Industry 4.
0
Generations of Manufacturing
[Link]
What’s it About ?
Industrie 4.0 : The merging of the virtual and the
physical worlds through cyber-physical systems and
Germany Trade And Invest the resulting fusion of technical processes and
business processes.
Factories of Future: High-performance production,
combining flexibility, productivity, precision and zero
European Factories of the defect while remaining energy and resource efficient
Future Research Association
including addressing the end-of-life of products.
Smart Manufacturing: Intelligent, real-time
orchestration and optimization of business, physical
and digital processes within factories and across the
Manufacturing Enterprise
Solutions Association entire value chain.
What’s it About ?
Smart Manufacturing is about systems that are fully-
integrated, collaborative manufacturing systems that
respond in real time to meet changing demands and
conditions in the factory, in the supply network, and
in customer needs.
Smart Manufacturing is the ability to solve existing
and future problems via an open infrastructure that
allows solutions to be implemented at the speed of
business while creating advantaged value
Industrial Internet connects streams of machine data
to powerful analytics, providing industrial companies
with valuable insights to manage assets and
operations more efficiently.
What’s it About ?
Combining ICT with innovative policies, services and solutions to deliver
transformation at unprecedented speed and scale while ensuring
sustainability.
What does the future look like ?
Germany Trade And Invest
●
Flexible production systems which are able to respond in almost real-time
conditions.
●
Smart factory "units" able to communicate independently and wirelessly with
other units.
●
Individualized customer product manufacturing.
●
Tailored adjustments to the human workforce so that the machine adapts to the
human work cycle.
Industry 4.0
Maintenance costs reduction: 10-40%
Productivity increase: 1-3% reduction
Machine down time reduction: 30-50%
Inventory holding cost reduction: 20-50%
Costs of quality: 10-20%
Forecasting accuracy: reached 85%
Time to market reduction: 20-50%
[Link]
What does the future look like ?
●
Adaptive and smart manufacturing equipment and systems.
●
Increase production performance through operation and planning optimization using
analytics.
●
Collaborative networked factories and dynamic supply chains for locally adapted
production.
●
Human‐centred manufacturing, intelligent workplaces.
●
Customer‐focused manufacturing, from product‐process to innovative services.
What does the future look like ?
●
Advanced Sensing, Measurement, and Process Control
●
Visualization
●
Analytics and Digital Manufacturing Technologies
●
Sustainable Manufacturing
●
Additive Manufacturing
●
Multi-tasking Manufacturing Equipment
●
Cobots.
Next Gen Business and Sustainability
GTAI, Germany
EFFRA, EU
SMLC, US
NIST, US
The Govt Office for Science, UK
●
Focus on customer experience
Institute for Manufacturing, UK ●
Co-creating products and services.
EPSRC, UK
The Japan Business Federation ●
Servitization
UNIDO
Siemens ●
Mass customization
Beckhoff
Bosch
●
Sustainability: Product upgrades
GE instead of throw away, Reverse
Capgemini
Mckinsey logistics.
PWC
How will these impact the way
manufacturing will have to operate?
Need for manufacturing flexibility
Mix: Uncertainty as to which products will be demanded by customers
Changeover: Uncertainty with respect to the length of production runs
Modification: Uncertainty as to which particular attributes customers want
Re-routing: Uncertainty with respect to machine downtime
Volume: Uncertainty with regard to the amount of customer demand
Material: Uncertainty with respect to material inputs
Sequence: Uncertainty in due dates, processing times, job priorities
Need for intelligence
Smart Product
1. Possesses a unique identification.
2. Actively interacts with the user, environment and other products.
3. Can store data about itself and learn.
4. Deploys a language to display its features, production requirements, etc.
5. Maintains optimal performance in variable circumstances
OR
5. Maintains optimal condition considering variable operating conditions
6. Is capable of participating in or making decisions eg., ‘What-if’ analysis.
7. Helps in executing an action.
Smart Machines
Flexibility through providing surface heat
treatment and metal additive fabrication in
addition to milling, turning and grinding on a
single machine.
Communication through MTConnect
MU-6300V LASER EX
Intelligence through apps
Co-creation through Open Windows Platform
[Link]
[Link]
Processes that learn
Smart Process:
A self aware process that can observe
its own execution and optimize its
behavior around a user’s or
application’s needs.
Processes that learn
Process Crawler:
Processes may not get set at the optimal
performance levels.
They also tend to drift away from the optimal.
The ‘Process Crawler’ allows the process to
gradually move to a more optimal operating point.
It also helps the process to ‘crawl’ back to its
optimal point if it has drifted away.
AI tools run simultaneously on the data to
generate a model.
Smart Assembly
Job BOM
Order
Assembly Filtered
Sequence BOM
Station Number
RFID
Warehouse verification Kitting
Cloud RFID
verification
Parts
Create a database
record from the M/C
RFID tag RFID for
identification and Assembly
authentication Station
Workforce
Transfer the
component details
and quality Record values of Quality Assly
parameter values quality parameters checks Completed
to M/C RFID
Technologies coming together
Smart Product
1. Possesses a unique identification.
2. Actively interacts with the user, environment and other
products.
3. Can store data about itself and learn.
4. Deploys a language to display its features, production
requirements, etc.
5. Maintains optimal condition considering variable
operating conditions
6. Is capable of participating in or making decisions eg.,
‘What-if’ analysis.
7. Helps in executing an action.
Technologies coming together
Technology
TechnologyEnablers
Enablers
Sensor
SensorTechnology
Technology
Artificial
ArtificialIntelligence
Intelligence
IIoT
IIoT
Machine
Machinelearning
learning
Ontologies
Ontologies
Sub System
Bearing
Algorithm (URL)
Parameter 1
Parameter 2
Threshold value
Value for good condition
Knowledge
Base
Collective learning has a lot of potential. MTConnect
Agent
Tried out at M&M Chakan Plant
QA