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Copyright © 2015 Accenture. All rights reserved
Driving unconventional Growth
through the Industrial
Internet of Absolutely Everything A Point of View of IOT for Korean IE Manufacturer
Tae-Jin Lee, Accenture “Copyright © 2015 Accenture. All rights reserved. Accenture, its logo, and High Performance Delivered are trademarks of Accenture”
1. Introduction
2. Industry 4.0
3. Smart Factory
4. Conclusion
Disclaimer
“This document and the information contained herein are proprietary to Accenture. This
document, either in whole or in part, may not be reproduced in any form or by any
means without Accenture’s prior written permission. This document provides no
warranties with respect to the offerings described within. Accenture, its logo, and High
Performance Delivered are trademarks of Accenture. Any third-party names,
trademarks and copyrights contained in this document are the property of their
respective owners.”
Copyright © 2015 Accenture. All rights reserved
Introduction
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Digital Industry 4.0 …. It’s complicated !
4
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Digitalization will impact the life of companies and individuals…
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… new information and communication technologies will connect almost
everything and create the Internet of Things.
6
Internet of Things (IoT):
Accenture understands
that the Internet of Things
is more valuable than the
sum of its parts. It is not
enough to be “connected”.
The goal is to be
pervasive, transformative,
and intelligent.
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What is the difference between the Internet of Things (IoT) and the Industrial
Internet of Things (IIoT) or Industry 4.0?
7
IoT is used more liberally to represent
all of the application of the seamless
integration of the physical and digital
worlds through networked sensors and
actuators, big data, processes and
people.
IIoT is the realization of IoT in the
industrial sector. The German
Government is running a strategic
program directed toward the year 2020,
under the name Industry 4.0 which has
the same meaning like IIoT.
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In the center of IIoT/ Industry 4.0 we see the smart factory which will differ
entirely from current factories
8
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• Advantages:
-Free capacities will be
announced directly
-Active support of production
process
-Real-time analytics of
components and machines
-Predictive maintenance
For the first time components, machines and humans will communicate
spontaneously which enables smart factory to be more flexible and resistant
9
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Industry 4.0
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Parallel Industrial and Communications revolutions converging on Industry 4.0
A Fourth Industrial Revolution, driven by new forms of technology
11
2.0 3.0 4.0
Steam power … Electrical power … Automation …
Mail … Telegraphy … Internet …
Smart
Connected
Devices …
1.0
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The Digital Industry 4.0 - Drivers for change
A convergence of technology forces is changing the industrial ecosystem,
triggering the Digital industrial revolution or Industry 4.0
12
Profound changes in
the entire industrial
ecosystem
+
=
Connected, always-on,
intelligent, software &
data powered
autonomous devices
Connectivity
Hyperscale Data Centers
Analytics and Algorithms
CPU Performance Chip Miniaturization
Software Push Internet Backbone
LTE
Technology
Progress
Smart Devices
Cyber Physical
Systems
(4th Industrial
Revolution)
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The Industrial Internet of Things (IIoT) will bring new
economic growth, reinventing sectors that account for
almost two-thirds of world output.
The raw technical conditions for the widespread
adoption of the IIoT are highly favourable.
The potential economic benefits of the IIoT may
be massive, but not guaranteed.
Seizing the opportunity
IIoT could add to the
global economy
$14.4tn
13 Source: © Copyright Cisco white paper “Embracing the Internet of Everything To Capture Your Share of $14.4 Trillion”
IDC – industrail IoT Value
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The economic impact of Industrial Internet is measured in trillions of dollars
Cisco: “Internet of Things will increase private-
sector profits 21 percent by 2022 and add $14.4
trillion to the global economy.”
“Gartner predicts that the total economic value
add for the Internet of Things will be $1.9 trillion
dollars in 2020, benefiting a wide range of
industries, such as healthcare, retail, and
transportation.”
