Big Data in Manufacturing
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1 Big Data in Manufacturing The Road to Industry 4.0 Michael Ger General Manager Manufacturing and Automotive July 30 th, 2018
2 Title Why Goes It Matters Here Quality & Recall Costs Cost of Stopped Production 53 Billion cars recalled in U.S (2016) $22 Billion in Recall Costs Source: AlixPartners $22,000 Per Minute Source: Advanced Technology Services & Nielsen Research 2 Hortonworks Inc All Rights Reserved
3 Title Big Goes Data Here For Manufacturing So What s New? Data Volume Data Variety Data Timeliness Insights Industrial Internet data to grow 2X faster than any other data source (Wikibon) OT/IT Convergence (Sensors, PLCs, Historians converging with MES, ERP, Quality) and New Data Sources (Image, Video, Audio, Social, RFID, Logs, etc.) Real-time data to grow 1.5X faster than historic data and account for 30% of datasphere* by 2025 (IDC) Real-Time Streaming analytics to grow by 34.8% CAGR through 2021 (MarketsandMarkets) 3 Hortonworks Inc All Rights Reserved
4 Title The Data Goes Management Here Challenge Inability to Leverage BOTH OT and IT Data Sources Siloed Real-Time Operations Data Sensor, PLC and Historian Data Which process variables predict equipment failure? Which process variables impact quality? Siloed Enterprise Data ERP Systems MES Systems Quality Systems Maintenance Systems PLM Systems OTHER Incomplete View of Manufacturing Processes 4 Hortonworks Inc All Rights Reserved
5 Title Real-Time Goes Here Connected Manufacturing Analytics Lifecycle Example: Real-Time Quality Actions (Quality and Equipment Uptime Optimization) ENTERPRISE TRANSACTION SOURCES I N GE S T Dealer Service, ERP, MES, QMS, PLM, ETC. 1 REAL-TIME DATA SOURCES Connected Manufacturing PLCs SCADAs Sensors Historians 1 INGEST 2 STORE 3 PROCESS MANUFACTURING DATA LAKE REAL-TIME QUALITY ACTION 6 MONITOR 5 Score ACT 4 Deploy Model Inputs Real-time sensor values Historic sensor values Historic quality issues, production, returns Design parameters, etc. LEARN Develop Models Machine Learning ANALYZE 4 Data Discovery Business Intelligence 5 Hortonworks Inc All Rights Reserved
6 Title Data Goes Platform Herefor Real-Time Connected Manufacturing Analytics ENTERPRISE TRANSACTION SOURCES I N GE ERP, MES, QMS, Maintenance, ETC. S T 1 REAL-TIME DATA SOURCES Connected Manufacturing PLCs SCADAs Sensors Historians INGEST D ATA I N M O T I O N STORE AND PROCESS D ATA AT R E S T MONITOR 1 5 MANUFACTURING DATA LAKE REAL-TIME MAINTENANCE ACTION 6 ACT 4 4 Deploy Model Inputs Historic sensor values Historic production Historic defects & repair orders Historic maintenance records Design parameters, etc. LEARN D ATA AT R E S T ANALYZE Data Discovery Business Intelligence 6 Hortonworks Inc All Rights Reserved
7 Title Solution Goes Component Here Detail REAL-TIME DATA SOURCES Connected Manufacturing PLCs SCADAs Sensors Historians INGEST MONITOR 1 5 REAL-TIME MAINTENANCE ACTION 6 ACT Model Inputs Historic sensor values Historic production Historic defects & repair orders Historic maintenance records Design parameters, etc. ENTERPRISE TRANSACTION SOURCES I N GE ERP, MES, QMS, Maintenance, ETC. S T 1 STORE AND PROCESS MANUFACTURING DATA LAKE 4 4 Deploy LEARN ANALYZE 7 Hortonworks Inc All Rights Reserved
8 Title Key Use Goes Case: HereVehicle Lifecycle Quality Analytics Enterprise Quality Data Lake Provides Foundation for Rapid Time-to-Resolution Problem Voice Of Customer Social + Web (Forums, Surveys, etc.) Call Center Service & Warranty Likes Dislikes Sentiment Complaints Claims 1 What Happened? DTC s Performance Parameters Telematics Voice of Vehicle Voice Of Factory Production and Operations Man Method Material Machine 2 Why Did It Happen? Man Method Material Machine Production and Operations Voice Of Supplier Voice Of Field Installed Base VINs Configurations Locations 3 Contain The Problem Designs Parts/BOMs Features Specifications Product Development Voice Of Design 8 Hortonworks Inc All Rights Reserved
9 Thank You 9 Hortonworks Inc All Rights Reserved
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