Cloud-Based Manufacturing: Perspectives From Industry and Academia

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Theme: Capturing Competitive Advantage via Advanced Manufacturing and Enterprise Transformation FAIM 14 Flexible Automation & Intelligent Manufacturing 24th International Conference San Antonio Texas

1 Theme: Capturing Competitive Advantage via Advanced Manufacturing and Enterprise Transformation FAIM 14 Flexible Automation & Intelligent Manufacturing 24th International Conference San Antonio Texas U.S.A. Cloud-Based Manufacturing: Perspectives From Industry and Academia Paul Evans Southwest Research Institute Director, Manufacturing Systems Department Automation & Data Systems Division Barbara Hutchings ANSYS, Inc. Director, Strategic Partnerships Can (John) Saygin University of Texas at San Antonio Professor, Mechanical Engineering Center for Advanced Manufacturing and Lean Systems Paul Rad Rackspace, Inc. VP Technology 1 24 th International Conference on Flexible Automation & Intelligent Manufacturing (FAIM)

2 Cloud-Based Agenda Evolution of Manufacturing Cloud Computing Manufacturing Industry Software and Computing 2

3 Evolution of Manufacturing 3

4 Evolution of Manufacturing First Industrial Revolution ( ) - Production processes were reorganized around the power distribution requirements. Steam power replaced waterpower. Steam-Powered factories - Factories conveyed power from a central steam engine (i.e. prime mover) to machinery on the floor via a network of overhead line-shafts, counter-shafts, leather belts, belt shifters, pulleys and gears. Second Industry Revolution ( ) - Electric motors were first used in the 1880s to simply replace the prime mover. 4 4

5 First Cloud-Based Manufacturing Steam engines powered all machine tools through long overhead line belts, shafts and pulleys. 5

Evolution of Manufacturing FORD Mass Production (1913):

moving assembly line revolutionized automobile production by

Delivery of parts by conveyor belt to the workers was

6 Evolution of Manufacturing FORD Mass Production (1913): Continuous Moving Assembly Line The introduction of the moving assembly line revolutionized automobile production by significantly. Delivery of parts by conveyor belt to the workers was carefully timed to keep the assembly line moving smoothly and efficiently. Before 728 minutes; After 93 minutes ~8:1 6 6

7 Evolution of Manufacturing: Lean Remove Waste 7

8 Design Manufacturing Computer Aided Materials Management Machine Control Production Planning and Scheduling Data Collection and Status Reports Also market analysis, sales, accounting, payroll 8

9 Joseph Harrington I have elected to call this new control and communication structure computer integrated manufacturing. Capitalizing the words has been carefully avoided for fear of creating one more acronym in a world already overburdened with acronyms Says Harrington in his book in

10 Harrington continues on page 6 of his book 10 10

11 Evolution of Manufacturing Systems 1970s s Flexible Manufacturing Systems/Cells a group of CNC machinery/equipment linked by an automated materials handling system, whose operation is integrated by supervisory computer control Provided efficient mid-volume, mid-variety production Increased machine utilization Reduced work-in-process inventory, labor and tooling costs, setup costs, lead time, lot size Ability to react quickly to engineering changes 11 11

12 Evolution of Manufacturing Systems 1980s...Computer Integrated Manufacturing computer assisted control and integration at all levels of a manufacturing enterprise Strict hierarchical information flow Totally automated, unmanned, paperless factory Integration problems in heterogeneous environments 12 12

13 Evolution of Manufacturing Systems 1990s Intelligent and Holonic Manufacturing architecture for highly decentralized manufacturing systems, built from a modular mix of autonomous, cooperative, and intelligent elements (holons, agents) Re-emergence of the human factor seeking to maximize the use of human intellectual skills and flexibility Migrating from hierarchy to holarchy Capability of rapid self-reconfiguration by incorporating human and machine intelligence 13 13

14 Evolution of Manufacturing Systems 2000-Beyond Supply Chains, Value Chains a teaming approach with some aspects of partner-like behavior Industry-centric, stable, and usually static collaborative networks Each partner leverages their own competencies; Increasing own profit is the default Cost-driven Workflow is emphasized Knowledge shared carefully 14 14

15 Evolution of Manufacturing Systems 2000-Beyond Extended Enterprise, Virtual Enterprise strong collaborative behavior with very solid partnering behavior A very dynamic and changing environment Partners bring part of the business solution, not necessarily industry-centric The emphasis is on leveraging the competency of the Extended Enterprise Value-driven Knowledge and learning are emphasized, in addition to workflow Knowledge shared widely 15 15

16 Extended Enterprise Evolution of Manufacturing Beyond Mainframe Computers Control Design NC CNC 2D CAD Robots in Mfg Direct Numerical Control Minicomputers CAE CAM Adaptive Control Microprocessor PLC 3D Wireframe CAD/CAM Solid Models FMC RISC Computers FMS IBM PC PC-based CAD/CAM CIM Network-Centric Mfg Web-Based Mfg Big M Manufacturing (Dr. Hsu-Pin Wang) Part Coding CAPP MRP-I MRP-II JIT ERP MES SCM E-biz Planning and Scheduling Beyond 16

17 Product Development - Evolution Customer Expectations FUNCTION RELIABILITY FUNCTION CONVENIENCE RELIABILITY FUNCTION 17

18 FROM Inventory Physical Assets VALUE SHIFT TO Information Functional Assets Product & Services Customer Solutions Cloud Computing As An Enabler? 18

19 Cloud Manufacturing a model for enabling ubiquitous, convenient, on-demand network access to a shared pool of configurable manufacturing resources (e.g., manufacturing software tools, manufacturing equipment, and manufacturing capabilities) that can be rapidly provisioned and released with minimal management effort or service provider interaction. 19

20 Cloud As Enabler - Level of Outsourcing Company s responsibility (Forrest Research, Inc., March 2002) Core Processes Cost savings for operational efficiencies External technologies for cross-company collaboration Supporting Processes IT Operations Core Processes Core competency focus for better margins Always-on infrastructure for global business Supporting Processes Core Processes Outsourcer s responsibility IT Operations Supporting Processes? IT Operations Pre Beyond Integrated Product-Process-Systems Thinking 20

21 Cloud Computing Enables Cloud Manufacturing REF: From Cloud Computing to Cloud Manufacturing by Xun Xu, Robotics and Computer-Integrated Manufacturing, Vol.28, pp.75 86,

22 Cloud Mfg As an Abstract Model REF: Cloud Manufacturing: A Computing and Service-oriented Manufacturing Model by F Tao, L Zhang, V C Venkatesh, Y Luo and Y Cheng, Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture Vol.225, pp ,

23 TOOLS 4I s Intelligent Integrative Interdisciplinary Innovative 4D s Data-driven Dynamic Distributed Domain-adaptive SYSTEM? BEHAVIOR PERFORMANCE 4R s Responsive Reconfigurable Reliable Rapid 4C s Coordination Collaboration Cooperation Competition 23 23

Business Decision-Making in the Factory of the Future. An IDC InfoBrief, Sponsored by Infor November 2015

Business Decision-Making in the Factory of the Future November 2015 The manufacturing industry is on the threshold of a massive structural shift This shift is defined as: Industry 4.0 Factory of the Future