McKinsey Global Institute: $36 trillion operating
costs of key affected industries (manufacturing,
health care, and mining) could be impacted by
Internet of Things
Sources:
• Cisco White Paper, “Embracing the Internet of Everything To Capture Your Share of $14.4 Trillion”, 2013
• Gartner Press Release, “Gartner Says It's the Beginning of a New Era: The Digital Industrial Economy”, October 2013
• McKinsey Global Institute Report, “Disruptive technologies: Advances that will transform life, business, and the global economy”, May 2013
14
Copyright © 2015 Accenture. All rights reserved 15
Of The Estimated $14.4 Trillion Of New Value At Stake, $5 – 9 Tr. Is In The Digital Industrial 4.0 Area.
Value at stake as a result of disruption – IDC – IoT value $ 7tr
Source: © Copyright Cisco white paper “Embracing the Internet of Everything To Capture Your Share of $14.4 Trillion”
IDC – industrail IoT Value
Customer experience
-> more and new customers
$3.7
Asset utilization (100%)
-> reduce costs $2.5
Employee Productivity (20 – 30%)
-> increase efficiency $2.5
Supply chain and Logistics (100%)
-> eliminate waste $2.7
Innovation (10 – 30 %)
-> reduce time to market $3.0
$14.4 Trillion
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There are multiple ways to extract business value from the Industrial IoT
Value Categories Value Levers
Unconventional Revenues
Most Valuable Information Provider
Product as a Platform
New Business and Operating Models
Products / Services Hybrid Treating Services as R&D for products
Enabling third parties to create information services
Locking customers into the information services
Sensors, analytics, and real time data for insights
Operations & Predictive Maintenance
Commercial Optimization
New Customer Experience
Flexible production techniques to boost productivity
Data to work as digital service for equipment performance
Gain opportunities to create customer touch points
Incremental Revenues
Operational Efficiency
Avoiding unnecessary product shutdowns
Computerize repetitive tasks and workflows
Improved supply chain and logistics performance
Reduce costs of energy, maintenance, repair etc.
Preventive Maintenance
Process Automation
Operation Optimization
Global Asset Visibility
Do what you do now,
and make more
money from it
Do things differently,
and make money in
new ways
Do what you do now,
at a lower cost
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We see the 4.0 transformation journey taking businesses through certain steps
that open new opportunities as they mature
Copyright © 2015 Accenture All rights reserved. 17
IIoT/ Industry 4.0
transformation
journey -In most cases, making
the case for operational
efficiency is a low-
hanging fruit providing
easy-to-estimate return.
-As strategies re-align
over time, new top line
opportunities arise
thanks to previous
investments and
organizational
realignment.
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IIOT : Redefining Industry Boundaries (HBR 2014 Nov)
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Interconnected system of systems Smart & Connected Products Smart but Standalone Outcome based services
Remote diagnostics
Individually customized outcome-based business models
Outcome-based business model
Digitization route of existing service businesses
Resource Sharing (ala Uber)
Support for Pay-per-use
model
Data Monetization
Ma
rke
t O
ffe
rin
gs
A Smart Products Roadmap
The path taken will vary the revenue mix of software, services & products
19
product
services
information
& ecosystem
Unconnected Products (HW)
Smart but Unconnected Products
Smart and Connected
Product
Ecosystem of products
Customizable / configurable products
Self-optimize, self-diagnose
product
Mobile- accessible products
OTA upgradable/ customizable products
Collaborate with other products
from same vendor
Cloud- enabled products
API-enabled products
Product as a platform (e.g., app store)
Collaborate with other products across
vendors
Scheduled equipment maintenance
On-demand & on-spot training
Predictive
maintenance
Real-time optimization
(e.g., fuel savings) Service Aggregation
Outcome-based service (single vendor)
Ecosystem of services
Shared Revenue model
More advanced business models and higher level of disruption
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Changes in the technology landscape are making this possible
Sensor technology advances: Physical, chemical and biological sensors based on
nano-structured materials and nano-materials such as conducting polymers and
composites are rapidly evolving towards autonomous analytical devices that perform
sophisticated analytical processes.
Cost of electronics: The cost of electronic components has dropped over 30% in the
last 5 years, making many new business cases possible today. (Gartner, June 2014)
Network advances: The advances and standardization in Internet network
technologies allow rapid and low-cost promulgation of information from physical
sensors to be combined with the avalanche of related business process and consumer
activity data.
