Coming up next – An introduction to Industrie 4.0 Simon Barnes Commercial Director High Speed Sustainable Manufacturing Institute Mob: 0778 712 0660
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Industry 4.0 - Manufacturing Digital Learning to speak a new language Simon Barnes – Commercial Director HSSMI
HSSMI’s Landscape for Collaborative Manufacturing Research and Deployment The ‘Valley of Death’
Launch
Experiment Validate Materials
Improve
Technology
Principles
Logistics Digital
Process
Academia
Catapults
Sustainable
HSSMI
High(er) Speed
Production Solution Providers
Manufacturing
Examples of collaborative partners:
Funding Sources
2016
Manufacturer
Looking back – the language of old
Learning the new
Industry 3.0
Industry 4.0
Automation
Digitalisation
Mass Production
Value Chain
Industry 4.0
“Smart factories in which machines are augmented with web connectivity and connected to a system that can visualize the entire production chain and make decision on its own.” (Forbes – Bernard Marr – 4/5/2016)
Forecast of Industrial Internet (II) Sensors ($ Million) 16000.00
14000.00
Industrial and Commercial (dark blue) Electricity (grey) Factory Automation (light blue)
12000.00 10000.00 8000.00 6000.00 4000.00 2000.00 0.00 2014
2019
Source: NanoMarkets report, “Markets for Sensors in the industrial internet”
2021
DATA / STORAGE MIGRATION FROM CLASSIC TO VIRTUALISED AND CLOUD ENVIROMENTS
PERCENTAGE OF STORAGE DEPLOYED [%]
60
50
Traditional / Classic
40
Virtualised server
30
Internal private cloud 20
External cloud 10
0
2011
2012
2013
2014
2015
Source: Managing Storage: Trends, Challenges, and Options (2013-2014). (EMC, 2013)
The Untapped Big Data Gap (2012)
THE DIGITAL UNIVERSE: 50-FOLD GROWTH FROM THE BEGINNING OF 2010 TO THE END OF 2020
25%
23%
20%
45,000
40,000
EXABYTES OF DATA
35,000
15%
30,000 25,000
10%
20,000 15,000
5%
10,000
3% 0.5%
5,000 0%
Source: IDC’s Digital Universe Study, sponsored by EMC, December 2012
2020
2019
2018
2017
2016
2015
2014
2013
2012
2011
2010
2009
0
Useful If Tagged and Analyzed
Tagged
Source: IDC’s Digital Universe Study, sponsored by EMC, December 2012
Analyzed
2016
Customer
Innovation
Planning and New Business Models
Product development
Supplier alignment
Service
Sales Marketing
Distribution
Assembly Manufacture
Components
Raw Materials Manufacturing
Manufacturing – responding to the Value Chain challenge Supply Chain
Value Chain
Industry 4.0 hierarchy – progressing your plans Level 1: Data capture – Capture of data related to machines, production performance, facilities and operator across the value chain
Level 2: Connectivity and visualisation – Connect the relevant data to create a “single source of truth” / digitally map the production processes with the digital representation Level 3: Interpretation – big data, data analytics for production planning, maintenance, training Level 4: Pre-emptive decision making / new business opportunities – production scheduling, “self-healing” or self-maintaining system, …
Data readiness
Challenges for implementation: Data ownership / integration – who owns the data when third parties are involved, how can the data be integrated People – cross-sectional coordination is necessary, new skills and talents are required Cyber-security – Sharing information may conflict with existing IT policies, Openness must not pose a data security risk to the organisation Return on investment – Business case needs to be defined to justify the expense
Collaboration
Interaction and integration with different sectors, suppliers and customers Share relevant and dedicated information across the company and supply chain– increase efficiency
Digital to Information
Creating a company knowledge pool with a single source of truth Usage of generic data for factory and product templates Visualisation of relevant information
Digital-Physical Integration
Data analytics as driver to increase maintenance efficiency, productivity, quality, energy efficiency Integrate physical and digital data Visualise relevant information
Industry 3.0
Industry 4.0
Industry 5.0
Automation
Digitalisation
Imagineering ?
Mass Production
Value chain
Distributed manufacturing ?
