production Models
Sensor Data
Suppliers
Heating & Forging
Power Mgmt & Energy Grid
Line Operations
Customers
DistributionSustainability
& Safety
Open-Architecture Infrastructure & Marketplace
• APPs & Toolkits•Composable Systems• Cloud Deployment• Private/Public IaaS
SM Value Proposition
Event Data Real-Time Data
MappingMapping
Smart Manufacturing PlatformBridging Seams Extending the
Real-Time Infrastructure
Smart Manufacturing Leadership Coalition
www.smartmanufacturingcoalition.org
Building InfrastructurePowering Smart Decisions
Smart Manufacturing Leadership Coalition
www.smartmanufacturingcoalition.org
US Mfg Needs Smart Sensors & SystemsNeed to Overcome Adoption Barriers
• Low Initial Cost- open• Low Cost to Install- robust wireless• Easy to Maintain- high uptime, increase mfg
efficiencies• Secure• Information- Respect What’s Not Yours• Bridge Workforce Generation Expectations• Make Smart Manufacturing a Prudent Risk
with <2 yrs. ROI
Smart Manufacturing Leadership Coalition
www.smartmanufacturingcoalition.org
US Mfg Needs Mindset Changes to Win in a Global Economy
• Expect Information- expect interoperability • Think Eco-system Broadly- physical and cyber• Integrate Existing Organization Silos- IT & engr• Place Increased Value in Data- knowledge• Automate What We Know- opens time to
solve the next problem • Re-Evaluate Roles- expanded skills required• Expect Lifelong Learning- facilitate achieving it
Smart Manufacturing Leadership Coalition
www.smartmanufacturingcoalition.org
Institute Structure