Reducing and Eliminating Downtime in Robots Using Predictive Analytics. Scott Melton FANUC AMERICA Corporation

Transcription

1 Reducing and Eliminating Downtime in Robots Using Predictive Analytics Scott Melton FANUC AMERICA Corporation

2 Transformation Transformation is not from new technologies but transforming your organization to take advantage of the possibilities - MIT Center for Digital Business

3 What is IoT? The Internet of Things (IoT) is the network of physical devices and other items embedded with electronics, software, sensors, actuators, and connectivity, which enables these things to connect and exchange data creating opportunities for more direct integration of the physical world into computer-based systems, resulting in efficiency improvements, economic benefits, and reduced human exertions. Source: Wikipedia How / Why did we get here?

4 Four Phases of Industrialization

5 Where is the IoT? Here are some examples of the IoT outside of manufacturing Smart Phones Proximity ads, traffic patterns, fuel prices, etc. Agriculture Smart irrigation, optimized seeding, etc. Jet Engine Monitoring Connected Logistics Systems Home Automation Nest, Echo, Wink, Arlo, Z- Wave, etc. Wearable Tech Apple watch, Fitbit, Google glass, Nike+, etc. Smart Cities Parking apps, Intelligent lighting Professional Sports Wildlife Tracking Medical Devices Glucometers, blood pressure, etc.

6 And companies are investing in it PWC surveyed 2,000 senior executives in 26 countries: Industrial companies around the world are expected to invest more than 900 billion dollars per year in Industry 4.0 through Reference: pwc 2016 Global Industry 4.0 Survey

7 And why are companies are investing in it Harley Davidson reduced BTO ratio by factor of 36 Rolls Royce 1% reduction in fuel usage savings of 250K per plane, per year Royal Dutch Shell - $1M return on $87K investment.

8 IIoT = Industrial Internet of Things The IoT and IIoT both rely on sharing and using data to provide value, but IIoT targets Industry - producers of goods and services The IIoT is expected to revolutionize manufacturing by creating new value streams through the collection, analysis and sharing of data to improve uptime, reduce scrap, optimize processes, etc. IIoT solutions require long term support and rugged design considerations IIoT solutions need to work with existing (legacy) equipment IIoT solutions MUST BE SECURE IIoT

9 Why is connectivity so important? Because Connectivity Enables Access to Data & Data Drives Value Creation

10 Some Facts about Data Collection Data storage is growing 4X FASTER THAN THE WORLD ECONOMY EVERY DAY WE CREATE 2,500,000,000,000, 000,000 (2.5 QUINTILLION) BYTES OF DATA Increasing quantity of data allows for MORE QUALITATIVE APPROACH That is enough data to Fill 10 million Blu-ray discs, the height of which when stacked, would measure the height of 4 Eiffel Towers one on top of another. Source: Adient / Adient Industry 4.0/ May 11, 2017

11 Alphabet Soup Industry Terminology IoT = Internet of Things IIoT = Industrial Internet of Things SCM (Supply Chain Management) = software to execute supply chain transactions, manage supplier relationships, and control associated business processes. MES (Manufacturing Execution System) = software to understand how current conditions on the plant floor can be optimized to improve production output. ERP (Enterprise Resource Planning) = business management software that tracks resources (cash, raw materials, production capacity) and the status of business commitments (orders, purchase orders and payroll).

12 Industry 4.0 Digital to Physical Conversion Reconfigurable Mfg Systems Cyber-Physical Systems ICT (Info & Comm Technology) Smart Products

13 Industry 4.0 Interoperability Connectivity Human-Machine Collaboration Additive Machining

14 Connecting Smart Manufacturing FANUC has been investing in connectivity and Smart Manufacturing for many years.

15 Connecting Smart Manufacturing We have been creating features that produce useful data at the Robot & Machine tool Maintenance Reminder Process Logger Operation Logbook & History I/O Signal Information Signal and CNC information Operation History

16 Connecting Smart Manufacturing Today we have smart phone apps to view data outside plants Data produced on CNC & Robots using existing software. Live updated information in real-time Data sent via messages to an in plant mail server

