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INDUSTRY 4.0:
Ron StuverDirector, Business Consulting, Industry 4.0
Make It Real
PRESENTER
October 24, 2019 Ron Stuver | SICK, Inc. 2
Ron StuverDirector, Business Consulting, Industry 4.0SICK, Inc.
Professional Background:• US Army Officer• Rockwell Automation (Allen-Bradley, Rockwell Software)• Consulting firm (Business Strategy, ERP Consulting)• Rockwell Automation• SICK, Inc
AGENDA
Defined
• Understanding Industry 4.0
Value• What can Industry 4.0 do for me
Data• Data is everywhere
Journey
• Example Use Case: What is the path to achieving value
October 24, 2019 Ron Stuver | SICK, Inc. 3
HOW OUR WORLD (HAS) WILL CHANGE
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DIGITAL EVERYWHERE IN OUR LIVES
Digital NativesGeneration Online
online access from everywhere configurable and personalized immediate availability
HOW OUR WORLD (HAS) WILL CHANGE
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DIGITAL EVERYWHERE IN OUR FACTORIES
Digital NativesSmart Manufacturing
Connectivity - access from everywhere Immediate or Analytical Diagnostic / Predictive / Prescriptive
INDUSTRY 4.0
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THE FOURTH INDUSTRIAL REVOLUTION
Late-1700’s Late-1800’s 1970/80’s Early-2000’s
TERMINOLOGY
October 24, 2019 Ron Stuver | SICK, Inc. 7
The use of computer systems to optimize the manufacturing process. This would be aligned with the 3rd industrial revolution.
Digital Manufacturing
The Industrial Internet of Things is a sub-set of IoT and represents the technology and devices that are networked / connected within manufacturing industries.
IIoTThe Internet of Things represents technology and devices in our lives that are connected and allows interaction and the exchange of data.
IoT
A trend in industrial automation that involves the assembly and connectivity of technologies in a manufacturing environment to support flow and exchange of data. The I4.0 term originates in Germany used to define high-tech strategy promoting computerization of manufacturing.
Industry 4.0A physical facility that is highly automated and incorporates I4.0 concepts.
Smart Factory
A broad term that provides an umbrella definition to the optimization of the manufacturing processes via the use of automation supporting the use of data throughout the product life-cycle. Often used in the U.S. interchangeably with the term Industry 4.0.
Smart Manufacturing
TERMINOLOGY
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SIMPLIFIED
Digital Manufacturing
IIoT IoT
Industry 4.0 Smart Factory
Smart Manufacturing
Computerization / 3rd Industrial Revolution
Things that are on the Internet!
Digital Manufacturing
IoTIIoTSubset of IoT“Industrial” things that are on the Internet!
Industry 4.0
Term originates in GermanyAssembling + Connecting technologyFlow + Exchange of DATA!
Smart FactoryFacility incorporates I4.0 concepts
Smart ManufacturingUmbrella term used in U.S.Flow of DATA throughout product life-cycle
INDUSTRY 4.0
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DATA IN THE SUPPLY CHAIN
R&D → Product• Item Num• Product Specs• Raw Materials
Create → Product• Status• Quality• OEE• Machine Setup
Store/Move → Product• Inventory• Orders• Delivery
Sell → Product• Product• Price• Profile
Data Flows Thru The Supply Chain
HARNESSING THE VALUE
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DATA + INDUSTRY 4.0
PRODUCTIVITY
COMPLIANCE
RELIABILITY
PREVENTATIVE MAINTENANCE
HARNESSING THE VALUE
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DATA + INDUSTRY 4.0
Homeland Security Research (www.hsrc.biz)
• 4.1% cost reduction (manufacturing efficiencies and improved value chain management )
• 3.0% revenue increase (driven by customized products, predictive maintenance, and additional services)
• Most assume a two-year full Return on Investment (ROI) and enormous long-term gains
HARNESSING THE VALUE
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DATA + INDUSTRY 4.0
Homeland Security Research (www.hsrc.biz)
“the Industry 4.0 market is projected to reach $214B by 2023”
“the Industry 4.0 revolution will be driven by an ensemble of emerging technologies, such as Industrial Internet of Things (Industrial IoT), Big Data analytics, advanced industrial robots, Artificial Intelligence (AI) and predictive maintenance.”
• 63% of the respondents stated that their business future depends on the Industry 4.0 Transformation
• 88% of the respondents agreed that delaying the Industry 4.0 transformation of their enterprises may risk their business future
• 12% of the respondents have already implemented some Industry 4.0 conversion and reported clear improvements in their value chain performance
What are we waiting for?
88%
HARNESSING THE VALUE
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WHAT’S HOLDING US BACK?
