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Smart Solutions with Connected Manufacturing · Aspirational Context for Connected Manufacturing...

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Smart Solutions with Connected Manufacturing Chet Namboodri Managing Director – Global Manufacturing Industry Cisco Systems, Inc.
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Page 1: Smart Solutions with Connected Manufacturing · Aspirational Context for Connected Manufacturing Solutions Industrial Smart Solutions Remote Expert for MFG Visual Factory of the Future

Smart Solutions withConnected ManufacturingChet NamboodriManaging Director – Global Manufacturing IndustryCisco Systems, Inc.

Page 2: Smart Solutions with Connected Manufacturing · Aspirational Context for Connected Manufacturing Solutions Industrial Smart Solutions Remote Expert for MFG Visual Factory of the Future

Agenda

• Manufacturing Industry Business Drivers

• Business Value of IoE with Connected Manufacturing

• Connected Manufacturing Smart Solutions

• Solutions Use Case Examples & Closing

• Business Demonstration over TelePresence

Page 3: Smart Solutions with Connected Manufacturing · Aspirational Context for Connected Manufacturing Solutions Industrial Smart Solutions Remote Expert for MFG Visual Factory of the Future

capturing knowledgefor my transitioning workforce

I need to achieve

How can I need toimprove

improveworkforceproductivity?

How can I

introduce newproducts faster?

How do I achieve

How can Ibetter manage my

Page 4: Smart Solutions with Connected Manufacturing · Aspirational Context for Connected Manufacturing Solutions Industrial Smart Solutions Remote Expert for MFG Visual Factory of the Future

Internet of Everything (IoE) ConvergenceHelps to Address These Priorities

Manufacturing Operations

Enterprise ITWhy converge networks?

– Time to market– Security: perimeter no longer viable– Simplicity and Flexibility:

maintenance and management– Problem resolution– Voice, video, data collaboration– Control of plant performance– Remote talent– Standards convergence …

open systems– Future proofing

ProprietaryNetworks

RuggedizedInfrastructure

Ethernet/IPOptimized for

Industrial ApplicationsIoE / IoT

Architectures

Connected Manufacturing – evolution of Operational Technology

Page 5: Smart Solutions with Connected Manufacturing · Aspirational Context for Connected Manufacturing Solutions Industrial Smart Solutions Remote Expert for MFG Visual Factory of the Future

IoE Business Value at Stake:~$2T for Manufacturing Industries

• Asset Utilization

• EmployeeProductivity

• Supply Chain /Logistics

• CustomerExperience

• Innovation

Page 6: Smart Solutions with Connected Manufacturing · Aspirational Context for Connected Manufacturing Solutions Industrial Smart Solutions Remote Expert for MFG Visual Factory of the Future

Smart productsand services

Smart opsprocesses

Advanced analytics

Source: Cisco IBSG, 2013

Connect devices,machines,facilities,transport fleets,grids andnetworks withadvancedsensors, controlsand softwareapps

Visual plantoperations, assetand peoplevisibility,interactive andmobile plantworkforce

Visual supplychainsInbound andoutbound visibilityand riskmanagement

CustomerexperienceOmni-channelexperience

Combination of power of science (physics, chemistry etc.), analytics,predictive algorithms, domain knowledge

1 2 3 4

EmployeeProductivity

5

Connectingpeople(enterprise,partners andcustomers)anytime to supportR&D, Operations,Maintenance,Service Levelsand Quality

IoE Business Value:Connected Manufacturing

Page 7: Smart Solutions with Connected Manufacturing · Aspirational Context for Connected Manufacturing Solutions Industrial Smart Solutions Remote Expert for MFG Visual Factory of the Future

Connected Manufacturing Solutions

• Industrial Smart Solutions for Manufacturing

• Remote Expert for Manufacturing – Business Video

• Visual Factory of the Future

• Connected Vehicle / Connected Product

Page 8: Smart Solutions with Connected Manufacturing · Aspirational Context for Connected Manufacturing Solutions Industrial Smart Solutions Remote Expert for MFG Visual Factory of the Future

What is a ‘Smart Solution’?

Cisco Industrial Smart Solution for Manufacturing• Validated and documented Smart Business Architecture

• Integrated Cisco and partner solutions and roadmaps

• Comprehensive support and service networkLifecycle services with smart capabilities

Five year product warranty

• ROI tools and financing

Page 9: Smart Solutions with Connected Manufacturing · Aspirational Context for Connected Manufacturing Solutions Industrial Smart Solutions Remote Expert for MFG Visual Factory of the Future

Smart Solution Benefits

Faster NetworkImplementation,Faster ROIThe Industrial Smart SolutionBusiness Architecturedeployment is prescriptive,out-of-the-box, scalable andflexible

Reduced Business RisksThe Industrial Smart Solution followsthe strict guidelines of Cisco’s SmartBusiness Architecture (SBA)

