Industry4.0/SmartManufacturingDigitizationofManufacturing

Masi Matteo

SalesSpecialist– Industry4.0

TechnologyProductsandServices

Pharmaceuticals

OilandGas

Utilities

Healthcare

CPGandManufacturing

MediaandEntertainment

FinancialServices

Telecommunications

Education

Retail

Source:GlobalCenterforDigitalBusinessTransformation,2015

Hospitality&Travel

DigitalVorteximpactinganyindustry

INNOVATIONANDEDUCATION

ECONOMICALINNOVATION

STRATEGIC INFRASTRUCTURES

SMARTCITIESANDPUBLICSERVICES

Industry 4.0 = Digital Transformation of ManufacturingThe use of technology to radically improve operations.

Cisco Confidential

Industry4.0 - A New Industrial RevolutionDigitizing Manufacturing to Capture the Value of the Internet of Everything

18th CenturySteam

20th CenturyMass Production

70’sRobots

TodayDigitization + Smart

Automation

TechnologyProgress

SmartDevices

It’s all about combining technology to define new innovative solutionsSource: SCM World/Cisco “Smart Manufacturing & the Internet of Things 2015” survey of 418 Manufacturing Business Line Executives and Plant Managers across 17 vertical industries.

GlobalManufacturingChallengesAhead…Increasing Complexity

Increasing Cost PressureDiverging Markets

Production FlexibilityValue Chain Insight

Product ServitisationChanging Customer Behaviors

Competitive LandscapeTechnology AdvancesInnovations & Insights

DigitalManufacturingDrivingBusinessOutcomes

ReductioninDefects

49%Defectrate

down

ReducedDowntime

48%Unplanneddowntime

down

OEEImprovement

16%AverageOEEimproved

ImprovedInventory

35%Inventory

turnsincreased

ReductioninEnergyUse

18%Annualenergycostdown

NewProductIntroduction

23%Newproduct

introductioncycletimereduced

Source:SCMWorld/Cisco“SmartManufacturing&theInternetofThings2015”surveyof418ManufacturingBusinessLineExecutivesandPlantManagersacross17verticalindustries.

“Bigvalueopportunity. WebelieveCiscocanhelpdramaticallyimprovemarginsandprofitabilityinmanufacturing.”

Industry4.0:ThepowerofcombinationGovernmentplanhttp://www.sviluppoeconomico.gov.it/images/stories/documenti/Industria_40%20_conferenza_21_9

DigitalManufacturingJourneyAlongaDigitalRoadmap

Plantpartiallyconnected:

SinglelayerLANLowsegmentation

LowsecurityLowSecurity

Proprietarysilos

DigitalSupplyChainProductionLogisticSuppliersSales

Customers

FactoryNetwork:

Openstandard-basedIntegratedSecure

Centrallymanaged

1 Advancedservices:

CollaborationAssettracking

SafetyAnalytics

2

3

TODAY

Connected R&D

Connected Factory

Supply Chain Security & Visibility

Connected Customer

Connected products providing innovate insights

Global, Virtual, 3D, Collaborative

Plant-floor platform providing converged connectivity

Advanced capabilities to streamline process

Visibility enabling informed and fast decision making

Security to enable traceability and confidence

Intelligent customer care through connected products

Empowered sales to reach the right customer at right time

Personalize Customer

ExperiencesEnable

WorkforceInnovation

ManageRisk

Optimize Business

Operations

Optimize Business

OperationsManage

Risk

Personalize Customer

ExperiencesEnable

WorkforceInnovation

ConnectedAssets

Insights into asset performance, usage patterns, and utilization

Improve response times by knowing the location / condition of critical assets

ManageRisk

Optimize Business

Operations

Personalize Customer

Experiences

Manufacturing Digitization Across The Value Chain

POC

Ecosystem/Startup

System Integrator

ConsultantBest

Practises

Roadmap

Customer way to Digital

Ciscotocreatetheecosystemtodrivetheroadmap

Converged Plantwide Ethernet Architecture

SiSiSiSiSiSi

SiSi SiSi

SiSiSiSiSiSi

AccessSwitch

DistributionSwitch

CoreSwitch

Firewall

EnterpriseNetwork

EnterpriseNetworkreferencemodel

IACS(IndustrialAutomationandControlSystems)referencemodel

Converged Plantwide Ethernet Architecture (CPwE)