A major barrier for Industry 4.0 is the general lack of clarity
McKinsey & Company
Lack of a clear business case to justify investments in IT architecture
Lack of talent, e.g., data scientists
Lack of courage to push through transformation
Concerns about cybersecurity when working with third-party providers
Difficulty to coordinate actions across organizational units
Gartner Research
Unclear business benefits
Insufficient expertise/staffing
No clear leadership for IoT
Security Concerns
Insufficient time to develop ideas to benefit from IoT
The Mechanical Engineering Industry
AssociationLack of clarity about economic benefit
Lack of expertise or skilled labor
General lack of clarity, hesitancy
Lack of confidence in data security
Lack of norms and standards
Source Left: McKinsey Digital - Capturing Value from Digital Disruption in Manufacturing Industries 2016Source Middle: Gartner Research – Solution Path for Executing an Internet of Things Initiative 2016Source Right: VDMA - Industry 4.0 Readiness 2015
Business Justification
Expertise
Understanding
Data Security
Many will find an Industry 4.0 partner to help guide the way!
DATA
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IT’S ABOUT THE DATA! (INFORMATION IS KEY)
DATA
Generate
Capture
Aggregate
DATA
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CONNECTIVITY IS CRITICAL
INTELLIGENT SENSORS
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SUPPLIERS OF INFORMATION IN INDUSTRY 4.0
Already today, support for networked machines and industrial processes
Extensive possibilities for self- and process diagnostics Integrated logic functions for signal processing directly in the sensor Higher efficiency and lower costs
INDUSTRY 4.0 DATA
October 24, 2019 Ron Stuver | SICK, Inc. 17
BIG DATA
VOLUME + VARIETY + VELOCITY = BIG DATA
Sheer amount of raw data
(i.e. gigabytes, zettabytes, etc
StructuredAndUnstructured
Density of inbound data(milliseconds)
INDUSTRY 4.0 DATA
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WHAT TO DO WITH ALL THIS DATA
DIAGNOSTIC PREDICTIVE PRESCRIPTIVEDECISIONS ACTIONS
Real-TimeStatusOn/Off
Pass/FailPay Attention
StatisticalAnalysisTrending
Collection of DataAlgorithms
Machine Learning
Identify ActionAnalysisTrending
Stream of DataAlgorithms
Machine Learning
What is Now What is Next What to do about it
INDUSTRY 3.0
October 24, 2019 Ron Stuver | SICK, Inc. 19
PURDUE MODEL
https://en.wikipedia.org/wiki/Purdue_Enterprise_Reference_Architecture
The old Purdue Reference Model provided a view of “levels” within manufacturing operations.
Level-4 Business Logistics Systems
Level-3 Manufacturing Operations Systems
Level-2 Control SystemsLevel-1 Intelligent DevicesLevel-0 The Physical Process
INDUSTRY 4.0
October 24, 2019 Ron Stuver | SICK, Inc. 20
THE LAYERS OF AUTOMATION
DATA is created at the “Edge”
Machines, Devices, Sensors, PLC’s
NETWORK INFRASTRUCTURE is the “highway” needed to enable
connectivity
Horizontally (machine to machine) and Vertically (from
operations to/from enterprise)
AUTOMATION provides for efficiencies in the
manufacturing operationsRobotics, AGC/AGV, Vision, etc
…
INFORMATION SOLUTIONS provide visibility to data, the ability to aggregate various
sources of data, and turn data into information that supports rapid and effective decisions
ENTERPRISE SOLUTIONS require exchange of data with operations
SERVICESData
Integration
Connectivity to machines
Remote Monitoring
1 2
3
45 6
THE EDGE
CUSTOMER EXAMPLE
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Product-A Machines
Manual Push Button.
Semi Automatic Rotary Machines.
Relay Logic. PLC Control.
Automatic Assembly Machines.
Oven.
Assembly Machines.
PLC’s(various)
Screw Machine.
Hook & Coil
Machines.
Cutting Machines.
Cold Forming Machine.
Injection Molding
Machines
Product-C2.
Product-C1
Promote Machine visibility:
• Fault• Emergency
Stop• Auto-Mode• Auto running• Cycle Count*
Product-B Machines
Current factory with very little connectivity.
Big Data Analytics. Overall Equipment Efficiency. Machine Downtime.
Product-A Machines
Product-C Machines
CUSTOMER EXAMPLE
October 24, 2019 Ron Stuver | SICK, Inc. 22
SICK SOLUTION → PROVIDE DATA CONNECTIVITY
Sensor Intelligence
Connectivity Thru TDC (Telmetic Data Collector), PLC & NAT: Network Adapter Translator
IIOT
DashboardMobile
App
All the devices connected. Push the Data into
Kepware. DB and Calculations. Mobile App.
PLC
Sensors
TDC
Product-A
Product-B
Product-C
Machines
Solution
INDUSTRY 4.0: PULLING IT TOGETHER
October 24, 2019 Ron Stuver | SICK, Inc. 23
IT’S ABOUT THE DATA! (INFORMATION IS KEY)
Implementing solutions that achieve desired outcomes = value
INTELLIGENT SENSORS: SUPPLIERS OF INFORMATION IN INDUSTRY 4.0
DATA
Generate
Capture
Aggregate
The journey insures alignment between business objectives and I4.0 initiatives.Alignment helps to identify the data (information) that enables business + operational decisions that support desired outcomes.
Assess + Understand
Confirm Value(use cases / data)
Identify / Prioritize Opportunities
RoadmapDesign / Spec
MANY THANKS FOR YOUR ATTENTION.
Ron StuverDirector, Business Consulting, Industry 4.0
