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Intelligent Manufacturing System Integration

Harish PantManaging Director

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97% of Indians find themselves in the bottom 60% of the world’s population when ranked according to incomes.

Irony of our country being a low cost country….

Labor is cheap so keep it Not Intelligent and without system – only short pulses of Jugad!

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• Who is Not Intelligent ?

• What should be intelligent and how much?

• What an intelligent device does? e.g. The Best Smart Phone vs Ordinary Phone

Why Intelligent?

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Why Intelligent?

To achieve better

• Quality, Cost, Delivery, Safety, Security, Reliability

• Environment, Sustainability, Comfort, Convenience

• Seamless / Integrated Service

• Futuristic Products and services: Quantum Research

>> Innovations to meet Uncertain, Volatile and ever Changing World

.. Return on investment (ROI) vs Survive on Investment (SOI)

Human

Can do Can’t do

Machine

Phase 1 - Human and MachinePhase 2 - Human Vs. Machine Phase 3 - Machine to MachinePhase 4 - Internet of ThingsPhase 5 – Intelligence to Intelligence

InformationIntelligenceIntegrationIOT

Capacity and Capability

Can do Can’t do

1. Principles of Motion Economy

2. Motion Study

3. Workstation Design

4. Application of Ergonomics

5. Fatigue Studies

6. Productivity/Safety/Comfort Device Design

7. Standardization of Operator Methods

8. Operator training

9. Incentive Systems

10. Job Evaluation

11. Learning effect capture

12. Work Measurement - Time Study

1. Process/op Analysis/OR 

2. Six Sigma

3. Value engineering

4. Statistical quality control ,

5. Statistical inventory control and ABC

6. Variety reduction

7. Standardization

8. Waste reduction or elimination

9. Activity based management

10. Business process improvement

11. Learning effect capture and continuous

12. 5S, SMED, Lean system

Techniques

Value

Human Motion Method

Productivity

Traditional

X In Built

IE FrameworkInnovation/Disruption

Context

TechnologyCompetitionSustenanceEnvironmentSocialEconomic

Integration

SeamlessWhole / TotalEnd to EndUser controlled

Value

• Disruptive Impact• Beyond “As desired” or “perceived”• Authentic / Real

The last mile/end changes are changing the structure / base creating multiple disruptions

>>>>>>

Value - Increasing Envelop

New Value Preposition

Chapati Making

Prepare DoughRollBake in oven

Prepare DoughPress and Bake

Fill Flour and WaterSelect roti thickness

• The next…..Grains Fill and auto operate…auto recognition….• Disruptive Change in Human Motion and Method: everything changed• Skill and knowledge required – a disruptive change!

EliminationsWastes (Muda) >>> Variations (Mura) >>> Strain (Muri)

ImprovementsQuality, Cost, Delivery…..)

Disruptions Mobility and scalability, Internet of things, Free

of Cost – Knowledge/Info/across the globe

Innovation Unique, New, Different

• The roti maker has to become expert in many dimensions• Streamlining processes and cutting cost is just 18th century• Complexity is managed by simple rules and constraints actually spur the

innovation

Changing Change @

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Manufacturing System Elements Interplay

Interplay of 5M’s

Man – Attendance, Attention, Availability

Machine

Idle timeChangeoversReduced lot size

Money

Cash FlowMargins

Material

Lead timeAvailabilityGlobal Supply chain

Method

Changing requirementsImprovements disruptions

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Systems System

• Quality System, EHS System• Customers requirements• CAD/CAM• Machine Programing software• Machine controllers• ERP• DOC Management System• Quality Lab Management• Out Source – In Source Interface• Individual Hardware / software/App• Social Media • Search engines

System Issues

• Standards• Compatibility• Availability• Affordability

Manufacturing System

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Information Technology (IT) Operational Technology (OT)

Internet of Things (IOT)

Internet of Things (IOT) as Service

Industry Era – 4.0

A world in which digital technologies are deeply embedded and in abundance.

The Future Factories

• The Internet of Things on the Plant Floor• 3D Printing and Emerging Production Technologies• Digital Manufacturing

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A future for manufacturing in which

• Pervasive connectivity, • Sensor networks, • Cyber-physical systems, and• Increased production flexibility

promise to drive the creation of ever-more customized and smarter products.

A new levels of digitization, automation, and integration within an enterprise, and many new areas of technical and software innovation.

http://www.gilcommunity.com/blog/hannover-highlights

The mantra of Industry 4.0

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• Dramatically change the products we manufacture and use, making them smart, connected, and, ultimately, more autonomous.

• The IoT era will require much tighter and more agile collaboration between what historically have been stove-piped organizational functions such as IT, engineering, R&D, service, and manufacturing.