Physical or Virtualized Servers• FactoryTalk Application Servers and

Services Platform• Network & Security Services – DNS, AD,

DHCP, Radius (AAA) Server, FireSIGHT• Aeroscout applications• Storage Array• FireSIGHT• Cisco Security Manager Remote

AccessServer

Physical or Virtualized Servers• Patch Management• AV Server• Application Mirror• Remote Desktop Gateway Server

DistributionSwitch

HMI

Cell/Area Zone - Levels 0–2Redundant Star Topology

Unified Wireless LAN (Lines, Machines, Skids, Equipment)

Location Based Services – Tags, Cell phones, Tablets

Cell/Area Zone - Levels 0–2Linear/Bus/Star Topology

Autonomous Wireless LAN(Lines, Machines, Skids, Equipment)

IndustrialDemilitarized Zone

(IDMZ)

Enterprise ZoneLevels 4 and 5

Manufacturing ZoneLevels 0–3

(Plant-wide Network)

6800 CoreSwitches

Phone

Controller

CameraSafety

Controller

Robot

Soft Starter

Cell/Area Zone - Levels 0–2Ring Topology - Resilient Ethernet Protocol (REP)

Unified Wireless LAN(Lines, Machines, Skids, Equipment)

I/O

Plant Firewalls• Active/Standby• Inter-zone traffic segmentation• ACLs, IPS and IDS• VPN Services• Portal and Remote Desktop Services proxy

Wide Area Network (WAN)

Physical or Virtualized Servers• ERP - Business Systems• Email, Web Services• Security Services - Active Directory (AD), Identity Services (AAA)• Network Services – DNS, DHCP• Call Manager

Enterprise

SafetyI/O

ServoDrive

Instrumentation

Level 3 - Site Operations(Control Room)

Internet

External DMZ/ Firewall

HMI

Active

AP

SSID5 GHz

WGB

SafetyI/O

Controller

WGB

LWAP

WGB

LWAP

Controller

LWAP

SSID2.4 GHz

Standby

WirelessLAN Controller

(WLC)

Cell/Area ZoneLevels 0–2

Cell/Area ZoneLevels 0–2

Drive

Catalyst 3850Switch Stack

IES IES IES

IESIES

IES IES

IES

IES IES

IES

SSID5 GHz

2.4 GHz

T2 T2EBT2S

Exciter

Identity Services Engine (ISE)

2.4 GHz

ISA

ISAISA

Cisco Prime, MSE

IES IES

IES IES

IFW

Industry4.0Solutions

Industry4.0InfrastructureandSolutions

FOUNDATION:Architecture4.0

Mobility

FactoryNetwork

FactoryWireless

FactorySecurity

SmartLogistic

FactoryCollaboration

PhysicalSafetyandSecurity

FogComputing&DataVirtualization

ConnectedMachine/Products

AnalyticsBusinessIntelligence

Plant/Machines/Robots

Security4.0

Plnt

Factory4.0

Assett 4.0 People4.0Safety&Security

Mobility&Collaboration4.0

Virtualization4.0

ConnectedMachinesConnectedProducts

Connected PlantFactory

Analytics and Big Data

Factory Virtualization

ConnectedAssets Connected

Machines

FactoryCompute

FactoryCollaboration

FactorySecurity

FactoryWireless

FactoryNetwork

Connected Flexible

Secure Efficient

Architecture4.0– FactoryNetworkFoundation between Automation Layer and Enterprise Network

• 1Network• Open,Standard-based,Secure,Scalable

• IntegratesManufacturingSystems+Businessnetworks

• Enablesrealtimevisibilitytobusinessapplications• Reducedowntime• ImprovedOEEandproductivity• Increasesafety

Casehistory

• Plantsafety,availability,integrity,intellectualpropertydefense

• Businesscontinuity• Quickcrisismanagementandresponse• Reduceriskofinadvertentplant

downtime• Implementnewbusinessmodelssuchas

remotemaintenanceandremotecollaboration

• ImprovedproductivitywithAny-timesecureandencryptedaccesstotheIndustrialZoneforEmployees,ContractorsandVendors

