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Manufacturing Operations TransformationEnabled by Industrial IoT&Industrie 4.0

Date : 09th March,2017

Murali Chandrahasan

Head- Engineering IT Solutions and Services


Digital Transformation for a Manufacturing Enterprise – Analyst View


DIGITAL DEFINITION OF MANUFACTURING ENTERPRISE

IOT Platform MOBILITY ANALYTICS CLOUD AR/VR 3D SCANNING

ROBOTS / COBOTSEMBEDDED

(Sensors, Gateways)

AUTOMATION

(PLC, SCADA, HMI)

CYBER SECURITY

(Privacy, Protection)COGNITIVE SYSTEMS 3D PRINTING

Execution ServiceEngineering Design

IT

ENA

BLE

RS

OT

ENA

BLE

RS

CO

RE

MOMIAM

QMS

WMS

EMI

MRO

CRMSLM

Prototype(CAD)

Product Analysis (CAE)

PLM

Inventory MarketingSalesSRMHRSCMFinanceERP

Production Operations Digital Twins

Quality Operations Remote Monitoring

Inventory Operations Track & Trace

Maintenance Operations

IT-OT Integration

Manufacturing Operations Consulting

Data Management

Product Protype through CAD

Product Analysis and Simulation using CAE

Digital PLM

PLM Consulting

PLM Professional Services

MRO

Field Services

Predictive Maintenance

Energy Management

Process Design

TFDS VMS

Assembly Process Simulation

Material Flow Simulation

Robot Simulation

Tools & Fixture Design and Development

Virtual Commissioning

Lean Consulting

Forecast CRMDemand


Integrating Physical & Digital through & IT, Engineering& OT

Operational TechnologyInformation Technology

Engineering


Enterprise Data Infrastructure for IT-OT Integration lays foundation for Digital

Mobility and Self Serve BI

Dashboards & Operational Analytics

“Big Data” /HadoopAnalytics/BI/EI

OT

High SpeedPI Integrator for Business Analytics

CleanseAugmentShapeTransmit(CASTing)

PI System Access (PSA)(ODBC, JDBC,Web Services)

Asset Based OT Context & Abstraction Infrastructure

Security

Real-time Geospatial Analytics (PI + eSRI)

Cloud Enabled, High Availability

Real-time Analytics

Predictive, Statistical,Visual Analytics, Machine Learning

.

Data WarehousesData Lakes

.MetaData/System integrationMaximo/P&S/LIMS/Etc.

Specialized models.

Business Imperatives

Energy ManagementCBM/asset reliabilityEnvironmental C&R


Smart Manufacturing Solution Architecture

IP – CYBER SECURITY

Machine - Analytics

Machine 1 Machine 2 Machine 3 Machine 4

Enterprise Analytics

Wo

rkfl

ow

Man

age

men

t

Smart Manufacturing/Industrie 4.0

Enterprise Business Apps: (ERP-SCM-CRM-WMS-AMS)

SENSORS - PLC - SCADA - HMI

PLM MES EAM QMS Manufacturing & Operations Management (MOM)

Functional Experts

Data Scientists

Technical Experts

Analysts

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Smart Manufacturing – An EcoSystem

Remote monitoring

Connected Plants/ systems/Machines

Smart worker

Smart warehouse

Smart logistics

Smart enterprise

Smart product


Digital TransformationWhat we do…


Tier 1 Auto supplier – Our Approach

8 Weeks

Ideation

•Facilitate discovery phase by conducting discussions, workshops with Business, Partners & IT Stakeholder by Site Visit & Plant walkthrough.

