SMART MANUFACTURING A POSSIBLE ROADMAP. FABBRICA FUTURO Bologna, June 08 th 2016

Transcription

1 SMART MANUFACTURING A POSSIBLE ROADMAP FABBRICA FUTURO Bologna, June 08 th 2016

2 Agenda Accenture POV on Industrial Internet of Things Digital Factory Vision The roadmap to a sustainable smart production Credentials Sizing the Opportunity 2

3 Fabbrica Futuro Smart Manufacturing Accenture POV

4 The Promise: Industrial Internet of Things A universe of intelligent products, processes and services that communicate with each other and with people over the Internet. That s how Accenture defines the Industrial Internet of Things (IIoT), which promises to be the most transformative industrial revolution yet for manufacturers, changing the way they think about resource allocation, production processes, materials handling, and the workforce 4

5 IIOT planned growth We believe the IIoT will enable industries that collectively account for almost two thirds of global output to benefit from digital transformation. * * 5

6 How will disruptive technologies impact Value Chain Technology R&D Planning Manufacturing Logistics Repair & Maintenance Connectivity Big Data Cloud Collaborative R&D Digital Supply Chain Connected Manufacturing Assets Connected Assets/ Truck Connected Asset /Remote diagnostic Sensors Embedded Software Intelligent Products Flexible Manufacturing Advanced Analytics Products usage analytics Demand & Supply Analytics Manufacturing Control Tower Supply Chain Control Tower Maintenance Control Tower/ Predictive Maintenance Mobile Wearables Augmented/Virtual Reality Virtual Prototyping/ Simulation Testing Connected Workers Connected Field Force 3D Printing Rapid Prototyping Parts & Tools Manufacturing Drones Robotics Cognitive Robotics Surveillance by drones Social Social Media Insights Social Media Insights 6

7 The impact of the industrial internet of things is transformational The impact of the industrial internet of things is transformational We see a world moving towards an outcomes-based economy where companies compete on their ability to deliver quantified results that matter to their customers Operational Efficiency Asset utilization Operational cost reduction Improvement worker productivity, safety and working conditions New Product & Services New business models Pay per use Software based services Product / Service hybrids Data monetization Outcome-based Economy Pay per outcome New connected ecosystems Platform-enabled marketplace Industry blur Autonomous Pull Economy Continuous demand-sensing End to end automation Resource optimization & waste reduction From Product to Service Outcome Pull 7

8 Operational Efficiency Operational efficiency builds the underlying infrastructure that enables manufacturers to advance in their IIoT journey, adapting their offerings and driving new revenue opportunities. Predictive Asset Maintenance Can* * G. P. Sullivan, R. Pugh, A. P. Melendez and W. D. Hunt, Operations & Maintenance Best Practices: A Guide to Achieving OperationalEfficiency, Release 3.0 8

9 Fabbrica Futuro Smart Manufacturing Digital Factory Vision

10 Digital Factory Vision: Capabilities enabling next generation manufacturing Control Tower Digital Plant OEM/MRO Suppliers Digital Engineering Digital Operations Offsite Pkg Digital Worker Digital Asset Feedstock Supply Digital Supply Chain Contract MFG MFG Digital Foundation ISA-95 Level 1: Device I/O & Controls ISA-95 Level 2: Automation Systems Talent Development & Learning ISA-95 Level 3: Manufacturing Ops & Control Warehouse & Shipping Sister Sites Digital Supply Chain Information Flow Material 10 Flow

11 Value Adding Functions Exploding the Digital Plant Digital Enablers Digital Plant M2M Connection Manufacturing Dynamic Contract Manufacturing Asset Remote Monitoring & Optimization (OEE) Analytics Operational excellence (Lean 6 sigma) Addictive printing (3D) for parts Smart-Phones/ Tablets Operational Control Center (KPI) Workforce skills Wearable Devices Manufacturing Control Tower Augmented Reality Industrial Automation Prod. Planning & Logistics Profit, Sales & Operations planning Energy Saving Equipment Drones Smart Plant Value Achievable Resources usage optimization Agile Manufacturing Process Sustainability Enhanced Safety (Cross plant) MRO Optimization Maintenance Predictive Maintenance Remote Surveillance Safety & Sustainability Real-time Working Capital Optimization 11

12 Fabbrica Futuro Smart Manufacturing The Roadmap to a sustainable smart production

13 Industrial Internet of Things can accelerate Smart Manufacturing Key success factors for manufacturers: Level of investments Ability to align IT&OT Affinity to technology changes Agility in deploying industrial security solutions Speed to reskill workforces 13

