Smart Manufacturing as a Real-Time Networked Information Enterprise

Transcription

1 The infusion of intelligence that transforms the way industries conceptualize, design and operate the manufacturing enterprise. Smart Manufacturing as a Real-Time Networked Information Enterprise Jim Davis UCLA/Institute for Digital Research and Education and Tom Edgar UT Austin SMLC (501c6)

2 What is Smart Manufacturing? Smart Manufacturing enables all information about the manufacturing process to be available when it is needed, where it is needed, and in the form that it is needed across entire manufacturing supply chains, complete product lifecycles, multiple industries, and small, medium and large enterprises.

3 Technology Roadmap Report (2009) 1. Motivating Smart Process Manufacturing 2. The Business Case and the Business Transformation 3. The Technical Transformation 4. The Smart Process Manufacturing Roadmap 5. The Path Forward 3

4 Implementing 21 st Century SM Report (2011) Priority actions in four categories: Industrial Community Modeling and Simulation Platforms for Smart Manufacturing Affordable Industrial Data Collection and Management Systems Enterprise Wide Integration: Business Systems, Manufacturing Plants and Suppliers Education and Training in Smart Manufacturing 4

5 SMLC Program Agenda for a Smart Manufacturing Platform Lower the cost for applying advanced data analysis, modeling, and simulation in core manufacturing processes Build pre-competitive infrastructure including network and information technology, interoperability, and shared business data Establish an industry-shared, community-source platform and associated software that functions as an apps store and clearinghouse Create and provide broad access to next-generation sensors, including lowcost sensing and sensor fusion technologies Establish test beds for smart manufacturing concepts and make them available to companies of all sizes

6 Industrial Gas Manufacturing Steel Energy Bio/Pharma Electronics Energy Supply Production and Delivery Healthcare Customers Our customers demand capital discipline and high reliability Our goal is to meet their demands and maintain high energy efficiency

7 Smart Manufacturing Helps Meet Our Goals Low cost sensors and wireless enable real time decisions Hosted computing improves results at a lower cost Design Operations Common infrastructure facilitates supply chain collaboration

8 Machine Operations & Line Management Trade-Offs General Dynamics Machine Function Benchmarking & Integrated Line and Energy Management Managing Power from the Grid

9 FORD In-Production Virtual Aluminum Castings Target Strength = 220 MPa Aging at 250C for 3hrs 220 Aging temperature 240C for 5hrs Initial Heat Treatment Process John Allison AIChE Optimized Heat Treatment Process Faster and Stronger!!

10 General Mills Customers pushing demands Farming Tracking & Traceability Supply Chain Manufacturing Plant Distributor Customer

11 EDI transaction & quality certifications General Mills Networked-Based Manufacturing Intelligence & Collaborative Manufacturing Business Systems, ERP Recipe Management Mapping formula into operating recipes Mapping SAP information Into operation 11 Supply Chain Smart Grid Smart Factory Distribution Center Green Light Analyze - to put into production Make right ingredients confirmation on recipe Release meet requirements to release Customer FDA Tracking & traceability

12 GM s ECO System of STUFF Value Creation Business Applications Overusage Green Light to Convert Allergen/Micro WorkFlow Demand Driven Supply Chain Green Light to Ship Trace/Recall BOM Validation Optimized Inventory ecoa Supplier Managed Inv Line Supply Bin Mgmt Yard Mgmt Directed Work Core Functions Core Systems Production History Plant Floor Inventory Direct Consumption WorkFlow Demand Plan Production Order Line Schedule Master Data (BOM,Specs,Vendor,Ingredients,FP) Raw Mat l Inventory Finished Product Inventory MQIS MES SAP ERP SAP MRP SAP APO SAP PLM Red Prairie Lot Tracking Optimization Engine Data Input

13 Test Bed Generated SM Systems Smart Machine Operations In production machine-product management Benchmarking machine-product interactions Integrated dynamic management of machine-electrical power interactions Adaptable machine configurations In Production Use of High Fidelity Modeling and Simulation High fidelity modeling for better management Rapid qualification of components and products In Production Decision Making with Global Integrated Metrics Dynamic Business and Operational Tradeoff Decision-Making Dynamic performance management of global integrated metrics Untapped cross factory degrees of freedom for optimizing efficiency and performance and compressing time Supply Chain Management Supply chain variability reduction and management of risk Tracking and traceability

