Dr. Thorsten [email protected]
Smart Manufacturing for SMM Opportunities and Challenges
SmalltoMediumManufacturing(SMM)NeedsandCaseStudies- Presentations&PanelSession -
NISTIndustryForumMay8,2018
Gaithersburg,USA
WestVirginiaUniversityBenjaminM.Statler CollegeofEngineering andMineralResourcesDepartmentofIndustrialandManagementSystemsEngineering
Dr. Thorsten [email protected]
1. SmartManufacturing
2. SmartMfg SurveyofSMEsinWestVirginia
3. Projects&CaseStudies
4. Recommendations
Agenda
Dr. Thorsten [email protected]
Youmayhaveheardof
Allthesetermsdescribeasimilardevelopment!
SmartManufacturingIndustrialInternet
Industrie 4.0Cyper-Physical(Production)Systems
FactoryoftheFuture
…andmanymore!ManufacturingIntelligence
IMS
IntelligentManufacturing
CloudManufacturing
Industry4.0SmartFactory
SMART MANUFACTURING PRINCIPLES/ CONNECTIVITY/ VIRTUALIZATION/ DATA UTILIZATION
Schmid &Wuest,2017
Dr. Thorsten [email protected]
Smart Manufacturing VisionFully Connected Smart Factory
I need morematerials
Alertsmonitor:Problemwithmachine#2.Please check
I’mcustomer order#312 and want tobered colored.
End of line test: Machine#1, Pleaseadjustmachineparameters
Source: http://smartamerica.org/teams/smart-manufacturing/
Control center:Aggregated data revealimprovementareas
Packingmaterial islow. Please releaseorder.
Cogwheel will break in fivedays. I haveordered spareparts and scheduled externalserviceprovider.
Schmid &Wuest,2017
Schmid &Wuest,2017
SMART MANUFACTURING MARRIES TECHNOLOGY, DATA AND HUMAN INGENUITY
Dr. Thorsten [email protected]
Siemens Digital factory
• Siemens’plantinAmberg,Germany
• Productscommunicatewithmanufacturingmachines
• ITsystemscontrolandoptimizeallprocesses
• Productionqualityisat99.99885%
Dr. Thorsten [email protected]
Upgrade existing systems• BoschupgradedLathefrom1887tobeSmartManufacturingready
• Newcapabilities:• processmonitoringforconstantqualityassurance
• anotherisconditionmonitoringinordertopreventunplanneddowntimes
• Extremeexamplebutshowcasesthepotential
http://www.bosch-presse.de/pressportal/en/69632.html
http://www.bosch-presse.de/pressportal/en/69632.html
Dr. Thorsten [email protected]
Background§ Internet of Things is changing the industrial landscape§ Manufacturing is undergoing a major transition§ Large corporations aredealing with this topic intensively
⇒ But how to apply Smart Manufacturing in small companies?⇒ How can small manufacturers takeadvantageof it?
Objectives§ Examinethecurrent stateofmanufacturingwithasurvey§ Understandthemanufacturinglandscapeanditsspecific
challenges andconcerns byconducting interviews andplantvisits§ Support small manufacturersinadoptingSmartManufacturing
technologies bysettingupatrainingworkshop
Work Packages1. Online survey2. Interviews&plantvisits3. Analysis ofresults&report4. Trainingworkshop
Schmid &Wuest,2017
Project Scope
Dr. Thorsten [email protected] &Wuest,2017
Survey Method
0
2
4
6
8
10
12Subsectors inManufacturing
Total#ofrespondentsfrommanufacturing53
Company sizeby#employees
lessthat20
100 - 499
20 - 99
500andmore
Who participated in the survey?
Dr. Thorsten [email protected] &Wuest,2017
Survey ResultsHow aware are companies of the transition towards Smart Manufacturing?
0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
Industry4.0
SmartManufacturing
IndustrialInternet
InternetofThings(IoT)
SmartFactory
Cyber-physicalsystem
Ihavealreadyheardabout...0% 20% 40% 60% 80% 100%
Mycompany isdealingwith...
Dr. Thorsten [email protected] &Wuest,2017
Survey ResultsHow prepared are companies for Smart Manufacturing?
0% 10% 20% 30% 40% 50% 60% 70%
Slightlyprepared
Moderatelyprepared
Veryprepared
Towhatextentisyourcompanyandyouremployees prepared?
0% 10% 20% 30% 40% 50% 60% 70%
Notrelevantatall
Moderately relevant
Very relevant
HowrelevantisSmartManufacturingforyourcompany?
Dr. Thorsten [email protected] &Wuest,2017
Survey ResultsWhat are the needs of manufacturers when it comes to Smart Manufacturing?
Dr. Thorsten [email protected] &Wuest,2017
Interview MethodWho participated in the interview sessions?
Manufacturing Experts
Intervieweesinmanufacturingcompanies
10Expertsinacademia,associations&state
agencies
Manufacturers
8
Smart Manufacturing in SMEs
Lack of opportunity
Resources & cost
Knowledge & awareness
Skilled workforce
Missing ‘success stories’
Dr. Thorsten [email protected]
SMART MANUFACTURING IS NOT ONLY FOR THE BIG GUYS.