14 Digitize Channels & Products Digital Services Digital Company Transformation As many leading organizations develop digital capabilities, the critical success GO Digital factor will be to combine digital technology with new approaches to operations Old & New Today Looking Digital Shifting old processes to new channels & products technology creating a new customer experience that is built upon traditional operations & models Digitize Processes & Operations New & New New & Old Being Digital Combining new technology, and new channels while transforming operations to create a new customer experience and innovative business models that drives higher satisfaction and lower costs Feeling Digital Applying new technology to optimize operations while focusing primarily on traditional channels & Products BE Digital Digital Enterprise 14

15 Building a Smart Production Roadmap

16 Root #1 : Equipments By making equipment intelligent enough to self-manage and collaborate with the rest of the manufacturing system, manufacturers can drive overall reliability, predictability and optimization. Retrofitting existing equipment with sensors to increase visibility Integrate Predicitve Data in ERP i.e. Taleris* 3D printing helps eliminate both outages and the need to maintain a spare parts inventory. i.e. Ford MC & GE Gas & Oil Division* The baselines created by condition monitoring, combined with analytical techniques 3dprinting-idUSL5N0KW2OA amitchowdhry/2013/10/08/what-can-3dprinting-do-here-are-6-creative-examples/

17 Root #2: Workforce Creating a blended workforce that comprises humans and machines working collaboratively and dynamically can deliver outcomes that neither could produce alone Mobile & wearable technologies, JIT Training Video Collaboration Integrating the human and machine workforce with the rest of the enterprise Designed to be easily trained (i.e. to learn by observation) i.e. Amazon* * or 17

18 Root #3: Material Supply Chain By leveraging the IIoT to enhance materials management, not only across the factory floor but also between supply chain partners, they can gain additional efficiencies. RFID used on the factory floor to track work-in-progress materials, route those materials efficiently Integrating the data obtained by real-time visibility into the availability of materials on ERP identify and predict what materials manufacters need at the right time, based on the anticipated production run 18

19 Root #4: Business Process The smart factory extends well beyond its floor. Intelligent products can tell designers how customers are using them and thus enable improvements. By enabling cross-correlation of multiple data streams i.e. SPC Sight Machines * Automated design software promises to accelerate this product development process i.e. Autocad Dreamcatcher* Real-time automation and process integration across the supply chain enables the necessary responsiveness * ccp/ / pdf 19

20 Root #5: Platform The platform will facilitate the transfer of IIoT data from sensors and devices for centralized data analysis, decision-making and use by enterprise applications in the cloud. Retrofitting existing equipment with sensors to increase visibility 20

21 Root #5: Work The Connected Platform as a Service of Accenture 21

22 Root #6: Environment & Facilities Environmentally conscious manufacturing facilities strive to make the most efficient and productive use of raw materials and natural resources, as well as to minimize the adverse impacts on workers and the natural environment. Deliver efficient response to emergencies are critical components of plant solutions Visibility into plant-level energy consumption, water usage,waste production and the associated costs By integrating energy use into the resource supply value chain a manufacturer can even become a prosumer of energy 22

23 IIoT Manufacturing Control Tower as a shared service center (network-level centered) Control Tower is a set of capabilities that helps each manufacturing plant to be connected and monitored about performances in real time Key Topics Reduce volatility, complexity and uncertainty Deliver specific business outcomes (e.g., cost, quality, customer service, asset utilization) Monitor the execution of Facilities activities, perform what if analysis, and dynamically respond to changes Real time visibility Root cause analysis Business Outcomes Rapid response through the interaction between supply chain processes and tools Response to business issue simple and fast Assets Dashboards, Alarms Generators and Action Plans KPIs and utility Management Management Reserves MRP and MRO Management Supplier and Transportation management 23

24 Fabbrica Futuro Smart Manufacturing CREDENTIALS

25 Wearable Credential: Airbus Help Airbus operators reduce the complexity of assembling cabin seats and decrease the time required to complete the task Delivered with Airbus a proof-of-concept, using Vuzix M100 for A330 cabin furnishing Expected to ultimately enable lesser skilled people to step up to jobs without having to read a training manual, instead relying on the data from the glasses in real time Accenture is looking to build on this proof of concept with Airbus by making it widely used in commercial aerospace and defense manufacturing. 100% quality (no more error) Improved ergonomics Improved teams flexibility by almost removing training needs Duration of task divided by 6 25

26 Fabbrica Futuro Smart Manufacturing Sizing the Opportunity

27 Sizing the Opportunity We have suggested six key dimensions for consideration, and identified the factors that can accelerate progress. Now it s time to move, Are you connected enough? 27

28 THANK YOU! Massimiliano Oddi Senior Advisor PL&M ICEG CP Manufacturing Lead 28