• ZonebasedandGranularsecuritypoliciesbasedonplantroles,device,location,andtime

Security4.0/FactorySecurity

PlantPhysical

RemoteAccess

OpenPort

Malware

Proximal

• FasterAssemblyLine,MaterialFlowEfficiency• EnableBYOD/Mobileworkforceproductivity• OnenetworkforBarcodereaders,VoIPandVoIPpicking,Data,Video,Collaboration• LocatepeopleincaseofemergencytoImproveSafety,Avoidedincident

managementcostsandpenalties• PhysicalAccessSecurity,Movementofcontractorsandvisitors• Locatetechniciansbasedonskills• IntegratedMaintenanceandImproved

Mobility4.0

Casehistory

Safety&Security4.0

• RealtimeEquipmentandAssetvisibility,location,condition

• Tracksuppliesintransit• Inventoryaccuracy• AGVcontrol• Improvedequipmentutilization• Realtimepushnotification• Correlatelocationofassetandoperatortominimizedowntime

Asset4.0

Casehistory

• WorkforceManagementtoImproveSafetyandPhysicalAccessSecurity

• Locateandcontactnearestpeoplewithspecificskills

• Voicecommandsforpickup• Real-timepushnotification• Real-timedialoguewiththemachineor

RemoteexpertforMaintenance

Collaboration4.0Real-timelocation-basedprofile-basedCommunication

Casehistory

• Enablesmonitoring,analyzingandreporting,allonasingleplatform

• SupportanalyticsforIoTenvironments,handlesmassivevolumesandhighvelocityofdata,enablinganalyticsattheedge

FogComputing&DataVirtualization4.0toenableEdgeAnalytics

• Newrevenuestreamthankstonewservices(predictivemaintenance,zerodowntime,machinerunning,DataAnalytics,remotesupport)

• Machine-As-A-Service• Timetomarket,Innovation,qualityassurance• Real-timeinventory

ConnectedMachine/ConnectedProductsBusinessmodelshiftfromProducttoServices

RetrofitCreatingValueforZeroDefectsFactories

<<<

IndustrialAsset

EndPointConnectivity

IndustrialNetworking

MachineLearning

• Small Form Factor WiFi based End Node with a low cost of installation and easy to manage

• Connect securely to the network every industrial machines and sensors via physical ports ( RS485, RS 232 ) and standard industrial protocols, such as ModBus, CANBus, OPC-UA

• Pre built configuration for a faster and easier integration to the Analytics Platform

• Advanced Machine Learning Platform able to self-learn the behaviors of the machines to anticipate increasingly earlier possible losses of processes and quality

• Specific pre-built algorithms and data models to address faster the 6 big losses of the Overall Equipment Effectives (OEE)

• Deployed in different operational models : Cloud, On Premise, Hybrid

• Factory Network is the Foundation, the essential first step of the digital journey, between automation layer and the Enterprise a connectivity

• Connects manufacturing systems and integrates factory floor with business networks

• Enables real time visibility to business applications

• Reduce risk of inadvertent plant downtime and risk intellectual property loss

Human- MachineInteraction

PredictiveMaintenanceatwork

Component changed during weekend

v Replacement component automatically sent to the customer

ü

Data analysis detects failing component from historical data and notifies customer.

-Action Required-

Data Storage

Analytics

Data Collector üüZD

T

ü

Alert message sent to the customer and machine producer

PredictiveMaintenanceatwork

Cell

Cell Zone ControlNetwork DMZ Private/Publiccloud

PLANT Internet

RobotSwitch– ManagedOpenCellArchitecture– NonblockingConnectedrouting– AnalyticsAccessSecurityIdentity- EnforcementthroughtherobotandZoneswitchRobotparticipatesincustomerITsecurityframework

KeyFunctions KeyFunctions KeyFunctions KeyFunctionsDataCollectionDataBufferingApplicationHostVirtualComputeMonitoringDataIntegrityAuthorizationDeepPacketInspect.

ConfidentialityEncryptionVPNConnectivitytoCloudSecureInternetConnectivity

SwitchPLC

BusinessIntelligenceAnalyticsReportingMonitoringSecurityDataIntegrity

Secure Portal

Switch

WhyCisco?

End-to-end network that enables more than Just connectivity

Computing from Edge to CloudSupports Big Data and Analytics

Centralized management of everythingSecurity across entire platform

Built for the future and flexible growth

Validated DesignsProven and tested architectures to reduce deployment risk, speed time to market and reduce time for PoC

One Unified Converged IP NetworkOpen standards vs. proprietary

Reduced TCO, simplified management

Strong EcosystemTechnology PartnersSystem Integrators

Startup