A validated architecture, rigorouslytested, beyond the QA testingof individual componentsand systems

Lifecycle of Services

Industry LeadingPartnersArchitecture interfacesseamlessly with partnersincluding ABB, Honeywell,Emerson, Rockwell Automation

Smart Solutions includecomprehensive services forindustrial network planning,building and management

Page 10: Smart Solutions with Connected Manufacturing · Aspirational Context for Connected Manufacturing Solutions Industrial Smart Solutions Remote Expert for MFG Visual Factory of the Future

Aspirational Context for ConnectedManufacturing Solutions

Industrial Smart SolutionsRemote Expert for MFG

Visual Factory of the FutureConnected Vehicle

Run and rebalance

Redesign

Innovate

Better execution ofcurrent ops. to improvecompetitiveness

Redesign operationsto improve cost and /or increase growth

Change the game byinnovating across theindustry value chain

Page 11: Smart Solutions with Connected Manufacturing · Aspirational Context for Connected Manufacturing Solutions Industrial Smart Solutions Remote Expert for MFG Visual Factory of the Future

Industrial Smart SolutionCustomer Use Cases

Discrete• Smart Assembly• Connected Machine

Process• Converged Plantwide Visibility• Plant OEE

• Integrated Industrial Energy Management• Plant Alarm and Event Resolution

Page 12: Smart Solutions with Connected Manufacturing · Aspirational Context for Connected Manufacturing Solutions Industrial Smart Solutions Remote Expert for MFG Visual Factory of the Future

Smart Assembly & Connected MachineCHALLENGE:• Inconsistencies in network integration between

the manufacturing and enterprise zones• Unable to share information between

production cells and partners• Static and inefficient processes• Lack of remote diagnostics

CUSTOMER BUSINESS BENEFITS:• Lower the cost of deployment and operation

through common, standard network• Reduce downtime by remotely accessing

systems and collaborating with partners• Enhance equipment performance with real-

time visibility and access to information

Provides a proven, unified control and information infrastructure deliveringprecision, resiliency and reliability from the Plant Floor to the Enterprise

Page 13: Smart Solutions with Connected Manufacturing · Aspirational Context for Connected Manufacturing Solutions Industrial Smart Solutions Remote Expert for MFG Visual Factory of the Future

Plant Alarm and Event Resolution

CHALLENGE:• Lack of real-time notification of alarms and

events at the sensor level• Skill and training gaps• Increased support cost due to service “standby”• Lack of remote access

CUSTOMER BUSINESS BENEFITS:• Secure remote access and monitoring• Leverage open standards and protocols to

connect with sensor-level network• Seamless integration with security and safety

systems

A Secure Integrated Plant Floor and Enterprise Architecture Decreasing Time toResolution and Driving Efficiency and Scale into Maintenance Operations

Page 14: Smart Solutions with Connected Manufacturing · Aspirational Context for Connected Manufacturing Solutions Industrial Smart Solutions Remote Expert for MFG Visual Factory of the Future

Industrial Smart Solution: Commitmentto Architecture and Product Roadmaps

Page 15: Smart Solutions with Connected Manufacturing · Aspirational Context for Connected Manufacturing Solutions Industrial Smart Solutions Remote Expert for MFG Visual Factory of the Future

“With the advances in networking technology, thetime is now for manufacturers to look into adoptingthe latest network technologies to overcome thehistoric isolation of the control platform from theenterprise. While only time will reveal the real valueof Cisco's Industrial Smart Solution, the company isnow better positioned to help their manufacturingcustomers overcome the historical isolation betweenfield level, manufacturing operations level, andenterprise level networks.”

Aberdeen 2013 Market Alert

Page 16: Smart Solutions with Connected Manufacturing · Aspirational Context for Connected Manufacturing Solutions Industrial Smart Solutions Remote Expert for MFG Visual Factory of the Future

Remote Expert for Manufacturing:Business Video Use Cases

Create Immersive, Nimble Supply ChainsElevate Supplier QualityImprove Delivery Performance

Improve Customer IntimacySpeed Issue ResolutionImprove Customer Service

Accelerate New Product Time to MarketDiscuss complex topicsTransfer knowledge quickly

Achieve Operational / Plant Floor ExcellenceReduce Plant DowntimeImprove Worker Productivity

Page 17: Smart Solutions with Connected Manufacturing · Aspirational Context for Connected Manufacturing Solutions Industrial Smart Solutions Remote Expert for MFG Visual Factory of the Future

Operational Excellence with ConnectedManufacturing Business Video

Onsite Presence Remote Expert

Share video, audio and annotated production failures withengineers in real-time

Monitor production line quality and react immediately to deviations

Link remote design teams for audits, design and service reviews

Deliver remote hands-on training and improve problemresolutions by over 200%

Mitigate risks with networked video surveillance

Page 18: Smart Solutions with Connected Manufacturing · Aspirational Context for Connected Manufacturing Solutions Industrial Smart Solutions Remote Expert for MFG Visual Factory of the Future

Visual Factory of the FutureCHALLENGE:• Information on the plant floor is often static• Employees need real-time visibility of safety /

security, and production information• Skill gap due to transitioning workforce• Corporate messaging difficult to deliver to

plant personnel• Incomplete awareness of critical production

data, like schedule and quality metrics

CUSTOMER BUSINESS VALUE:• Info presented dynamically throughout plant• Improved productivity and quality metrics• Fewer safety incidents and removes silos for

training, and production data

Deploy secure real-time access to production data to enhanceplant efficiency, safety, and return on assets.