14 Industry Test Bed Strategy

15 Industry-Driven Defined from Test Bed systems

16 The Technical Basis for Collaborative Manufacturing and the SM Platform Challenge 1 Factory and supply chain demonstrations sites of applied manufacturing intelligence Meta 1 Integrated Workforce, Cyber, Physical System Performance Variability Reduction Benchmarking Challenge 2 Integration of manufacturing enterprise data, control, automation, management and optimization infrastructures Meta 2 Demand-Dynamic Customer to Source Variability Planning Multi-Dimensional Smart Manufacturing Meta 3 Higher Fidelity Production Real-time Qualification Integrated Computational Materials Engineering Materials & Energy Mgmt. Challenge 4 Precompetitive and competitive community source modeling innovation & simulation assimilation platform META 4 Interoperable Supply Chain Network Control, Automation, Optimization Management & Decision Challenge 3 Real-time syncing virtual models and physical operations Enabling New & Dormant Technologies

17 SMLC Industry-Driven Integrated Performance Metrics Micro, Meso, Macro Real-time Data & Modeling Workflow To& & Metric Toolkit/ App Development Key Development Resources Universities, SME s Manufacturers, Labs First Concept of the Smart Manufacturing Platform Infrastructure for Real-Time Data Driven Modeling and Simulation Community Source Resources UCLA Variability Management Real-time Plan Passes Pre-competitive & Competitive Hub Benchmarking Rapid Qualification ICME Community Source Apps Store Cloud Services Market Place SMEs Small & Medium Enterprises Manufacturing Consortia Test Bed Manufacturer & Supplier Crosslinking Engagements Standards and Reference Architecture IT Providers Real Time Virtual Manufacturing Demonstration Facility 17 (VMDF)

18 SMLC Partners & Collaboration Roles Test Beds - General Dynamics, General Mills, General Motors, Praxair, Corning, Pfizer, Alcoa, Exxon Mobil, Shell, Air Liquide, RPI/Center for Advanced Technology Systems Design/manufacturing Platform Providers JPL/NASA, UCLA, Rockwell, Honeywell, Emerson, Nimbis Modeling & Simulation Materials, Design, Manufacturing Caltech/JPL, NETL, Argonne, UCLA, UT Austin, Tulane, NCSU, CMU, Penn, Purdue Smart Manufacturing/Smart Grid EPRI Global Performance Metrics AIChE, ACEEE, Sustainable Solutions Agency partners NIST, NSF Regional partners - Center for Smart Manufacturing (CA), Wisconsin Manufacturing Institute

19 Multi-Layer Smart Manufacturing (MLSM) Workflow Foundation Design Data Prototype Materials & Process Tech Product Manufacturing Qualification In Service Macro Layer Product Volume Scheduling Supply Chain People Involved Integrated Metrics & Decision Making APP Store Reference Flows Process Models Control Metrics Conditional decisions Model building &updates Model insertion Meso Layer Management Machine Flow Optimization Micro Layer Sensors/Actuators Control/Optimization Automation Virtual MDSM Host Dash Board Collaboration MDSM Program Host Manufacturing Initiatives

20 Workflow Distinguished from Control & Automation

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22 Process & Line Data Machine Benchmark Data Factory Data Control Automation Factory Workflow General Dynamics Benchmarking Model Workflow Service Framework Process & Line Set Point Conditions Check Table Optimal Machine Usage Calculate Machine, Energy, Product Metric Dashboard Recommend Tradeoff Points Batch Scheduler Computational Resources New Machine Maintenance Process Data Run Machine Usage Pattern- Based Analyzer Update Machine Usage Model Build Table Optimal Machine Usage Windows Table Model Accepted

