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Low Cost Adoption of Digital Capabilities
Sameer Savani, Head of Innovation & Engineering
ADS is the premier trade organisation advancing the UK Aerospace, Defence,
Security and Space industries. Farnborough International Limited (FIL) which
runs Farnborough International Airshow, is a wholly owned subsidiary.
The Organisation
Priorities for ADS
The industries represented by ADS are vital to the UK economy and are major drivers of growth and prosperity. The following priority objectives are designed to give focus to the work ADS undertakes:
• Improve the image and profile of our industries
• Influence the policy debates of most importance to our industries
• Support UK manufacturing and our industries’ supply chains
• Encourage investment in technology and innovation
• Support business development opportunities nationally and in priority international markets
• Increase Member value
Why Industrial Digitalisation is important to ADS
“Our review identified a £17.5
billion opportunity for the
aerospace sector over the next
ten years through the adoption
of currently known digital
technologies.
“Of all the sectors we examined,
aerospace offers the greatest
potential in terms of both cost
reduction and new business
models.”
This is what people think of as 4IR…
…looking through a technology lens
www.manufactringtomorrow.com
www.aethon.com/industry-4-0-means-manufacturers/
The technology isn’t flying in formation
• What are you actually trying to do?
• What skills and processes need to be in place for the technology to work?
• How much better is it than what it replaces?
• Are you over-engineering a solution?
• What are the connections between?
• Those who pay for it
• Those who have to implement it?
• Those that benefit from it?
• Those that will be disrupted by it?
Industry 4.0 goes way beyond technology
• Skills and Training
• Competency Frameworks
• Digital Mindsets and Culture
• Attractiveness to Talent
• New Business Models
• Risk Management
• Business Cases and Finance
• Business Transformation
• Security and Resilience
• Communication Networks
• Architecture and Integration
• ICT Services
• Data
• Analytics
• Digital-to-Physical
• Human-Machine Interfaces
TechnologySystems &
Networks
Skills &
Competencies
Business &
Strategy
Valu
e D
rivers
Technology isn’t even the starting point
Efficiency
Utilisation
Servitasation
Time-to-Market
Productivity
Inventory and Supply
Quality
Rapid prototyping and experimentation
Concurrent Engineering
Challenge-led Open Innovation
Agile Batch Sizing
Data-driven Demand Prediction
Additive Manufacturing
Robotics and Cobotics
Digital and Remote Performance M’gmt
Flexible Manufacturing
Predictive Maintenance (Factory)
Virtual and Augmented Reality
Smart Energy Consumption
Real-time OE Optimisation
Remote Maintenance
Predictive Maintenance (Product)
Data-enabled Business Models
Digital Quality Management
Sensor/Data-driven Process Control
Tech
no
log
ical c
ap
ab
ility le
vers
Risks with technology - centricity
• Transformation Strategy vs. Technology roadmaps
• Chasing the latest technology hype
• Numerous tactical projects of limited total-business value
• Bounded by a legacy systems and approaches – lack of vision
• Myopia - cross-impacts not understood by working in silos
• Scope constrained by technology, not what the customer wants
Never
Later
Tomorrow
NOW
Why now?
Learn Test Scale
Why now? Trends in capability
• Technologies are becoming far more affordable (and therefore, more available and accessible)
Why now? Trends in capability
• Discrete manufacturers starting to servitize – powered by connectivity
Why now? Trends in capability
• Larger companies are already getting on board
Why now? Trends in capability
• Data is getting Bigger…and Faster
Why now? Trends in capability
• Becoming increasingly affordable, available and accessible
• Larger companies (your customers) are doing this for themselves
• Data is getting Bigger…and Faster; analytics is already providing actionable insights
What’s Stopping Faster Adoption?
Awareness
Time
Ability to
invest
Expertise
Company
structures
Good
practice left
in silos
Not
knowing
where it fits
“Trying to change
the fan-belt while the
engine’s running”
Barriers
to
Adoption
for SMEs
Legacy
Case studies of low-cost adoption
• OEE (Overall Equipment Effectiveness) on a five-axis milling cell was <60%
– Getting to 80% would yield ~£27,000 per machine per year
• Engaged with CNC Data and CNC Connect; installation of £750 - £1500 per machine
• Return on Investment was less than two weeks once additional capacity was utilized; achieved through
– Operator awareness– Reduced setup times– Improved programme performance
through identifying machine stoppages
Case studies of low-cost adoption
• Created a demonstrator to showcase capability for SMEs to understand
– Data precision– Data accuracy
• Provenance and traceability
– Sensors calibrated by NPL– Measurements traceable to national standards
• End-to-end at low cost
– Multi sensor– Internet/Cloud enabled– Machine Learning– Introducing companies to servitisation models
Digitally Enabled Supply Chains• Enabling confidence in data
Case studies of low-cost adoption
• Digitally enabling a Cincinnati H5
• Fitted with a full range of sensors
Full Monty LLIVE – low-cost legacy informatics for value chain equipment
• Connected legacy machines across multiple companies
• Demonstrating
– Date validity– Interoperability– Trust and Cyber Security– Supply chain visibility to
OEMs
• 2x accelerometers for vibration measurement
• 1x thermocouple for temperature
• 3x Current transformer for power
• 1x NI 9211 for data acquisition
• 1x NI9230 for data acquisition
• 1x sbRIO 9627 – for edge analytics and visualisation
Bridgeport manual machine
Case studies of low-cost adoption
• Distributed intelligent monitoring architecture
– Utilising COTS IOT technologies– Easy to integrate with 3rd party systems
• Although this is a £2.5m programme over 3 years…
Case studies of low-cost adoption
• Affordable digitalised energy and site
management systems already available, which
often deliver far more than just a reduction in
energy bills.
• Monitor, manage and compare the performance
of assets and sites, helping it to spot
maintenance issues and optimise site resource
• Identify cost-effective opportunities for reducing
energy bills
• You can even make money by being more
flexible about the way the way you use energy
• Establish Farnborough as the home of showcasing Aerospace 4.0 solutions
• Demonstrate point solutions, integration and scale up
• Lead the narrative on the Aerospace sector’s approach to digital transformation
Aerospace 4.0
In Closing…
• Industry 4.0 doesn’t come in a box; different solutions will suit different companies
• Transformation needs to business-led and value-centric
• “Digital” is an enabler to business strategy; Technology is only part of the answer
• Large companies are already investing, but everyone will need to get on board
• Think big, start small, scale fast, act now
• Plenty of examples that you can touch and feel
• Digital transformation affects ALL parts of the business
• Come and find out more at Aerospace 4.0 at the Farnborough Airshow