SMART MANUFACTURING MAKING AUTOMATION INTELLIGENT Jagdish Rebello PhD Global Vice President MarketsandMarkets
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PRESENTATION AGENDA
WHAT IS SMART MANUFACTURING
KEY TRENDS IN SMART MANUFACTURING
DRIVING FACTORS AND KEY CHALLENGES
SMART MANUFACTURING ADOPTION
CASE STUDIES
KEY TAKEAWAYS
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WHAT IS SMART MANUFACTURING
MORE PRODUCTIVITY
SMART MANUFACTURING IS ALL ABOUT HARNESSING DATA
MORE FLEXIBILITY
Data will tell us WHAT TO DO and WHEN TO DO IMPROVED SAFETY
INDUSTRY 1.0
INDUSTRY 3.0
Age of Steam End of 18th Century
Age of Automation Start of 1970s
Water and steam power used to create mechanical production facilities
Electronics and IT technologies automated the production lines
1800
1900
1970
Age of Electricity Start of 20th Century Mass production line driven by electricity
INDUSTRY 2,0 w w w . m a r k e t s a n d m a r k e t s . c o m
2010…. An Era of Data driven Manufacturing Since 2010
Cloud technology & IIoT and many more
INDUSTRY 4.0 3
RESPONSIVE TO SHORTER LIFE CYCLES
CONTINUALLY RESPONSIVE
Every thing is connected on shop floor Data Communication
• Machine
SUPPLY SIDE
TRANSFORMING THE SHOP FLOOR
• Vendors • Raw Materials
• Products • Manufacturing Process Machine
Any change in consumer preference will be • Reflected in products • Its manufacturing Process Manufacturing Process
Products Data Communication
• Also reflect in supply chain Data Communication
• Vendors
DEMAND SIDE
• Machine which produces it
• End Consumers • Physical and virtual Store
• Raw Materials w w w . m a r k e t s a n d m a r k e t s . c o m
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SMART MANUFACTURING – TRENDS
IMPLEMENTATION OF SOFTWARE Implementation of Predictive maintenance • Big data; Cloud computing; Analytical Software's
AUTOMATING AND CONNECTING Automating and connecting every vertical within the factory floor • Process Flow • Material Flow
MATERIAL FLOW
Helps us in knowing where every material and product is within the factory floor • Preciously plan the production process • Makes work place safer • Place the right kind of tool at right place at right time
AUTONOMOUS MACHINE Autonomous machines and equipment's • Automated Guided Vehicles (AGV) • Robots; Industrial Robots; Collaborative Robots
AR AND VR Implementation of Augmented Reality (AR) and Virtual Reality (VR)
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SMART MANUFACTURING – DRIVING FACTORS
IMPROVEMENT IN TECHNOLOGY
• Huge improvement in the technology, especially with regards to data generation, communication, data collection, and computing power
ROBOTICS SYSTEMS
GOVERNMENT SUPPORT
EMBEDDED SYSTEMS
• Growth and implementation of Robotics systems in the manufacturing systems
• Government support with regards to the implementation of Smart Manufacturing
• Machine manufacturer and developer has started embedding systems right at the concept phase
• Industrial Robots; Collaborative Robots
• China, South Korea, India, Germany, U.S.
