2017 NAE-AAES Convocation of the Professional Engineering Societies April 24, 2017
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1 2017 NAE-AAES Convocation of the Professional Engineering Societies April 24, 2017 Jim Davis CESMII VP IT CTO UCLA
2 Smart Manufacturing Simply Stated The Operational Business and Technology Practice of radically increasing the application of real-time data throughout the manufacturing enterprise and changing the operational structure The right data in the right form, the right people with the right knowledge, the right technology and the right operations, whenever and wherever needed throughout the manufacturing enterprise
3 Smart Manufacturing A Term of Practice Enterprise integration to realize untapped market, productivity and performance opportunities Real-time and Modeling to qualify materials, parts, properties, assemblies and drive real-time precision Operational Practices (A Vocabulary of Practices: intensification, virtualization, modularization, qualification and optimization) to achieve value in an increasingly customized product space with accelerated demand dynamics
4 Smart Manufacturing, IoT and IIC Manufacturing Vertical Static physical facilities Legacy operations Always operating Need to qualify moving product IP in product & operations Highly compartmentalized Highly Heterogeneous High risk profile IoT, IIC Big Collaborative Innovation & Practice Smart Enterprise Manufacturing Integration Smart Factory Manufacturing Analytics & Device Integration & Orchestration Secure Highways Secure I, P and SaaS Collective Manufacturing Intelligence Converting Knowledge to Manufacturing Intelligence Smart Converting Information to Knowledge Converting to Information
5 What is the CESMII? Edit in view > header and footer
6 TM CESMII A National Network of Capability Headquartered in LA Northwest Northeast California HQ Southeast Gulf Coast C L E A N E N E R G Y S M A R T M A N U F A C T U R I N G I N N O V A T I O N I N S T I T U T E
7 Precision, Productivity, Product Space Energy a Material Cost REVENUE, GROWTH & REINVESTMENT CESMII s goals: Double energy productivity in US manufacturing every 10 years Halve the cost of deploying SM systems relative to state of the art in 5 years Increase the SM workforce in US multifold in 10 years Double the SM technology supply chain rate of increase in value and participation Reduce U.S. energy use in 10 years while increasing manufacturing competitiveness
8 Enterprise Thinking and Practice Let s Consider Some Examples
9 Connect across Boundaries Field to Fork 2017 General Mills
10 OEM Collaborative & Network-Based, Smart Manufacturing Connected Supply Chain Agile Demand Driven Raw Material to Finished Product Business Systems, ERP Safe Production Improved safety Fewer incidents More user friendly Sustainable Production Higher value products for decision making Product Lifecycle Management Customer Supply Chain Distribution Center Smart Grid Energy Efficient Lower emissions Less energy used Green manufacturing Smart Factory Optimization Asset Utility/Zero Downtime Quality/Zero Defects Reliable results 5
11 Production History Plant Floor Inventory Direct Consumptio n WorkFlow Demand Plan Production Order Line Schedule Lot Tracking Optimizatio n Engine Raw Mat l Inventory Finished Product Inventory Value Creation Business Applications Core Functions What Got Us Here Won t Get US There Demand Driven Supply Chain Green Light to Convert Green Light to Ship Optimized Inventory Allergen/Micro WorkFlow ecoa Supplier Managed Inv Line Supply Bin Mgmt Overusage Trace/Recall BOM Validation Yard Mgmt Directed Work General Mills Eco System of STUFF Core Systems Master (BOM,Specs,Vendor,Ingredients,FP) MQIS MES SAP ERP SAP MRP SAP APO SAP PLM Red Prairie Input 2014 General Mills
12
13 Supply Side Management Chain of Custody 2017 General Mills
14 First Steam Methane Reformer Furnace Port Arthur, TX Already efficient Distributed sensing Distributed actuation (96 burners) High fidelity model & reduced order models reduction wasted energy Simple Model Reduce Cameras Halve capital cost Praxair Intensification through Measurement & Operational Integration reduction wasted energy HPC Model Burner Controls Dynamic energy management Metrics Extend to 20 U.S. SMRs
15 Operations Business Virtual Enterprise & Distributed Asset Modularization Enterprise thinking: virtual enterprise model that incorporates physical assets as components to execute production Customers Port Arthur TX 2 nd Location Production on Demand Steel Energy Bio/Pharma Electronics Production and Delivery Production and Delivery Healthcare
16 Production on Demand & Intensification General Dynamics Scranton, PA Integrated line management of part precision, materials/metallurgical properties, dynamic part movement, defect reduction, energy management Billet quality Part Tolerances Part quality Part Properties 3D Radiation Part quality Part quality Variable Contracts Predictive Maintenance Reduce idle time Improved gas flow control Recuperation Reduce defects destructive tests Reduce defects Dynamic machine configuration 16
17 Enterprise Thinking and Practice Corning modularize (integrate) upstream supplier LA & Orange County small metals, food & apparel utility demand-response/ renewables Pfizer micro reactors for product customization qualification Alcoa real-time optimization of sheet & plate manufacturing flow paths Over 90% manufacturing in SME s PATTERNS OF APPLICATION