17 ZDT Data Collector Challenge No visibility on how machines are utilized Machine downtime cost millions Data collection and edge compute Cloud managed service across plants Solution ZDT data collector with UCS on-premises Streaming machine data to Cisco Cloud service and perform data analytic with Cloudera cluster Business Outcomes ZDT Service Center Portal Alert Monitoring, Schedule Parts and Maintenance, Enhanced Customer Service Tools ZDT Customer Portal Track alerts, View ZDT network status, Access ZDT reports, Authorize users, Web Services Customer Business Intelligence/ Reporting Area Data Analytics Plant 1 Plant 2 Plant X Cisco Security Machine Learning FANUC CLOUD Persistent, Secure Encrypted Cisco Customer Security ZDT D/C Data Visualization Data Receive Save estimated $40M in machine downtime Provide visibility on machines are utilized and increased the Overall Equipment Effectiveness (OEE) We have cases where downtime is costing over $20,000 per minute. With Cisco, I saw a potential for the solution that could change our entire go to market strategy This has the potential to have the biggest impact of anything I ve seen in my 35-year career. --- Rick Schneider, former North America CEO

18 ZDT A Transformational Tool Started from 10 robots in 10 factories Grown to 17,200 robots around the world Already detected and avoided 360 failures Estimate $40M+ saved by avoiding downtime

19 ZDT - The Big Picture ZDT FANUC Analytics Data analysis detects failing component from historical data and notifies customer. -Action Required- Replacement component automatically sent to customer ZDT Data Storage Partnered with Cisco for Network Security and Reliable Cloud Services Alert message sent to customer and FANUC Service team Component changed during weekend -ZERO DOWN TIME- ZDT Data Collector

20 Global Installed Base Japan 64 Europe 1,570 Europe S. Korea 205 China 8 China Canada 1,789 USA 10,700 USA Africa Taiwan 48 Mexico 1,850 India 13 Thailand 51 Australia Brazil 698 ZDT is deployed on more than 17,200 robots

21 Downtime Avoided by ZDT Downtime Avoided by ZDT Notifications: Total # of robots : 17,252 Total # of plants : 71 Total # of countries : 17 Total # of alerts confirmed : 363 Total downtime avoided: 1,579 hours In production since : May, 2015 If downtime costs $500/minute, the total savings is $47,370,000

22 ZDT is Re-Defining Robot Support Strategy Even though FANUC robots are highly reliable, we are not always kept up to date on how they are used or applied. With ZDT we can continually monitor the use and performance of our robots to predict failures before they happen. ZDT and FIELD System enhance our support strategy from improving our ability to quickly react to predicting and addressing issues before they occur. DOWN TIME PREVENTED BY ZDT Normal Drive Replaced Alert

23 ZDT Provides Additional Value

24 Advantages of Cloud Connectivity Increases awareness of how our products are being used after shipment Connects our service team to our robots for improved response time Speeds the deployment of new and refined analytic functions Enhances technical support capabilities Provides a foundation for future value added services SECURE

25 Cisco & FANUC IoT Machine Integration MTConnect with FANUC s CNC (FOCAS) adapter 1) IOT Fog Node hosts Adapter + Agent 2) Extracts Machine Data Securely 3) Managed at Scale 4) IOT Ready Machine 5) Factory integration that IT Supports 6) POE+ for Sensor support IOT Fog Node Cisco IE-4000 Hosts FANUC Adapter and MTConnect Agent

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28 FIELD system FANUC Intelligent Edge Link and Drive An open platform that links all devices at the edge of the network to make their data available to intelligent applications that drive Smart Manufacturing systems. Edge Heavy Open Platform

29 How Open is FIELD system? Connect Any Device FIELD system is designed so network enabled devices from FANUC or any other company can connect, including competitor products. 3rd Party App Development FIELD system is designed so Apps can be written and sold by FANUC or any company that wants to be a FIELD system App development partner.

30 How does FIELD system work? Key Components FIELD system Server Device Converters FANUC FIELD Apps 3rd Party FIELD Apps FIELD system Manager & Store Edge Heavy FANUC FIELD Base Pro Open Platform Cisco UCS Server

31 Thank You