the road to smart manufacturing in the uk

© ABB| Slide 1

The road to smart manufacturing in the UK

Mike Wilson, 19 October 2016

© ABBSeptember 10, 2009

Fire & Emergency

Actions on hearing the Fire Alarm (continuous bell tone) Evacuate the building via your nearest available fire exit Proceed to the Assembly Point and await instructions DO NOT stop to collect personal belongings DO NOT re-enter the building until authorised to do so DO NOT rely on assistance outside normal hours

If you discover a fire Operate the nearest fire alarm call point (break glass) DO NOT tackle the fire or take personal risks

Robotic Demo Area

TrainingSuite

Workshop

Customer Support

SolutionsCentre

Office

Fire ExitFire Exits

Fire Exit

Fire ExitMain

Entrance

Fire ExitFire Exit(First Floor)

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First Floor Only

Smoking shelterPlease use main entrance

Auriga House

Fire Assembly Point in Visitors

Car Park

June 2014

Storage Building

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The 4th Industrial Revolution

• Machines;• Water power;• Steam power.

1nd Industrial Revolution

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• Electrical power;• Division of labour;• Mass production.

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2nd Industrial Revolution

3rd Industrial Revolution

• Automation;• Robotics;• PLC.

3rd Industrial Revolution

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4th Industrial Revolution

• Information and Communication Technology (ICT)

Source: The Manufacturing Technology Centre

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Industry 4.0 – The vision

Seamless connectivity

Leveraging information through intelligence

Smart factories

• Robots & automation

Source: The Manufacturing Technology Centre

© ABB| Slide 6May 1, 2023

Achieving the factories of the futureExample – ABB breakers & switches production plant

- 22 robots installed at ABB’s breakers and switches plant in Vaasa, Finland

- Automation is used extensively throughout order to delivery chain

- Automation applied to key areas including materials procurement, switch assembly and logistics

- Robots used throughout the process, handling picking, packing and assembly

- Robot night shift assembles and tests switches ready for morning – reduces lead times


ABB breakers & switches production plantKey benefits

- The reliability of deliveries is now 98.3 percent, up from 94.4 percent

- The average lead time has improved from ten days to five

- Profitability has nearly doubled in four years

- Production can be adjusted according to demand

- The quality of work has improved, and the number of customer reclamations has halved

- Sick leave is down 30 percent

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How do we see the future?The Internet of Things, Services and People (IoTSP)


The Internet of Things, Services and PeopleA new age of industrial production

Things Intelligent things and smart data Includes intelligent machines, devices and systems Generate large amounts of data – when analysed, this data allows functions to be controlled,

prepared and automated

Services Availability of data enables pre-emptive diagnostics and maintenance Predictability increases operational reliability, consistency, cost effectiveness and safety Mobile and Cloud based data makes it easier to control and interrogate equipment remotely

People Enables organisations to get more from their people Human participation will be less about strenuous and dangerous tasks – people will perform added

value functions, e.g. programming, supervision

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Does the UK need to change?Mike Wilson, 19 October 2016

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The world will changeSirkin, Zinser & Rose – Sept 2015

Three major trends behind growth of advanced industrial robots: - Greater cost-effectiveness when compared with human labour - Technological advances are wiping out barriers to adoption- Arrival of systems that smaller manufacturers can afford and easily use

By 2025, the share of tasks performed by robots will rise from a global average of around 10 percent to about 25 percent across all manufacturing industries

Wider robotics adoption will boost manufacturing productivity by up to 30 percent When costs are sufficiently low, robot installation rates likely to accelerate rapidly,

creating a substantial competitive advantage

But…….

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Germany Sweden Italy Spain France UK

UK invests far less in robotsComparison with European countries

Source: IFR World Robotics report – 2015

Robot density in non-automotive sectors(Number of robots per 10,000 employees)

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Could Industry 4.0 enhance UK manufacturing?