• Manufacturing companies create what he called “Unified Data Groups,” led by Chief Data Officers, that would be tasked with turning the mountains of data generated by IoT infrastructure into competitive assets that could truly be exploited by existing business units

• Whether manufacturers decide to graft the data management function onto their existing organizational structures, set up new centers of excellence, or partner for expertise, the structural changes forced by IoT are likely to be, at least for a time, a source of conflict or a source of Collaboration.

• Require a new generation of manufacturing employees with a unique combination of not just mechanical and software engineering skills but also data science skills and knowledge of domains such as post-sales product service and support.

Internet of Things

Excerpts from M.Poter

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• Deep Learning : Hardware's designed for the Machine Learning Techniques

• Many gadgets will be able to understand images and video thanks to chips designed to run powerful artificial-intelligence algorithms."

• Companies like Google have made breakthroughs in image and face recognition through deep learning, using giant data sets and powerful computers...\

• Quantum Computing Algorithm for advanced Artificial Intelligence• The Dutch government, research institute TNO* and other organisations have agreed to

invest Euro 135 m• New design recognized speed-limit signs in footage from a car.

• A home security camera could start sending data over the Internet only when a human entered the frame.

• Being able to do things like analyze images on a device without connecting to the Internet can make apps faster and more energy-efficient because it isn’t necessary to send data to and fro

New Advances in Artificial Intelligence

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To offer a range of services including

• A new IOT platform-as-a-service offering, that will allow developers to integrate IOT-generated data with existing business applications such as enterprise asset management;

• A cloud-based service that IBM, its customers, and its partners can use to design and deliver analytics applications that are focused on specific vertical industries; and

• An ecosystem of partners that will deliver IOT solutions based on IBM’s platforms.

• Working with Cummins and Pratt & Whitney, to create IOT solutions that monitor the functioning and health in the field of products such as engines.

• Partnering with the University of South Carolina to create IOT-enabled analytics tools and skills that can enhance predictive maintenance.

- See more at: http://www.gilcommunity.com/discussion/ibm-will-invest-3-billion-internet-things-initiative/#sthash.5EQlNY1N.dpuf

IBM Will Invest $3 Billion in Internet of Things

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Futuristic Festo R&D program, the partially 3D-printed BionicANTS communicate with each other to coordinate both their actions and their movements to achieve cooperative tasks. Each ant takes autonomous decisions but is always subordinate to the common objective

http://www.gilcommunity.com/blog/hannover-highlights

The electro-mechanical e-Motion Butterflies, meanwhile, autonomously coordinate their flying patterns using indoor GPS, a collection of spatial infrared cameras and controller, plus on-board guidance and monitoring systems so they never collide. 

New Developments

ABB --- YuMi – combines a vision system, grippers, touch-sensitive sensors, software, and integrated safety components in a form factor that weighs 38 Kg and consumes one square foot of space. YuMi is designed for consumer product manufacturing applications such as electronics, phones, and various small parts

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SmartFactory’s Plug and Produce ApproachPioneering German research initiative, SmartFactory KL e.V., and the German Center for Artificial Intelligence demonstrated how the Industry 4.0 concept can be integrated into existing industrial applications.

Harting’s Customized Production LineThough still in development, Germany’s Harting Technology Group is showcasing a prototype modular factory line able to create individually customizable products with the speed and efficiency of mass production volumes. Called the Harting Integrated Industry 4 You (HIIA4YOU) project, it connects an eShop customer selection system, with an SAP ERP network, and finally the production and assembly machinery in a three-cell production line.

Volkswagen’s e-Golf and Factory PowerwallThe digital networking will become an essential part of the auto industry in the future, featuredA number of digitally-driven production and product developments, including augmented reality systems that show where specific parts are installed in the body of a car, the e-Golf electric vehicle which features wireless charging and a digital key that can be operated by smartphone, and what it calls the Powerwall – a virtual wall screen, adapted from a similar technology used earlier in vehicle design and engineering, that now allows factory teams to simulate a plant and plan and refine an entire production process for a new product in a virtual world before any physical changes are made to the factory itself. 

- See more at: http://www.gilcommunity.com/blog/hannover-highlights-day-1-industry-40-clever-collaborations-and-plug-and-produce/#sthash.DejGlQbr.dpuf

New Developments…

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Impact on Education System

• CS/IT/Analytics to be embedded in all courses

• Projects to be done with across the branches of various discipline

• Create infrastructure throughout the campus to facilitate cutting edge research

• Very active involvement of Industry – Academia – Research and Development

• Content no more important and to be made available online – application is important

• Create similar experience in running the Education Institute

• Create a platform for Intelligent Manufacturing System for active participant of Faculties, Students and various Research scholars

• Carry out an India specific research on where IOT will bring immense benefits to industry and society

• More collaborate and then compete

• Be a Role Model