us: smart manufacturing europe: industry 4.0 china: made in … · 2016-11-04 · product...

SMART Manufacturing and IoTfM

Michelle Pastel

November 2016

US: Smart Manufacturing

Europe: Industry 4.0

China: Made in China 2025

India: Make in India

“Next Industrial Revolution”

Right Data, Right People,Right Time,

Right Decisions

2.

© 2016 Corning Incorporated ..

Corning’s Story…

• Corning’s strategic approach is deeply rooted in innovation of products and processes

• Our sales are enabled by producing quality products with the attributes our customers want at the right price

• Our profitability comes in part from supply chain management and manufacturing excellence

Corning is a world class manufacturer of specialty materials,...…SMART Manufacturing will help us continue our legacy

All of us deeply depend on Data…

… and Information Technology Systems…

… to Deliver our Objectives for Business Success

Smart Manufacturing is Redefining All of the Above

4.


Today…Think of Manufacturing Systems as a Puzzle

Each piece can exist and function independently

But the real impact can’t be seen until all the

pieces are connected

ProductManagement

QualitySystems

WareTrackingOrder

ManagementInventory

ProcurementPlanning

Product&

ProcessData

LabTesting

Environmental/Qualification

ProductDesign

Experiments

ProcessDocumentation

MaintenanceManagement

DowntimeTracking

DefectCollection

Park, Janisch, Jefferson 2012

5.


The Puzzle can be logically grouped by Functionality

ProductManagement

QualitySystems

WareTrackingOrder

ManagementInventory

ProcurementPlanning

Product&

ProcessData

LabTesting

Environmental/Qualification

ProductDesign

Experiments

ProcessDocumentation

MaintenanceManagement

DowntimeTracking

DefectCollection

Product Management

System

Rules for what we make

& how

Manufacturing Execution

Systems (MES)

What to do &What Happened

EnterpriseResource Planning (ERP)

Financial Control ofwhat we buy and sell

Product & ProcessData Tracking

Detailed Data supporting whathappened


6.


Once assembled…Integrated Manufacturing Systems of Today

•• Mfg Scheduling• Ware Tracking• Defect Collection• Downtime Tracking• Maintenance Management

• Order Management• Procurement• Inventory Management• Planning• Human Resources• Time Tracking

• Quality Systems Documents

• Process Documents• Experiment Tracking• Specifications• Material• Products

• Bill of Materials• Routings• Product Documents

• Product/Process Data Collection and Analysis

• Lab Testing• Product Design• Environmental/ Qualification

Product & Process Data

Tracking

Product Management

System

Manufacturing Execution

System - MES

Enterprise Resource

Planning - ERP


7.


But Today’s Information Systems Aren’t Seamlessly Connected from Plant-to-Plant Across the Supply Chain

•• Mfg Scheduling• Ware Tracking• Defect Collection• Downtime Tracking• Maintenance

Management

• Order Management• Procurement• Inventory Management• Planning• Human Resources

• Time Tracking


• Process Documents

• Experiment Tracking

• Specifications• Material• Products

• Bill of Materials• Routings• Product

Documents


• Lab Testing• Product Design• Environmental/

QualificationProduct

& Process

Data Tracking

Product Manage

ment System

Manufacturing

Execution System

- MES

Enterprise

Resource Planning

- ERP


Management


• Time Tracking






Documents




& Process

Data Tracking

Product Manage

ment System

Manufacturing

Execution System

- MES

Enterprise

Resource Planning

- ERP

Minimal Supply Chain Data Sharing


Management


• Time Tracking






Documents




& Process

Data Tracking

Product Manage

ment System

Manufacturing

Execution System

- MES

Enterprise

Resource Planning

- ERP

…

…………

…………………

1st Factory“Corning”

2nd Factory“Contract”

3rd Factory“Customer”

Finished Product

8Manufacturing Technology and Engineering.


Smart Manufacturing

Corning’s SMART Manufacturing (SM) is the concept of combining multiple capabilities (Integrating Measurements, Controls, Computing Platforms, Modeling and Analytics)

to improve process/product development, manufacturing performance, and reduce manufacturing cost within a plant and across the supply chain.

Smart Manufacturing Leadership Collation (SMLC) is a national coalition to promote, standardize and enable SMART Manufacturing. Corning- member since 2011.

DOE’s Clean Energy on Smart Manufacturing Innovation Institute (CESMII) is a public-private partnership to advance SM and Clean Energy creating competitive US manufacturing. The SMLC awarded the Institute June 2016.



Corning’s SMART Manufacturing

• State of the art Cyber Security

• Cloud computing platform

• Access to Data Analysis and real-time Predictive Modeling

• Advanced Controls, sensors and data protocols

• New data Visualization tools

• Infrastructure to enable improvements in Mfg.