Enhanced competitiveness and greater level of individualised choice for customers through: Increased flexibility Greater product customisation Localised manufacturing Shorter lead times

Barclays report: Future-proofing UK manufacturing

“Even a moderate increase of £1.24bn in automation investment could raise the overall value added by the manufacturing sector to the UK economy by £60.5bn”

“Would be expected to amount to 33,000 manufacturing jobs by 2020 and 73,000 jobs by 2025”

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The challengeSmart manufacturing needs technology AND people

Industry 4.0 has the potential to displace many types of demanding, strenuous and dangerous tasks BUT: automation will not replace employment

“Complete automation is not realistic. Technology will mainly increase productivity through

physical and digital assistance systems, not the replacement of human labour.” 1

New roles requiring flexibility, problem solving and customisation Industry 4.0 workers will need to combine knowledge of a specific job or process with IT skills

- Basic skills, e.g. using spreadsheets, accessing interfaces, etc- Advanced skills, e.g. advanced programming, data analysis, etc

- Onus will be on the employee as well as the employer to ensure that skills are kept up to date

Ingo Ruhmann, special adviser on IT systems, German Federal Ministry of Education and Research, quoted in Man and Machine in Industry, Boston Consulting Group

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The challenge

Move towards smart manufacturing may provide the incentive needed to boost take-up of robot automation in the UK

ABB survey in 2013 of 221 UK companies of all sizes Aim was to identify the major barriers to robot adoption in the UK 60% were not currently using robots Of these, 29% ruled out an investment in robotic automation in the near future 58% of these respondents cited lack of experience in robotic automation as the major

reason This includes both skills needed to operate and maintain / support robots

ABB survey 2013

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Driving the change to smart manufacturing

Two main areas need to be addressed:1. Bridge the robot skills gap

- Give organisations the skills they need to make the most from an investment in robots

2. Make robots easier to operate, maintain, supervise and own- Provide support when and where needed to help ensure maximum robot uptime

How do we get UK companies to embrace smart manufacturing?

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Bridging the skills gapDean Phipps, 19 October 2016


How are we helping to bridge the skills gap?ABB Robotics training centre

• Designed to teach the skills needed to program, operate and maintain robots

• Around 1000 students attend our courses every year

• Wide variety of robots and robot systems represented

• Courses vary in duration and content, from machine operators through to advanced programmers


ABB Robotics training centre2016 upgrade

• £250k investment in new equipment, including latest generation of robots and controllers and integrated safety guarding

• Training cells reflect typical guarding arrangements in industry

• Updated range of robots, including latest generation IRB1200 and YuMi robots

• Expanded range of courses added to training programme, including YuMi, collaborative robot

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Tour….


Connected ServicesJörg Rommelfanger, Global Product Manager, ABB Robotics Customer Service


Looking backThe world has changed….

The Internet is just a hype

Bill Gates , 1993


Looking aheadIncrease in connectivity provides more opportunity

6.4 billion connected “things” in 2016

More than 20 billion by 2020

5.5 million new things every day

In 2016, global Internet traffic will exceed

the 1 zettabyte mark (1 trillion GB)

Traffic growing at 23% per year

By 2019, traffic will be 64x that of 2005

Majority of traffic from non-PC devices

Things and Connectivity

Source: Gartner public forecast (Nov. 2015); Cisco Virtual Networking Index (2014)


The technical revolution has started(just look into your pockets…)

Within 8 year ~100% market penetration

Two days after pope Johannes Paul II died. His successor Benedikt XVI retired and a new pope has been elected.

2005 2013

Source: www.spiegel.de, Christian Klettner /BASF


Customer Service trendsConnectivity changes the world

50 billion devices connected by 2020

Reactive Proactive

Source: Gartner


ABB is a Pioneer in Digitalization Increasing Uptime, Reliability and Efficiency throughout the Life Cycle

Creating value for partners and customers

System / Fleet Management

ProductionOptimization

Machine LearningHTML5 interface

Remote Assistance

Condition Monitoring

All products IoT enabled

Pioneers in Remote Services with long

experience

Robot StudioDigital Engineering

Yesterday – Remote Services Today – Connected Services Tomorrow

ABB became a pioneer in robot Remote Services already in 2007, with optional hardware allowing for significantly reduced time to fix

Service Intelligence Unit

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Connected ServicesNew Product Structure