Schmid &Wuest,2017
Opportunities for entrepreneurs
Brave new world
‘Low’ initial investment
Dedicated ‘Apps’ (Platform solution)
Scalable solutions (interoperable & extensible)
Fast deployment
Dr. Thorsten [email protected]
Dr. Thorsten [email protected]
Boiler Revision Project (1/2)
Provided by : EagleManufacturing, [email protected]
at Eagle Manufacturing
Concepttoreviseboiler controlsPlant maintenance cancontrol and monitor the steamboilersfromoutside of the plant instead of coming to the plant toschedule and check on themphysically
Before
Schmid &Wuest,2017
Dr. Thorsten [email protected]
Boiler Revision Project (2/2)at Eagle Manufacturing
Provided by : EagleManufacturing, [email protected]
AfterSolution• Using newertechnology• PLCs with integratedEthernetandSMTP (email) protocol• along with advanced HMIand smarthubnetworkfunctionality
Benefits• Better control& schedulingof system
• Real-time alarm monitoring(throughmobile devices)
Schmid &Wuest,2017
at Homer Laughlin China Company
Problem• Compressed Air Systemwas experiencing unacceptable pressurevariationsduringpeak demand hours
• Current systeminefficient consuming 80%of full load energywhile producing 20%capacity
Solution• Balancesystem(compressorrelocation,pipingimprovements,andincreasedstoragecapacity• Changecontrolmethodtoaload– noloadsystemmanagedbyacomputersystem
System operation• Compressorsaremonitored&systemismonitoredforpressure• Compressorsarestartedandstoppedwithsystematicmethodbasedondemand• Operatingsequenceisdeterminedtomaintainpressureandequalcompressorrun-time
Provided by : Homer Laughlin, [email protected]
CompressedAir System Monitoring (1/2)
Dr. Thorsten [email protected] &Wuest,2017
Provided by : Homer Laughlin, [email protected]
CompressedAir System Monitoring (2/2)at Homer Laughlin China Company
System benefits• Annual energy savings over $100,000• Real time information allows personnel to quickly identify problems• Run time of compressors is reduced extending theiroperatinglife• PreventativeMaintenancetracking and scheduling• Consistent system operatingpressure
Next steps• Vibration and airend temperature monitoring to improvepredictive maintenance of system• Investigating use of Bosch CISS (Connected Industrial Sensor Solutionmulti-sensor device)
Further benefits• One device type can be used in a variety of applications• CISS connects existing machines without intervening to the machine control• Visualize live and historicdata• CISS integrates easily to various platforms
Dr. Thorsten [email protected] &Wuest,2017
Problem
• Howtoprovidethebestpossible service formanufacturingequipmenttocustomers?
Approach
• Collaborate&Innovate
Solution
• I4.0Platfrom thatprovidesinterfaceandcloudaccesstomachinedataincl.visualization
• Allowsmonitoringallequipmentsetpointsandactualsincl.feedbackonperformance
• UptimeGuaranteedTM withSmartServices
at Conair Group (IPEG Inc.)
Smart Services Project
Dr. Thorsten [email protected]
Source&moreinformation:https://www.conairgroup.com/product/smart-services/
• ProvideeducationalresourcesonSmartManufacturingandIndustry4.0(‘spreadtheword’inanaccessibleway)forindustrialpartners.
• Jointlydevelopcurriculumfor1)professionalstoequipthemwithrequiredknowledgetoinnovateandoperatewithinaSmartManufacturingenvironment,and2)includeSmartManufacturinginexistingengineeringcurriculaacrossinstitutions(‘highschooltomasters/Ph.D.’),departmentsandmajors.
• Communicatesuccessesbroadlyandencouragepeer-to-peerexchange(acrossindustries)ofbestpracticesandlessonslearned.
Recommendations (1/2)for Smart Manufacturing in SMEs
Dr. Thorsten [email protected]
• Buildstrongandsustainablepartnershipsbetweencompanies,academiaandindustryassociations.Forexample,leverage(local)technologystart-upstoteam-upwithestablishedmanufacturersandacademia.
• Startwithsmall‘lighthouse’projectstargetingspecificpainpointstolearnandachievequickwins.
• LeveragestateandfederalfundingtocomplementthelimitedrecoursesavailabletomanufacturingSMEs.
Recommendations (2/2)for Smart Manufacturing in SMEs
Dr. Thorsten [email protected]
SMART MANUFACTURING CANNOT BE BOUGHT. THE SUCCESS HAS TO BE EARNED.
Schmid &Wuest,2017
Dr. Thorsten [email protected]
My take on this issue:
• SolutionsmustbetailoredtoSMEs’(real!)needs&requirements!
• Createrealvalue(shortANDlongterm)!
• Fitthestrategy/vision!
TodosoSMEsneedto:• Assess theircurrentprocessescritically
• Identify theircorecompetencies• Build onthoseand• Developaroadmapwithspecificmilestones/objectives
• (keep80/20ruleinmind!)
Contact:
ThorstenWuest,Ph.D.AssistantProfessor SmartManufacturingWayneandKathyRichardsFacultyFellow
WestVirginiaUniversityIndustrialandManagementSystemsEngineering347EngineeringSciences BuildingMorgantown,WV26506-6070,USA
+1(304)[email protected]
Thank You!
