IOT and Digital Manufacturing The new evolution Alexis Malchair - - PowerPoint PPT Presentation

Alexis Malchair Solutions Sales Manager, Internet of Things June 2016

IOT and Digital Manufacturing

The new evolution

Digitization Trends Across Major Industries

ENABLE NEW BUSINESS MODELS

Create recurring revenue models with increased customer intimacy

TRANSFORM BUSINESS PROCESSES

Higher productivity by predictive maintenance and better asset utilization Smart Manufacturing Grid Modernization Shopper Insights

IoT Enabling Transformation

Smart Cities Connected Transit Smart Space

Where is the value

Connect the Unconnected 50Billion

Smart Connected Devices by 2020

Hyper-connectivity, IT and OT convergence Interoperability across silo’ed systems required to capture 40% of IOT value <1% of data currently used, more can be used for optimization and prediction Over 60% of the IOT value will be generated in Enterprise deployments

Source - McKinsey: The Internet of Things: Mapping The Value Beyond The Hype

CONTROL ACT AUTOMATE

IoT: The Internet of Things

Sensors Connectivity Analytics & insights Processes & integration

Christian Horner Team Principal, Infiniti Red Bull Racing

“The network will play a crucial part in how we develop the car; gathering data, learning from it and adapting will ultimately determine our season.”

A New Industrial Revolution

Digitizing Manufacturing to Capture the Value of the Internet of Everything 18th Century Steam 20th Century Mass Production 70’s Robots Today Digitization

Technology Progress Smart Devices

Digital Manufacturing Priority Investments #1 Analytics | #2 Connectivity | #3 Automation | #4 Mobility

Source: SCM World/Cisco “Smart Manufacturing & the Internet of Things 2015” survey of 400 Manufacturing Business Line Executives and Plant Managers across 17 vertical industries.

Design principles for Industry 4.0

• There are 6 design principles
• 1. One open standard for communication
• 2. Virtualization and simulation models of production
• 3. Flexible and decentralised control
• 4. Capability to collect, process and store data in real time
• 5. Service possibillities over the network
• 6. Modular and flexible production for fast adoption and small seriespå produkt

Reduction in Defects

49%

Defect rate down from 4.9% to 2.5%

Reduced Downtime

48%

Unplanned downtime down from 11% to 5.8%

OEE Improvement

16%

Average OEE improved from 74% to 86%

Improved Inventory

35%

Inventory turns increased from 14 to 19

Reduction in Energy Use

18%

Annual energy cost down from $8.4M to $6.9M

The Real Economic Value is Immense

New Product Introduction

23%

New product introduction cycle time reduced from 15 to 11

Source: SCM World/Cisco “Smart Manufacturing & the Internet of Things 2015” survey of 400 Manufacturing Business Line Executives and Plant Managers across 17 vertical industries.

Digital Manufacturing Driving Business Outcomes

Disruptive Trends in Manufacturing

Security Convergence Convergence (industry 4.0, Industrial Internet Consortium)

• Network integration between machine and factory
• Factory network integrates with the enterprise network
• Single network platform

Increased focus on Services by OEM’s

• Customer demand for high availability and uptime
• Take control of after market for parts and tools
• Remote connectivity and monitoring to reduce service costs
• Zero touch deployment and provisioning

Data Driven Manufacturing

• TQM: Real time quality control with in-line re-work
• Real time operator visibility with OEE alerts from OEM
• Flexible cell manufacturing, rapid re-tooling

Secure Operations and Machines

• Operations needs IT to address security
• Security strategy drives new business and partnership models
• Framework approach to address organization boundaries

Manufacturing Data Cloud Services Smart Industry

9

IOT

Standard topology

Ethernet/IP, Profinet or any standard Ethernet protocol Real–Time Control Fast Convergence Traffic Segmentation and Management Managed switches Site Operations and Control Multi-Service Networks Network and Security Management Routing Application and Data share Access Control Threat Protection

Gbps Link for Failover Detection Firewall (Active) Firewall (Standby) HMI Scada Application Servers Cisco ASA 5500 Cisco Catalyst Switch Network Services Cisco Catalyst 6500/4500 Cisco Cat. 3750 Switch Stack Patch Management Terminal Services Application Mirror AV Server Cell/Area #1 (Redundant Star Topology) Drive Controller HMI Distributed I/O Controller Drive Drive HMI Distributed I/O HMI Cell/Area #2 (Ring Topology) Cell/Area #3 (Linear Topology) Layer 2 Access Switch Controller

Enterprise/IT Integration Collaboration Wireless Application Optimization Cell/Area Zone Levels 0–2 Layer 2 Access Manufacturing Zone Level 3 Distribution and Core Demilitarized Zone (DMZ) Firewalls Enterprise Network Levels 4–5

Web Apps DNS FTP

Internet

Cisco Validated Ethernet Architecture

Supply chain

Factory IT in a Box

Fog-Edge Cloud

Core Data Center

Backup & Replication Backup & Replication Management Centralized

SW/HW Machine Adapter

Connected Machine service model

Machine monitoring Machine as a Service

green light, utilization, OEE streaming analytics Zero Down Time like Services Condition based Monitoring New OEM services models w/ SLA’s Machine, Process, & Quality Optimization Advanced Analytics Cloud or Data Center Manufacturing Plant

Connected Machines

Rapid Provisioning IT/OT Interface, security

Network Hosted OPC MTConnect IoT SW Agents 1:1 machine 1:1 cell 1:1 Plant Plant Level Systems OEM MES Quality OEE Plant Perimeter FW DPI Policy Data Center Perimeter FW DPI Policy Data Store Applications Analytics Visualization

1 Persiste sistent Secure Connect ction Transa sactio ction/S /Str treaming Utilizat izatio ion OEE Machine ine Applica cation (ZDT DT, , Advance ced Quality ity Monito itoring, Advance ced Analyt ytics) cs) IT/O /OT, , Security, ity, NAT

Plant Network Plant Systems IoT Platform embedded/cell Distribution