Simon Barnes
[email protected]
Liverpool 28th June Siemens, Sony, PWC, WMG, Mentor RTLS
Industry 4.0 - Manufacturing Digital Learning to speak a new language Simon Barnes – Commercial Director HSSMI
HSSMI’s Landscape for Collaborative Manufacturing Research and Deployment The ‘Valley of Death’
Launch
Experiment Validate Materials
Improve
Technology
Principles
Logistics Digital
Process
Academia
Catapults
Sustainable
HSSMI
High(er) Speed
Production Solution Providers
Manufacturing
Examples of collaborative partners:
Funding Sources
2016
Manufacturer
Looking back – the language of old
Learning the new
Industry 3.0
Industry 4.0
Automation
Digitalisation
Mass Production
Value Chain
Industry 4.0
“Smart factories in which machines are augmented with web connectivity and connected to a system that can visualize the entire production chain and make decision on its own.” (Forbes – Bernard Marr – 4/5/2016)
Forecast of Industrial Internet (II) Sensors ($ Million) 16000.00
14000.00
Industrial and Commercial (dark blue) Electricity (grey) Factory Automation (light blue)
12000.00 10000.00 8000.00 6000.00 4000.00 2000.00 0.00 2014
2019
Source: NanoMarkets report, “Markets for Sensors in the industrial internet”
2021
DATA / STORAGE MIGRATION FROM CLASSIC TO VIRTUALISED AND CLOUD ENVIROMENTS
PERCENTAGE OF STORAGE DEPLOYED [%]
60
50
Traditional / Classic
40
Virtualised server
30
Internal private cloud 20
External cloud 10
0
2011
2012
2013
2014
2015
Source: Managing Storage: Trends, Challenges, and Options (2013-2014). (EMC, 2013)
The Untapped Big Data Gap (2012)
THE DIGITAL UNIVERSE: 50-FOLD GROWTH FROM THE BEGINNING OF 2010 TO THE END OF 2020
25%
23%
20%
45,000
40,000
EXABYTES OF DATA
35,000
15%
30,000 25,000
10%
20,000 15,000
5%
10,000
3% 0.5%
5,000 0%
Source: IDC’s Digital Universe Study, sponsored by EMC, December 2012
2020
2019
2018
2017
2016
2015
2014
2013
2012
2011
2010
2009
0
Useful If Tagged and Analyzed
Tagged
Source: IDC’s Digital Universe Study, sponsored by EMC, December 2012
Analyzed
2016
Customer
Innovation
Planning and New Business Models
Product development
Supplier alignment
Service
Sales Marketing
Distribution
Assembly Manufacture
Components
Raw Materials Manufacturing
Manufacturing – responding to the Value Chain challenge Supply Chain
Value Chain
Industry 4.0 hierarchy – progressing your plans Level 1: Data capture – Capture of data related to machines, production performance, facilities and operator across the value chain
Level 2: Connectivity and visualisation – Connect the relevant data to create a “single source of truth” / digitally map the production processes with the digital representation Level 3: Interpretation – big data, data analytics for production planning, maintenance, training Level 4: Pre-emptive decision making / new business opportunities – production scheduling, “self-healing” or self-maintaining system, …
Data readiness
Challenges for implementation: Data ownership / integration – who owns the data when third parties are involved, how can the data be integrated People – cross-sectional coordination is necessary, new skills and talents are required Cyber-security – Sharing information may conflict with existing IT policies, Openness must not pose a data security risk to the organisation Return on investment – Business case needs to be defined to justify the expense
Collaboration
Interaction and integration with different sectors, suppliers and customers Share relevant and dedicated information across the company and supply chain– increase efficiency
Digital to Information
Creating a company knowledge pool with a single source of truth Usage of generic data for factory and product templates Visualisation of relevant information
Digital-Physical Integration
Data analytics as driver to increase maintenance efficiency, productivity, quality, energy efficiency Integrate physical and digital data Visualise relevant information
Industry 3.0
Industry 4.0
Industry 5.0
Automation
Digitalisation
Imagineering ?
Mass Production
Value chain
Distributed manufacturing ?
Simon Barnes
[email protected]
Liverpool 28th June Siemens, Sony, PWC, WMG, Mentor RTLS