Business and governmental understanding of the potential benefit: Businesses
are realizing that this data can be used to optimize cost and delivery of industrial
services.
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Smart Factory
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Trends in Manufacturing
Productivity requires information moving to people rather than
people moving to the information. Remote Monitoring
• Predict and reduce downtime
• Improve decision making
• Refine processes
• Save Energy
Information
Leverage
Integrating customer preferences in development and production
processes, facilitated by exchanging data with machines
Industry 4.0
Social Media
Drone 3D printing
Big
Data
Exponential growth in data
due to low cost computers
and wireless sensors
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Industry 4.0 & its use cases
Machines
organize
themselves
Supply
chains
coordinate
automatically
Unfinished
products
send data to
processing
machines
Predictive
maintenance
Flexible
products
Reduced
energy
consumption
Telepresence
platform for
service
maintenance
Industrial
software
security
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Future of Manufacturing: Customer Centric Production
The manufacturing will follow the customer centric production process where customer knows the
status of the product and its stage. Customer can change the product feature before each stage of
production
Traditional Manufacturing Process
• Harmonization of Business
and IT structure
• Security aspects (like firewall,
SSL and user level) need to be
well established
• Modularization and reuse
strategies need to be
developed for cost effective
and highly productive factories
• Plant floor and top floor
employees need to be trained
to understand the impact
of the approaches
Smart Manufacturing Process Impact
Product Design
After Sales
Consumer
Product Planning
Manufacturing
Consumer
After Sales
Product Design
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Future of Manufacturing: Mass Customization
Customization parameters for Region 1
Customization parameters for Region 2
Impact
• Localized teams need to be
trained for creating the product
and quality assurance
• Smart factories should work
on a different revenue model
based on the localization
• Need to have a data analysis
system which can analyze the
local customer requirements
Global Factory
Keypad Display size No front camera
3D printers Quality assurance
Local customer Group 1
Local product house
Quality assurance
Local customer Group 2
Keypad Display size No front camera
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Future of Manufacturing: Self organizing factories
When a machine is faulty, production system automatically finds the best assembly line which can
meet the deadline and continue production
Impact
• Much more complex
communication across
subsystems on plant-floor
• Real time handling of errors
and decision making
• Every subsystem / device able
to communicate its status to
other subsystem
Production begins
Faulty machine communicates its state to MES
MES finds an alternate
path which needs to meet
• Dead line
• Cost
MES Instructs
faulty
assembly line
to change
the working
assembly line
Product is moved
to Assembly line - 2
Assembly
line – 2
instructs
MES
MES continue tracking
production process
Finished Product
1
2
4
6
3
5
Production
system 7
Unfinished product
Working machine
CPS
Unfinished product
Faulty machine
CPS
26
Assembly line 1 Assembly line 2
CPS : Cyber-Physical System
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Future of Manufacturing: Flexible Factories
Factories will have Dynamic production line, in which product moves autonomously through the
CPS enabled workstations based on customer needs of the products
PLM
Impact
• Production system needs
to interface with 3rd party
systems for getting
customer inputs
• Production line needs to be
dynamic to have changes
in workflow
• Interface of PLM, MES,
Production line
Design
House 1
Design
House 2 • No front camera
• Low RAM
• Low Phone Memory
• White case
Configuration Configuration
• Front camera
• High RAM
• High Phone Memory
• Pink case
Configuration
• No front camera
• Low RAM
• Low Phone Memory
• White case
Configuration
• Front camera
• High RAM
• High Phone Memory
• Pink case
Customer A Customer B
Workstation Grid
27
4
1
7
5
2
8
6
3
9
CPS
CPS
CPS
CPS
CPS
CPS
CPS
CPS
CPS
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Future of Manufacturing: Energy Consumption Reduction
Closed loop demand response power utility services and localized automated power management
system for the individual equipment in the industry
Pla
nt 1
Energy Monitor
HVAC Robot Lighting System
Pla
nt n
Energy Monitor
Pla
nt 2
Energy Monitor
Energy
Management
System
Impact
• Manufacturer have significant
scope in reducing energy
consumption
• Security aspects (like firewall,
SSL and user level) need
to be well established
• Different Trainings need to
be identified & provided to
white color and blue color
job holders
HVAC Robot Lighting System
HVAC Robot Lighting System
Demand
Response
Client
DRAS –
Demand
Response
Automation
Server
Utility Demand
Response Server Cloud
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Future of Manufacturing: Predictive Maintenance, Downtime Reduction
Smart Maintenance avoids costly downtime and maintenance costs. The early identification of
symptoms of the machinery helps in deploying optimum resources, maximizes machine uptime and
improve supply chain processes.