18 Vocabulary of SM Practice Modularization, Intensification Virtualization & Optimization with Sensors, Controls, Platforms & Modeling SM Value propositions Intensification Production on demand Customization and value add in the trade space Supply side management and chain of custody Portable continuous miniaturization Distributed modularization & ecosystems Business virtualization & asset modularization Modularization and scaling flexibility
19 Corning s SMART Manufacturing Right *, Right People, Right Time, Right Decisions Today s Integrated Mfg Systems SMART Mfg Cloud computing for mfg & supply chain State of the art Cyber Security Access to Adv. Analytics & real-time Predictive Modeling Advanced Controls, sensors and newer technology (AI, ML) New data Visualization tools Reduce cost w/ open platforms & collaborative biz models 2017 Corning Incorporated
20 OT & IT Systems Sharing OT & IT Systems Sharing OT & IT Systems Sharing SM Provides New Value Streams for Corning: Information Product with Seamlessly Connected Contextual Vendor Agnostic Supply Chain Sharing Across the Supply Chain 1 st Factory Supplier/Corning 2 nd Factory Contract/Corning 3 rd Factory Customer 2017 Corning Incorporated
21 Control & Automation Business Systems / Design Operational Space of Seams, Time, & Action Sweet Spot for Operational Modularization & Intensification Machines People - Materials Dynamic Manufacturing Ecosystem Training Analysis/ Evaluation Systems Integration & Engineering Validation In Service Time days/hours Multiple Pass Variability Reduction Supply Chain Performance Macro Time hours/minutes Event Variability/ Tradeoff Adjustment; Dynamic Performance; Integrated Metrics Meso Time minutes/ mseconds Tolerance & Resilience Qualification; ICME, High Fidelity Precision Micro
22 Smart Manufacturing Practice and Reusability Edit in view > header and footer
23 One-off, Proprietary, On Premise Will not Get Us There This is not secure Modeling Provider Product 1 Assets Config1 Model On Premise Compute Analytics Provider Product 2 Config2 Visualiza tion Transaction Modeling Provider Product 1 Assets Config1 Model On Premise Compute Analytics Provider Product 2 Config2 Visualiza tion Operation 1 Operation 2
24 Span Heterogeneous Environment On-premise Off Premise On Premise Maintain State Contextualized Steps Modeling & Analytics Steps On Premise Edge Compute SM Platform Structure Assets Model Config Modeling Provider Product 1 Config Analytics Provider Product 2 Visualiza tion Enterprise Workflow Don t Reinvent Discretize and Reuse Security at Business Granularity
25 Spin Up Multiple Projects Reuse & Application Configurations Workflow On Premise Edge Compute SM Platform Structure Contextualized Steps Assets Model Config Oats Config Dairy Config xxx Analytics 2 Modeling 1 Visualization Access to data from Application Container Public/Private Key Trust relationship EMS
26 Systems Infrastructure for Smart Manufacturing Practice Edit in view > header and footer
27 Smart Manufacturing Platform Open Infrastructure SM Software Marketplace APPs & Toolkits Compose Workflows Cloud Deployment Private/Public IaaS Cloud & Enterprise Virtualization Services to Applications Physical & Cyber reusability SM Value Proposition Private Smart Manufacturing Platform Appliance Traditional Manufacturing Automation Environment and Software Tools Event Calibration & Maintenance Applications Context Mapping Production Models Time Series Sensor Paper Steel Metals Glass Food Micro electronics Industrial gas Coatings Plastics Composites 27
28 SM Platform Infrastructure Certified app configurations Search Engine Compose and reuse IoS for manufacturing DevOps for manufacturing to Applications Trusted, Marketplace, End-toend State Services
29 Build a Business Model Open Architecture Vendor Agnostic Open Access low cost & easy to use Open Market Place composable software libraries & data Open Market Place - Innovation Trusted Broker Valuation Collective vs. Proprietary Practice Valuation Collective vs. Proprietary IoT Big Collaborative Innovation & Practice Smart Enterprise Manufacturing Integration Smart Factory Manufacturing Analytics & Device Integration & Orchestration Secure Highways Secure I, P and SaaS Collective Manufacturing Intelligence Converting Knowledge to Manufacturing Intelligence Smart Converting Information to Knowledge Converting to Information
30 Build a Rich Marketplace Reusable Configurations Core Deployment Services Trusted Services OSISoft Ansys Fluent Cloud Integration Services Security; Machine & Human Interfaces; Virtual Compartments; Interoperability; Standards SMR data config Company data config Single, multi, full tube models Converged reference model Company config Industry Marketplace Reusable Configurations
31 Smart Manufacturing Reinvestment Potential A Comprehensive Approach to Manufacturing At the Intersection Workforce Productivity Business & Product Agility Supply Chain Agility & Optimization Asset Management and Risk Product Lifecycle Energy & Material Productivity Environment, Sustainability & Safety Next Generation IT for Next Generation Manufacturing Make a Key Asset Advanced Real-Time Sensing, Controls, Platform and Modeling
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