• Sensors • Communication Technology
• Cost of computing has decreased to a large extent • Drastic decrease in the cost of data storage • Ability of connect and integrate has become much easier and simpler than before w w w . m a r k e t s a n d m a r k e t s . c o m
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SMART MANUFACTURING – DECREASE IN THE COST OF COMPONENTS
SOLID STATE DRIVE – DECREASE IN COST PER GB
$0.99 per GB
Declining IoT Sensor Cost
$0.7
$0.48
$0.17 per GB
2012
2013
2014
2015
2016
2017
2012
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2013
2014
2015
2016
2017
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SMART MANUFACTURING – CHALLENGES
HUGE INITIAL COST Huge initial implementation cost, which will be compensated in the coming futures in terms of increased productivity
COMPATIBILITY Compatibility issues between technology, equipment, and communication protocol
SECURITY ISSUES
POLITICAL ISSUES
MONUMENTAL TASK
Security is important, specially in the critical process; the companyis implementing smart manufacturing at their production floor; technology gives access to deep dive into the data
Constant pressure from government in many country to either maintain or add the manufacturing Jobs
Implementation of sensors and other communication technology and its management may create huge IT glitches
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IMPLEMENTATION Implementation of smart manufacturing concept is major challenge – especially when manufacturing facility is old compared with the newer facilities
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SMART MANUFACTURING – ELEMENTS OF THE ECOSYSTEM
Data Communication
INDUSTRIAL ROBOTS
INDUSTRIAL 3D PRINTING
117.4
Sensors
2016
Data Communication
2022
System Integrator
Sensors
1.0 2022
2016
System Integrator
SMART MANUFACTURING
2022
79.1
0.7
130.3 64.8
0.1
28.7
Sensors 2022
CLOUD, CYBER SECURITY AND PLATFORM AS A SERVICES
4.0
Data Communication
40.5
2016
AUGMENTED REALITY
4.8
79.6
2016
Data Communication
Sensors 2016
Data Communication
2016
2022
INDUSTRIAL INTERNET AND COMMUNICATION
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Data Communication
2022
BIG DATA, ANALYTICS, AND SOFTWARE
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ENABLING TECHNOLOGIES – STRONG GROWTH
Industrial Robotics Market & Forecast (USD Billion)
INDUSTRIAL ROBOTICS
75.99 2016
40.38
2022 3.59
0.12 Traditional Industrial Robots
Collaborative Industrial Robots
Industrial Communication Market & Forecast (USD Billion)
INDUSTRIAL COMMUNICATION
59.2
56.27
2016
37.73
2022
23.29 3.75 Fieldbus
Industrial Ethernet
Wireless
Asset Management Market & Forecast (USD Billion)
ASSET MANAGEMENT 7.72
4.64
5.76
Source: MarketsandMarkets
6.71
5.36 2.38
Barcode
14.87
GPS
2.23
RFID
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1.71
2016 2022
RTLS
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ENABLING TECHNOLOGIES – STRONG GROWTH
Augmented Reality Market & Forecast (USD Billion)
Augmented Reality Market 117.40 2016 2022 4.0 Augmented Reality Devices
Manufacturing Execution System Market & Forecast (USD Billion)
MANUFACTURING EXECUTION SYSTEMS
11.59 2016 6.63
5.26
2022
3.23
Services
Software
Industrial 3D Printing Market & Forecast (USD Million)
INDUSTRIAL 3D PRINTING
1.82
1.63 2016 0.96
0.43
Printer
Source: MarketsandMarkets
0.298 Material
0.225 Service
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2022 0.069
0.34
Software
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SMART MANUFACTURING – VALUE CHAIN
ASSET MANAGEMENT
INDUSTRIAL ROBOTICS
3D PRINTING
COMMUNICATION
Datalogic S.P.A.
ABB LTD.
General Electric Company
ABB Ltd.
Honeywell International Inc.
Fanuc corporation
Hitachi Data Systems
General Electric Co.
Sato Holdings Corp.
Kawasaki Heavy industries
Ubisense Group
Mitsubishi Electric Corporation
Honeywell International Inc.
Schneider Electric SE
Zebra Technologies Corp.
Yaskawa Electric Corp.
Microsoft Corporation
Siemens AG
Siemens AG
TE Connectivity Ltd.
Corporation
Rockwell Automation, Inc.
SMART MANUFACTURING
ABB Ltd. General Electric Co. Mitsubishi Electric Corporation Rockwell Automation, Inc. MACHINE BUILDERS
CLOUD AND BIG DATA
SENSORS
AR AND VR
Schneider Electric SE Siemens AG Yokogawa Electric Corporation
DMG Mori
General Electric Co.