Sensor 1
Sensor 2
• Checks life expectancy
data sheets
• Check against
boundary conditions
• Compare with similar
healthy systems
Impact
• System need to handle
complex predictive
maintenance analysis
• Need to connect your supply
chain with production system
• Form ecosystem with device
manufacturers
Component
Manufacturer
Place order
Historical
data from other
similar systems
Analytics Energy Motor
ORDER
29
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A Smart Production Roadmap
Companies can take all three paths to greater efficiency and flexibility
30
Manual / unconnecetd produciton
Agile factories
Basic mfct.
services
Remote servicing
Demand driven
production
Pro
du
cti
on
sys
tem
&
pro
ce
ss
au
tom
ati
on
Semi-automated & Connected Serviceable & fully automated Intelligent /smart factories Externally connected production eco-systems
Dynamic Re-planning
RFID tracking
Remote Monitoring
Internally & externally integrated
Joint demand planning & execution
Dynamic spot marketplace
Automated process changes & SMED
Machine optimization
Maintenance as a service
Just in time Inventory
Mass customization
Predictive Maintenance
Plant floor Optimization
Ultra Postponement Of products/ parts
Dynamic scheduling and task mgmt.
Inventory adjustment based on material condition alert
I need
maintenance
in 200h
working hours
In 20 minutes,
I m going to get
assembled with
the wrong part
Internally integrated
Provision of digital Services to support maintenance & repair
Static process, Manual variant production (bespoke)
More advanced production and service systems and higher workforce skill requirements
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New IT for the Industrial Internet of Things
What technologies will make the Industrial Internet of Things a source of
breakthrough innovation and competitive advantage?
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Accenture Digital Plant Solution
HMI Clients
Plant
Remote HMI Devices
Digital Plant loT platform on DCPP/Azure
Universal Plant Gateway
Industrial Controller
Industrial Equipment/Devices
Universal Plant Gateway
Digital Plant Platform Cloud loT (Azure ISS)
Equipment Devices Sensors
Allan Bradley 5561 Siemens PLC S7 313C 2DP
WinCC/OPC Servers
Industrial
Internet
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Accenture Digital Plant Framework is implemented for the following use cases
• Predictive Maintenance & Supply chain connectivity
• Remote Monitoring
• Expert Collaboration
Digital Plant Mapping to Industry 4.0
Digital Plant
Machines
organize
themselves
Supply
chains
coordinate
automatically
Unfinished
products
send data to
processing
machines
Predictive
maintenance
Flexible
products
Reduced
energy
consumption
Telepresence
platform for
service
maintenance
Industrial
software
security
Accenture
implemented the
framework and
basic scenarios
…
Supply chain
connectivity
Predictive
Maintenance
Expert
Collaboration
Service
Maintenance
Industrial
Security
33
Copyright © 2015 Accenture. All rights reserved 34
Digital Plant Screenshots
Executive
Dashboards
Remote
Monitoring
Predictive
Maintenance
Expert
Collaboration
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Conclusions
Copyright © 2015 Accenture. All rights reserved 36
Unconventional Revenues
Incremental Revenues
Operational Efficiency
Sense and Act
Analyse and
Visualize Communicate
Smart Factory
Smart product
(Unfinished)
Smart product
(Finished)
Smart Logistics
Smart Product
(Delivered)
Smart Tool
IOT Benefits For Manufacturers
Copyright © 2015 Accenture. All rights reserved
Disrupt or be disrupted.
Start building the bridge to the future.
Decide to fight or flight.
Not to be the first, make sure the last.
Innovation is unforeseen.
Closing
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