•Build initial hypothesis for testing during analysis

•Ideate on potential interventions

Deep Dive Analysis

•Identify use case

•Data Collection and Analysis

•Detailed Use Case Development

•High Level Technical Architecture Definition

•Prioritize and identify quick wins

Recommend

•Formulate the Digital Strategy

•Create an Implementation plan as per priorities and interdependencies

•Prepare high level business case to enable quick wins self fund subsequent phases

2 weeks 4 weeks 2 weeks

Deliverables

Prioritized Roadmap

Readiness Assessment

Detailed Use Case

Inputs

Business & IT priorities •Problem Statement with Business Objectives

•Key KPIs that indicate current state and Benchmarked KPIson future state

Discovery Workshop(Design Thinking Led)

Maturity AssessmentFramework

Industry Best Practices Repository

Business Value Prioritization Framework

Enablers


Tier 1 Auto supplier – Key Highlights

• 20 use cases identified having 13 full digital stack and 7 Manufacturing Improvement ideas impacting all digital leavers.

• Deep dived 04 potential business cases with cost -benefit analysis.

• Built Digital maturity assessment model for benchmarking.

• Presented Implementation Approach Roadmap & Rollout plan with quick wins.

• IT/OT architecture for industry 4.0 (Reference as well as integrated for all the plants)

Digital maturity assessment Implementation Approach Roadmap & Rollout Plan

IT/OT architecture for Industry 4.0

Deep dived on four Potential Business Cases


Smart Manufacturing Case Studies


Remote Monitoring Automated Guided Vehicle Smart User guides through AR


Smart Work Instructions

Body Area Network is established using zig-bee (Xbee Pro) Protocol

Smart Safe Worker


LTTS CapabilitiesSmart Manufacturing Building Blocks


Intelligent Industrial Automation Capability & Infrastructure Overview

PLC’s

Hybrid DCS

SafetyControllers

(GaurdLogix)

PLC

HMI Layer

SCADA / HMI

Recipe

Historian

MES Integration Support

Optimization

Asset Information

Application Space

Controller Layer

Field Level Engineering

Capability Overview

150+ engineers with varied experience in Power, Control, Instrumentation and Automation carrying out Detail Engineering and Automation Projects for Process Plants / Facilities

State of the art Smart Manufacturing Lab provides us the facility to carry out pre-deployment testing.

Experienced SI with set templates & methodologies developed overs years through multiple Project experience.

Approach Smart Manufacturing Lab

Partners / Memberships

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PI

Co

nn

ect

ors

& In

terf

ace

s

OSI PI based IT-OT Integration Solutions across industry verticals

Factory Applications

Chemicals & CPG

Increase Asset Health & Uptime, Optimize Processes, Elevate Quality, Improve Energy Efficiency

Consulting, Development, Migration, Ongoing Support Services

Manage Risk & Regulatory Compliance, Advance Safety Performance

Implementation, Customization, Integration, Upgrade Services

Industries Manufacturing Industrial Products Energy & Utilities

PI Notifications

PI Server

PI ProcessBook

PI DataLink

PI WebParts

PI Visualization Tools

PI IntegratorsPI Event Frames

PI Analytics

PI AF

PI Data Archive

MOTORS

PUMPS

Enterprise to Plant Integration and customized dash boards for Operational Intelligence

ACTUATORS

Solutions

Services

PI Infrastructure

http://www.sap.com/index.epx

http://www.sap.com/index.epx


Integrated Manufacturing & Supply Chain Mgmt. Model (IM&SCM)

Digital manufacturing

Robot simulation Throughput simulation Machining Simulation Tool access validation Human simulation & Ergonomics

Fixture : Welding, Assembly, Checking, Special purpose

Stamping Dies Trolley / conveyor Special Tooling

Tooling & Fixture design

Work cell definition Material flow Production layout MHE & containerization Management : Inventory, warehouse,

spares, FG & Containerization

Layout Engineering

IM&SCM

Lean Manufacturing & Production Planning

Value Stream mapping Reduction : Waste, Cost, Lead Time Optimization : Flow, Layout, Resource,

Inventory Productivity Improvement Process Planning & Validation

Manufacturing Operations Management (MOM)

Consulting Implementation Upgrade, Migration & Support Enterprise Integration

Supply chain

Sourcing & Management Support Supply Chain Management


THANK YOU

For more Information please contact

Murali Chandrahasan

E-mail: [email protected]

Mobile: +9198846 99072

mailto:[email protected]

manufacturing operations transformation enabled by …tntdpc.com/automotive-2017/murali...

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