Smart Manufacturing – Industrial Automation Solutions

Industry 4.0 initiativeBy Unmesh Ballal

Commitment to vision of Smart FactoryIndustry 4.0 environment are for the strong customization of products under the conditions of mass production. The automation technology is improved by the introduction of methods of self-optimization, self-configuration, Self-diagnosis, cognition and intelligent support of workers in their increasingly complex work

Technologies and concepts for Value Chain Organization Solutions that include:

Embedded system – Links the Physical elements to computational elements

Internet of Things Internet of Services

Design Principles of Industry 4.0

Interoperability - The ability of cyber-physical systems, humans and Smart Factories to connect and communicate with each other via the Internet of Things and the Internet of Services

Virtualization - A virtual copy of the Smart Factory which is created by linking sensor data with virtual plant models and simulation models

Decentralization - The ability of cyber-physical systems within Smart Factories to make decisions on their own

Real-Time Capability - The capability to collect and analyze data and provide the derived insights immediately

Service Orientation - offering of services via the Internet of Services Modularity - flexible adaptation of Smart Factories to changing

requirements by replacing or expanding individual modules

Impact areas of Industry 4.0

Machine safety Industry value chain Workers Socio-economic Industry Demonstration

Key Problem Areas in Manufacturing Quality, Regulation, Compliance

Consistent quality Cost Control

Reduce rejection ration, scrap and utility management, Vendor management, quality raw material at lowest price

Safety Automated safety and protection devices, uninterrupted safe operations

Innovation Integrated SCM, Process improvement, Process analytics and efficiency

Growth Expansions, Automation and speed improvement and increase productivity Asset Management

Sustainability Predictable operations, maintainability and Productivity

Transformation Strategies

Digital enterprise software suite Develop scalable IT systems Manage end-to-end processes Increase Social Interactions 360 degree information availability Eliminate Hierarchies

Elements of growth for Industry 4.0

Devices – smart sensors, controls, software applications, obtain and share real time data, enable autonomous actions

People – connectivity across business functions, geographies and real time. Provide intelligent design, operations and maintenance as well as high quality of service and safety

Processes - information sharing on global manufacturing value chain from supplier to customer – flexible and adaptable supply chain

Connectivity -

Realizing the vision of Industry 4.0

Industry 4.0

Processes

CollaborationTechnology

Industry 4.0 - components

Technology Internet of Things Cloud Platforms Big Data Wireless

Intelligence

Collaboration Integrated

Industries IP Centralization Social Innovation

Processes• Internet of

Services• Lifecycle

assessments• Sustainable

Manufacturing

Industrial IT and Manufacturing applications

Integrated enterprise ecosystem ERP PLM MES – Production planning, scheduling,

tracking, traceability Manufacturing Enterprise

Ethernet devices VR predictive maintenance Asset Management Apps 3D operator training Assistance Industrial Internet

SCADA, HMI

Cloud IT infrastructure Wireless Communucations Mobile maintenance Social Media Apps Data Processing and Analytics Commercial IT

Remote Home control apps Cyber security apps Warranty Management

Big Data Analytics

Techniques Data Acquisition Management Decision Simulation Contextualization Action based Intelligence

Results Maximizing asset utilization Reducing energy consumption Optimizing Production

Protocols used Connectivity RS232 Modbus Wireless USB NFC QR Code

Link Protocol Layer ZigBee BLE Bluetooth Wifi Ethernet GSM RFID

Transport IPv4 IPv6

Session Communication HTTP FTP Telnet SSH AMQP XMPP

Example - Manufacturing plant

•Pay per use model

•Machine optimization•Energy optimization•Resource optimization

•Asset Analytics•Energy Analytics•Process Data Analytics

• Industrial Cloud platform•Ecosystem for Partners•Modularization

Plant Data Asset Optimization

Cloud infrastructur

eProcess

Optimization

Conclusion

A systematic transformation across existing structures, systems, processes and strategies is required to reap benefits from Smart Manufacturing Initiative

Existing systems need to be evolved keeping the result oriented ness and within the priorities of organization’s profitability and efficiency improvements.

Rest assured that initiative will lead to New business models, more value and experience to customers and profitability.