2017 NAE-AAES Convocation of the Professional Engineering Societies
April 24, 2017
Jim Davis
CESMII
VP IT CTO UCLA
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Smart ManufacturingSimply Stated
The Operational Business and Technology Practice of radically increasing the application of real-time data
throughout the manufacturing enterprise and changing the operational structure
The right data in the right form, the right people with the right knowledge, the right technology and the right
operations, whenever and wherever needed throughout the manufacturing ‘enterprise’
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Smart ManufacturingA Term of Practice
• Enterprise integration to realize untapped market , productivity and performance opportunities
• Real-time Data and Modeling to qualify materials, parts, properties, assemblies and drive real-time precision
• Operational Practices (A Vocabulary of Practices: intensification, virtualization, modularization, qualification and optimization) to achieve value in an increasingly customized product space with accelerated demand dynamics
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Secure I, P and SaaS
Secure Data Highways
Data & Device Integration &Orchestration
Smart Factory ManufacturingAnalytics
Smart EnterpriseManufacturing Integration
Smart Manufacturing, IoT and IIC
Collaborative Innovation &
Practice
Converting Datato Information
Converting Informationto Knowledge
Converting Knowledge toManufacturing Intelligence
IoT, IIC
Big Data
Smart
Collective Manufacturing Intelligence
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Manufacturing Vertical• Static physical facilities• Legacy operations• Always operating• Need to qualify moving product• IP in product & operations• Highly compartmentalized• Highly Heterogeneous• High risk profile
CESMIIA National Network of Capability
Headquartered in LA
California
Northwest
Northeast
Southeast
Gulf Coast
HQ
C L E A N E N E R G Y S M A R T M A N U F A C T U R I N G I N N O V A T I O N I N S T I T U T E
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TM
REVENUE, GROWTH & REINVESTMENT
Precision, Productivity, Product SpaceEnergy a Material Cost
CESMII’s goals:• Double energy productivity in US
manufacturing every 10 years• Halve the cost of deploying SM systems
relative to state of the art in 5 years• Increase the SM workforce in US multi-
fold in 10 years• Double the SM technology supply chain
rate of increase in value and participation
• Reduce U.S. energy use in 10 years while increasing manufacturing competitiveness
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OEMCollaborative &
Network-Based, Smart Manufacturing
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Supply ChainDistribution Center
Customer
Business Systems, ERP
Smart Grid
Smart Factory
Connected Supply Chain
•Agile
•Demand Driven
•Raw Material to Finished Product
Energy Efficient
•Lower emissions
•Less energy used
•Green manufacturing
Safe Production
•Improved safety
•Fewer incidents
•More user friendly
•Higher value products
•Data for decision making
•Product Lifecycle Management
Sustainable Production
5
Optimization
•Asset Utility/Zero Downtime
•Quality/Zero Defects
•Reliable results
Dir
ect
Co
nsu
mp
tio
n
Core Systems
Data Input
Core Functions
Raw
Mat
’lIn
ven
tory
Fin
ish
ed
Pro
du
ct
Inve
nto
ry
Pro
du
ctio
n
His
tory
Pla
nt
Flo
or
Inve
nto
ry
Dem
and
Pla
nP
rod
uct
ion
O
rder
Lin
e Sc
hed
ule
MQIS MES SAP ERP Red PrairieSAP APO SAP PLMSAP MRP
Value Creation Green Light to Convert
Green Light to Ship
Demand Driven Supply Chain
Wo
rkFl
ow
Lot
Trac
kin
g
Overusage
Op
tim
izat
ion
En
gin
e
Trace/Recall BOM Validation Yard Mgmt
Optimized Inventory
Business ApplicationsDirected Work
Supplier Managed Inv Line Supply Bin MgmtAllergen/Micro WorkFlow eCOA
What Got Us Here Won’t Get US There
© 2014 General Mills
Master Data (BOM,Specs,Vendor,Ingredients,FP)
General MillsEco System of
STUFF
First Steam Methane Reformer Furnace
Port Arthur, TX
• Already efficient
• Distributed sensing
• Distributed actuation (96 burners)
• High fidelity model & reduced order models
Simple Model
HPC Model
Burner Controls
ReduceCameras
reduction wasted energy
reduction wasted energy
Halve capital costDynamic energy
management
Metrics
Extend to
20 U.S.SMRs
Praxair
Intensification through Measurement &
Operational Integration
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Business Virtual Enterprise &
Distributed Asset Modularization
Production and Delivery Production and Delivery
Operations
Port Arthur TX 2nd Location Production on Demand
Enterprise thinking: virtual enterprise model that
incorporates physical assets as components to execute
production
Steel
Energy
Bio/Pharma
Electronics
Healthcare
Customers
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Production on Demand & Intensification
Part Tolerances
Improved gas flow controlRecuperation
Part Properties3D Radiation
Dynamic machine configuration
Reduceidle time
Reducedefects
destructivetests
Integrated line management of part precision, materials/metallurgical properties, dynamic part movement, defect reduction, energy management
General Dynamics Scranton, PA
Predictive Maintenance
Partquality
Partquality
Partquality
Reducedefects
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16
VariableContracts
Billetquality
PATTERNS OF APPLICATION
Enterprise Thinking and Practice
Corning – modularize (integrate) upstream supplierLA & Orange County – small metals, food & apparel utility demand-response/
renewablesPfizer – micro reactors for product customization qualificationAlcoa – real-time optimization of sheet & plate manufacturing
flow pathsOver 90% manufacturing in SME’s
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Vocabulary of SM Practice
Modularization, Intensification Virtualization & Optimization with Sensors, Controls, Platforms & Modeling