Page 19: Smart Solutions with Connected Manufacturing · Aspirational Context for Connected Manufacturing Solutions Industrial Smart Solutions Remote Expert for MFG Visual Factory of the Future

ERP, etc.

Operations

Operations IT Network

OperationsRouter

DistributionRouters

IT Servers

CoreRouters

ManagementAutomation andControl Applications

Automation andControl Devices

Hardened Wi-Fi Network

Sensor MeshNetwork

Remote

AccessSwitches

Ethernet

Industrial SwitchCell/AreaWireless SensorNetwork

SiSiSiSi

SiSiSiSi

Teleworkers/Customers and

Partners

Wi-Fi Mesh and Location Receivers

Wi-Fi Voice

IndustrialVideo

LocationChokepoint

LocationTags

Operations DMZ

WirelessController

LocationEngine

Security and Network Administration

TerminalServer

Video

Voice

Wireless, Videoand Voice Servers

Wide AreaNetwork

Internet

Managers,Engineers

IoE Enables Connected Manufacturing• Integrated key expertise through voice, video and access to applications improving operational efficiency

• Increased information on plant process and assets by extending sensor network and adding location determination

• Reduced cost by relying on standard network

Safe and Secure Operations Integration• Tightly manage access to operational systems• Control flow of traffic and data between key zones

1

1

Extend Visibility: Plant or System-wide• Improve operational efficiency with more information

by cheaply deploying additional sensors and devices• Reduce loss and search time with location context of

mobile assets and product

Improve Operational Response• Key experts respond to issues with access to

operational applications and access to voiceand video

• Mobile technicians stay in touch and have access tokey data

3

3

Reduce Support Costs• Rely on IT for support on standard networks• Reduce the number of technologies supported

Improve Support and Decision Making• Management or enterprise users access up to date

operational status• Back-office applications integrate real-time

with operational applications

2

2

Page 20: Smart Solutions with Connected Manufacturing · Aspirational Context for Connected Manufacturing Solutions Industrial Smart Solutions Remote Expert for MFG Visual Factory of the Future

Connected ManufacturingAddresses Business Imperatives

Rapidly shift capacity toaccommodate demandshifts or geographicevents

Optimize materialsmanagement throughproduct lifecycles

Decrease risk

Access to detailedproduction data speedsdecision making

Secure remote accessenhances globaloperations

Intellectual property anddowntime safeguards

Agility with EfficiencyAgility with Efficiency Speed with SecuritySpeed with SecurityNew Business ModelsNew Business Models Reduce problem resolution

and TTM by collaboratingwith remote, virtual expertswith context-rich audio,video and immersive data

Create new service modelswith machine-to-machinenetworks feeding serviceexpert workflows

Page 21: Smart Solutions with Connected Manufacturing · Aspirational Context for Connected Manufacturing Solutions Industrial Smart Solutions Remote Expert for MFG Visual Factory of the Future

Producing Tangible Business Benefits

• 8 hours of downtime per year (99.91% Uptime)• 11% total cost of ownership reduction for industrial network• 90% Overall Equipment Effectiveness (OEE)• +25% operating margin vs. corporate plan

• Downtime: 36 hours/year• OEE: 80%

Middle 50%

• Downtime: 135 hours/year• OEE: 60%

Bottom 30%

Source: Aberdeen Group 2012

33% Converged Industrial Ethernet Adoption Rate

67% Converged Industrial Ethernet Adoption Rate

Best-in-ClassManufacturers

Top 20%

Page 22: Smart Solutions with Connected Manufacturing · Aspirational Context for Connected Manufacturing Solutions Industrial Smart Solutions Remote Expert for MFG Visual Factory of the Future

“This is about abusiness change,to make ourmanufacturingfacilities moreflexible, more agileand more lean.”

Kirk GutmannGM Global Information Officer,Manufacturing and Quality

Page 23: Smart Solutions with Connected Manufacturing · Aspirational Context for Connected Manufacturing Solutions Industrial Smart Solutions Remote Expert for MFG Visual Factory of the Future

Questions?

Thank You

Page 24: Smart Solutions with Connected Manufacturing · Aspirational Context for Connected Manufacturing Solutions Industrial Smart Solutions Remote Expert for MFG Visual Factory of the Future

TOMORROW starts here.


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