Infineon Technologies AG
Daqri LLC
Komatsu NTC
Hitachi Data Systems
NXP Semiconductors N.V.
EON Reality, Inc
Robert Bosch GmbH
Google Inc.
Mitsubishi Electric Corporation
Corporation
Okuma Corporation
Honeywell International Inc.
STMicroelectronics
Infinity Augmented Reality Inc.
Samsung Machine Tools
Microsoft Corporation
TE Connectivity Ltd.
Schneider Electric
Siemens AG
Texas Instruments Inc.
Oculus VR, LLC
Microsoft Corporation
Siemens
Qualcomm Inc.
TRUMPF
Samsung Electronics Co., Ltd.
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SMART MANUFACTURING ADOPTION TRENDS PROJECTED GEOGRAPHY AND INDUSTRY VERTICAL MARKET FOR SMART MANUFACTURING MAJOR COUNTRIES RAPIDLY ADOPTING AND DEPLOYING SMART MANUFACTURING TOP ADOPTERS: INDUSTRY VERTICALS
Canada U.K.
Poland
Germany
Oil and Gas
Japan
U.S.
Chemical
Food and Beverages
South Korea Saudi Arabia & UAE
Mexico
Brazil
Taiwan
CPU
Vietnam India
Automotive Manufacturing
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Machine Manufacturing
Electronics and Semiconductor
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SMART MANUFACTURING –ROBUST GROWTH
80 70
USD Billion
60 50 40 30 20
45.57
49.85
2016
2017
54.38
59.15
64.18
69.19
74.8
10 0 2018
2019
2020
2021
2022
Note: Market size is based on Technology and component implemented in a smart manufacturing facility. Technology segment includes PLM, MES, PLC, SCADA, ERP, DCS, and HMI; and component segment includes sensors & actuators , communication technologies, industrial robotics, machine vision, control devices, and control valves
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CASE STUDY – SMART MANUFACTURING
FEW INITIATIVES TAKEN BY MAJOR MANUFACTURING COMPANIES
“ Facility is considered to be the one of the most advanced automobile manufacturer facility It is expected to help in optimizing the entire process chain and its operation 30% faster Smart factory equipped with modern equipment and highly efficient logistics will help to achieve annual production volume of 150,000 Audi Q5 vehicles
Audi has started its advanced manufacturing plant in Mexico
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CASE STUDY – SMART MANUFACTURING
“ Important feature of the said facility is the implementation of 3D printing to develop next generation fuel nozzles This technique will develop fuel nozzle 25% faster and will be five time stronger Anticipated to develop 100,000 next generation fuel nozzles by 2020 Helps GE to develop approximately 44,000 fuel nozzle per year
General Electric recently opened smart manufacturing facility (2nd phase) in Chakan near Pune in India
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SUMMARY & CONCLUSIONS
• Data will command the entire manufacturing operation • Will create flexibility and customizability in manufacturing environment
• Implementation of smart factory will not happen in few days • Will need various technologies to come together in order to complete the ecosystem
• New set of trained workforce is required at the smart manufacturing facility • Skills required will be changes in software engineering, data management, and IT networking • Government is emphasizing either retain or add the workforce
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SMART MANUFACTURING CURVE AND MNM’S COVERAGE
Supervisory Control and Data Acquisition
Manufacturing Execution System
Level Transmitter
Micro Nano PLC
Leak Detection Control Valve
TECHNOLOGY MATURITY
Industrial Safety Intelligent Flow Meter Industrial IIoT Industrial Communication
Industrial PC
Machine Safety Advanced Process Control Market Plant Asset Management Digital Substation Water Automation
Internet of Robotic Things (IoRT)
Industrial Augmented Reality Digital Manufacturing Immersive Training Simulator
HORIZON
Industrial 3D Printing
ASCENT
ZENITH
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PLATEAU
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THANK YOU! Jagdish Rebello Phd
[email protected] &
Pankaj Raushan
[email protected]
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