SM Value propositions– Intensification– Production on demand– Customization and value add in the trade space– Supply side management and chain of custody– Portable continuous miniaturization– Distributed modularization & ecosystems– Business virtualization & asset modularization– Modularization and scaling flexibility
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Corning’s SMART Manufacturing
• Cloud computing for mfg &
supply chain
• State of the art Cyber Security
• Access to Adv. Data Analytics &
real-time Predictive Modeling
• Advanced Controls, sensors
and newer technology (AI, ML)
• New data Visualization tools
• Reduce cost w/ open platforms
& collaborative biz models
SMART MfgToday’s Integrated Mfg Systems
Right Data*, Right People, Right Time, Right Decisions
2017 Corning Incorporated
SM Provides New Value Streams for Corning:
Information Seamlessly Connected
Across the SupplyChain
Vendor Agnostic Supply Chain Data Sharing
…
…………………
1st Factory
“Supplier/Corning”
2nd Factory
“Contract/Corning”
3rd Factory
“Customer”© 2017 Corning Incorporated
Product with
Contextual
Data
OT
& I
TS
yste
ms
Data
Sh
arin
g
OT
& I
TS
yste
ms
Data
Sh
arin
g
…………
OT
& I
TS
yste
ms
Data
Sh
arin
g
Operational Space of Seams, Time, Data & ActionSweet Spot for Operational Modularization & Intensification
Machines – People - Materials Dynamic Manufacturing Ecosystem
Systems Integration & Engineering
Analysis/Evaluation
Training ValidationIn
Service
Multiple Pass Variability Reduction
Supply Chain Performance
Time – minutes/
mseconds
Time – hours/minutes
Time – days/hours
Bu
sin
ess
Sys
tem
s
Co
ntr
ol &
A
uto
mat
ion
Event Variability/Tradeoff Adjustment; Dynamic
Performance; Integrated Metrics
Tolerance & Resilience
Qualification;
ICME, High Fidelity
Precision
Macro
Meso
Micro
Data/Design
Smart Manufacturing Practice and Reusability
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One-off, Proprietary, On PremiseWill not Get Us There
This is not secure
Data Assets
Analytics Provider Product 2
Visualization
On PremiseData Compute
Data Model
Data Config1
Data Config2
ModelingProvider Product 1
Data Assets
Analytics Provider Product 2
Visualization
On PremiseData Compute
Data Model
Data Config1
Data Config2
ModelingProvider Product 1
Operation 1 Operation 2
Transaction
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Span Heterogeneous EnvironmentOn-premise – Off Premise – On Premise
Maintain State
SM PlatformData Structure
Data Assets
ModelingProvider Product 1
Analytics Provider Product 2
Visualization Enterprise Workflow
Contextualized Data Steps Modeling & Analytics Steps
On PremiseEdge Data Compute
Data Model
Data Config
Data Config
Don’t Reinvent Discretize and ReuseSecurity at Business Granularity© SMLC, Inc. All rights reserved.
Spin Up Multiple ProjectsReuse Data & Application Configurations
SM PlatformData Structure
Data Assets
Contextualized Data Steps
On PremiseEdge Data Compute
Data Model
Data Config Oats
Data Config Dairy
Data Config xxx
Workflow
Analytics 2
Modeling 1
Visualization
EMS
Access to data from Application ContainerPublic/Private Key Trust relationship
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Systems Infrastructure for Smart Manufacturing Practice
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Cloud & Enterprise Virtualization ServicesData to Applications
Physical & Cyber reusability
Applications
Context
Data
Mapping
Calibration &Maintenance
Production Models
Sensor Data
Time Series
Event Data
Traditional Manufacturing Automation Environment and Software Tools
Private Smart Manufacturing
Platform Appliance
PaperSteel
MetalsGlassFood
Micro electronicsIndustrial gas
CoatingsPlastics
Composites
Smart Manufacturing Platform Open Infrastructure
• SM Software Marketplace• APPs & Toolkits
• Compose Workflows• Cloud Deployment• Private/Public IaaS
SM Value Proposition
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SM Platform Infrastructure
• Certified app ‘configurations’
• Search Engine• Compose and reuse• IoS for manufacturing• DevOps for
manufacturing• Data to Applications• Trusted Data,
Marketplace, End-to-end State Services
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Open Architecture – Vendor AgnosticOpen Access – low cost & easy to useOpen Market Place – composablesoftware libraries & dataOpen Market Place - InnovationTrusted Data Broker
Secure I, P and SaaS
Secure Data Highways
Data & Device Integration &Orchestration
Smart Factory ManufacturingAnalytics
Smart EnterpriseManufacturing Integration
Build a Business Model
Collaborative Innovation &
Practice
Converting Datato Information
Converting Informationto Knowledge
Converting Knowledge toManufacturing Intelligence
Data ValuationCollective vs.Proprietary
Practice ValuationCollective vs. Proprietary
IoT
Big Data
Smart
Collective Manufacturing Intelligence
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Build a Rich MarketplaceReusable Configurations
Core Deployment ServicesTrusted Data Services
30
Security; Machine & Human Interfaces; Virtual Compartments; Interoperability; Standards
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Ansys Fluent
Single, multi,full tube models
Company config
Converged reference model
Company dataconfig
OSISoft
SMR data config
Cloud Integration ServicesIndustry Marketplace
Reusable Configurations
Smart ManufacturingReinvestment Potential
A Comprehensive Approach to Manufacturing
At the Intersection• Workforce Productivity• Business & Product Agility• Supply Chain Agility & Optimization• Asset Management and Risk• Product Lifecycle• Energy & Material Productivity• Environment, Sustainability & Safety
Next Generation IT for Next Generation Manufacturing
• Make Data a Key Asset• Advanced Real-Time Sensing,
Controls, Platform and Modeling
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