Up to 25% fewer incidents, 60% faster response times and issue resolution

Connected Services

Condition Monitoring & Diagnostics

Backup Management

Remote Access

Fleet Assessment

Asset Optimization


Connected Services Secure Connectivity embedded

Connected Services preinstalled in every delivered robot

Additional Remote Service Box Embedded in Controller and Robotware

InternetGPRS3G

3G, Wi-Fi optional

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Connected ServicesCondition Monitoring & Diagnostics

Information at your fingertips , proactive and immediate support

Avoidance of unplanned production stoppages, typically 1 shift

Increase of equipment availability Fault repair in planned production shutdown Fast notification and identification

of failure root cause Optimal spare part recommendation Typical error detection on fans, power supply

unit, connectivity , storage, software resources, cables and mechanical components

Benefits

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Connected ServicesBackup Management

Fast recovery in case of trouble

Fastest controller and production recovery Avoidance of new programming Correction of unwanted changes in program or

configuration Historical data available Part of web-based User Interface ‚MyRobot‘

Benefits

© ABB 2014

Connected ServicesRemote Access

Expert knowledge at any anytime

Benefits

Endcustomer

Integrator ABB

Common support platform

Get instant access to experts Fastest response time to avoid downtime Saving travel time and expenses Fast identification and remedy the cause of the

error Successful troubleshooting in 70% of cases Low one-time investment, no license fees,

no additional software One time purchase, lifelong use in conjunction with

service agreement Condition monitoring and remote access on same

secure platform

© ABB| Slide 32

Connected ServicesFleet Assessment

Giant leap towards Predictive Maintenance

Benefits

Features Fleet Assessment Report

Criterias : Utilization and Estimated Gearbox Lifetime Benchmarking: Customer Fleet

or ABB Population

Optimized usage / reduction of the maintenance budget

Assistance for maintenance strategy (refurbishment, replacement, second lifetime)

Assistance for long term investment planning Identification of candidates for further audit

activities or higher service demand Limit risk of critical failures in gearbox and motors


Connected ServicesAsset Optimization

Highest support level for maximum performance

AGBSN Increase Performance and availability of the

system ‒ Avoid unnecessary downtime from specific

motion or stoppage alarms‒ Minimize warnings & messages for smooth

operation Identification of high attention areas to reduce the

risk of failure Extend equipment lifetime Increase value of maintenance

Lowest downtime Benefits


Connected ServicesOffering highlight – Service Intelligence Unit (SIU)

Local Specialists

Global monitoring, alarm management , reporting, pre-diagnostics, remediation, development and management of service intelligence

Equipped with appropriate tools and resources Diagnostics and prognostics based on remote data Recommendation of actions towards local ABB units Daily support for >4,000 robots in 40 countries

Global Service Center

Device Data / Datalake

Global monitoring

Supervise whole fleet, advice local ABB to act when relevant

Reporting

Regularly improvement advisory reports

Proactive support

High-light “attention areas” and advisory


IoTSP EcosystemNew ABB Cloud platform

Related External Data Data Management

Analytics Engine

ABB Cloud

Large Volume Customers

Analytics Apps / User Interfaces /

APIs

Advanced Service Agreements

Field Service Information and

Consultancy

R & D Information

Secure Real Time Connection

Services based on Analytics

IntelligentEngineering

CloudMESERPData

Prediction / Fleet

API


The way forwardEngineering an automation nation

Current estimated number of robots currently in use in the UK – approximately 16,935 (IFR 2015)

Estimate around 5,000 active robot users in the UK

UK manufacturing sector comprises:- 1,200 large UK-based companies (>250 employees) - Approx. 87,000 SMEs (<250 employees)

10,000 to 20,000 companies could be considered as potentials for Industry 4.0 technologies

© ABB| Slide 39

The way forwardGrabbing the opportunity

“The companies that do well out of the fourth industrial revolution will be the ones that recognise the business opportunities and apply the technologies in a focused way to drive the benefits. The winners as always will be the companies with the best people, vision and determination to succeed.”

Professor Ken Young, Technology Director, Manufacturing Technology CentreQuoted in BDO’s Industry 4.0 Report, June 2016

the road to smart manufacturing in the uk

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