• Reduce costs by changing mfgsystem suppliers’ biz model

SMART Mfg

Cyber Security

Equipment PI MES Test Data

Many other devices

Databases & Data Systems

Data Analysis

Quality Ops

Typical IMS

Energy Maint. Supply Chain

Right Data*, Right People, Right Time, Right Decisions



Modeling& Analytics

Platform*

Process Control

Advanced Sensors

SM Technologies

ProcMeasCntrlStatsModelIMS

QualProg

Biz Prog

CorpProg

Supply Chain

Mfg Plant

Biz Unit

SM Project Managerled

Team

Business Functions Initiatives / Programs

Technical / Domain Expertise

Corning’s Successful Execution of SM:Requires Commitment to a Common Vision & Shared Goals

Keys to Success:• Partnerships across Corning • Collaboration amongst multi-disciplinary people

*Edge+Cloud=Fog technology with state-of-the-art Security

We know what we measure…

… We manage what we know

12.


Coupled Process

• Process instrumentation is critical in coupled process, but especially so in a decoupled process• Identify and implement process controls based on quality requirements and process variability• Improve fundamental understanding, monitoring, & control within a plant and from plant-to-plant

Decoupled Process

Leveraging Smart Manufacturing’s Cloud Technology to “Couple” Decoupled Processes

Corning Factory Contract Mfg Factory

Glass Process Step 1

Process Step 2

Final Inspection

Process 1 Setup

Inspection Feedback

Meas &Controls

Inspection Feedback (Very Large Data Sets)

In-Process Meas

Feedback

Model Outputfor Control

Process 2 Setup

Ahrens, Sammaknejad 2016



Evaluating Cloud Based Technologies to Address: Industry data requirements, Multi-locationmfg plans; Large data sets for advanced analytics; and Design for future functionality

Draft-Not Complete Systems Architecture: Prototype SM Tech

Process 1 Setup

Final Inspection

Glass Data

Process Step 1

Process 2 Setup

Process Step 2

Lab Tests

IQA Recipe and Process Data DB

LIMS

Recipe and Process Data Inspection

Data -DB

SM Framework Database - Hadoop

SM Framework Managed Analytics – Hadoop + Others (Tableau, JMP, Custom, etc.)

Workflow Managed Analytics

Data Lake

Data Collection

Distributed Data

Process Flow

SM Framework Database -Hadoop

Decoupled Process

Pastel, Kuhn 2016



Manufacturing Data System Standards are Being Tested

Process Sensors

Process Sensors

Process Sensors

System: ERP – Enterprise Resource PlanningISA 95 Classification: Establishing the basic plant schedule – production,

material use, delivery and shipping. Determine inventory levels.

Time Frame: months, weeks, days

System: MES – Manufacturing Execution SystemISA 95 Classification: Work flow/recipe control to produce the desired end

products. Maintaining records and optimizing the production process.

Time Frame: days, shifts, hours, minutes, seconds

System: SCADA/HMI - Supervisory Control and Data Acquisition / Human Machine Interface

ISA 95 Classification: Monitoring, supervisory and automated control of the production process.

Time Frame: minutes, seconds, milliseconds, microseconds

System: PLC – Programmable Logic ControllerISA 95 Classification: Sensing and manipulating the production process.Time Frame: milliseconds, microseconds

System: Field Devices – Plant instrumentation and controlsISA 95 Classification: The actual production process.Time Frame: milliseconds, microseconds

Bus

ines

s Pr

oces

s Tr

ansa

ctio

nsLe

vel 4 Business Planning

& Logistics Systems

Leve

l 2

Manufacturing Operations &

Control Systems

Batch Controls

Continuous Controls

Discrete Controls

Machine I/O

Machine I/O

Machine I/O

Rea

l-Tim

e C

ontr

ol E

vent

s

Manufacturing Control (SCADA)

Leve

l 3Le

vel 1

Leve

l 0

Manufacturing Process

Lei Yan 2016



IOTfM: Low Cost Sensors a Key Element in Smart MfgProvides Faster Issue Resolution with Real-time Analysis

Image courtesy http://www.telecom-cloud.net/wp-content/uploads/2015/05/Screen-Shot-2015-05-27-at-3.51.47-PM.png

Sensor Needs:• In-situ process

monitoring: Temp, pressure, vibration, etc.

• Facilities and energy monitoring

• Mfg supply chain: impact, location, humidity, context

Methods of Integration:• Network Type: copper,

fiber, wireless (WiFi, Bluetooth, Low Power Bluetooth, etc.) cellular

• Receiver: PLC, PC, other TBD

Considerations:• Secure, noise rejection,

temp and humidity safe, reliable, robust



SMART Manufacturing & IoTfM… Complimentary

Right Data*, Right People, Right Time, Right Decisions

• Starts with making sure you have the right dataà IoTfM• Mfg needs low cost and easy to integrate sensors• Network and data system architecture standards may

need modification• Devices must be reliable, robust, and secure• Facilities and energy, in addition to process and supply

chain have real needs for IoTfM• Develop for brown field and green field mfg• Partnering with the SMLC/CESMI can accelerate

learning, collaborate, go faster, and spend less

ModelingAnalytics

Platform*

Process Control

Advanced Sensors

SM Technologies