23 Multi-Layered Smart Manufacturing Management (MLSMM) Time Managed as Workflow Not Control Transformational Machines People - Materials Dynamic Manufacturing Ecosystem Design Data Prototype Materials & Process Tech Product Manufacturing Qualification In Service 10s of control loops Control Points -? Manpower - X Time days 100s of control loops Control Points -? Manpower 10X Time -hours Macro Layer Meso Layer Current Practice One Pass per Day per Event; Too Late, Stale Data, Slow Responsive Manufacturing Goals: 100x Event Variability Adjustment Capability & Dynamic Certification Improvement 1000s of control loops Control points - Manpower 100X Time - minutes Micro Layer Focus: Integrated metrics, Qualification, Computational Materials Engineering, High Fidelity Dynamic Operations

24 The Concept of Data-to-Applications Performance Management Data & Modeling Workflow Process sensor data Data and Computation Management Dashboard Ref Arch Data Collection Manufacturer Ref Arch Data Collection Supplier Manufacturer Real-time Manufacturer Data Warehouse Local/Global Integrated Productivity Metric Dash Board Encrypted links Data Validation App EPM App from Toolkit SM Platform Workflow, Data and Computation Services Reduced Order Model Scenarios App Real-time Action & Risk Support App Linked Apps to Form Function Risk Scenarios App

25 Major Platform Concepts Multi-Layer Workflows interface with control and automation and factory optimized workflows Real-time is defined by the workflow & actionable objective Data-to-Application instead of Application-to- Data Workflow as a Service (Wfaas)

26 Implementation ENGINEERING THE PLATFORM FOR THE USE CASES

27 Local Web Server Process Data Praxair SMR Example Data Control Automation Proprietary Workflow Process Data Transfer New ROM Transfer Workflow Control Server Data Validation and filtering Local Storage Workflow Service Framework Validated Data ROM Accepted CFD Preprocessing CFD Runs Update ROM using CFD Output Offline Simulation with ROM ROM Validation Rerun ROM Batch Scheduler Computational Resources

28 SMLC Concept Workflow as a Service (WfaaS) Factory Data Control & Automation Workflow Workflow (WFaaS) Provisioning Orchestration Proprietary Workflow Tasking Security State Provenance Application Instances

29 WfaaS Integrated with SaaS, PaaS, IaaS Factory Data Control & Automation Workflow Workflow (WfaaS) Provisioning Orchestration Tasking State /UCLA Services Technical Computing Marketplace Buyer/User (SaaS) Proprietary Workflow Security Provenance Buyer Dashboard Buyer Catalog Portal Apps Seller/Provider (PaaS) Seller Dashboard Dev Tools Software Images Application Instances Compute Platform (IaaS) Cycles Software / Licenses Storage

30 Nimbis Secure Cloud Portal Architecture Data and Application Management Foundation Web Browser / Desktop Application Nimbis Ecommerce Subsystem (NES) URL Dispatcher Caching View Template Message Queue Model Database Browse, Configure, Price, Purchase HTTPS / SSH VPN / VNC Nimbis Broker Subsystem (NBS) Compute Platform Application Images HTTP / REST / SOAP Asynchronous Task Queue Tasks OAuth-OpenID Compute Provider Interface (CPI) License Manager Nimbis Services Inc. Proprietary Job/Session Management Resource/License Metering PBS Remote Access Node Shared Storage

31 Open Architecture Workflow Construction & Management

32 SM Platform Apps Store, Shared Market Place & Distribution Hub Multiple Service Environments

33 Apps Store Process & Line Set Point Conditions CFD Preprocessing Check Table Optimal Machine Usage CFD Runs Calculate Machine, Energy, Product Metric Update ROM using CFD Output Dashboard Recommend Tradeoff Points Offline Simulation with ROM Integrated Metric ROM Sync Library of Workflows CFD Preprocessing CFD Runs Workflow Components Machine, Energy, Product Metric App Toolkits Data Definition Maps CFD ROM Template for SMR Machine energy usage calculation Apps as a Service Apps as code module

34 Breakthrough Systems Deployment Data-to-Apps Paradigm for Broad Access Inverts current Apps to Data approach Facilitates big data apps Distributes App support Separates proprietary and shared Layers security Composable Sensor Based SM Systems Apps store Data, metrics, models, actions, displays Increased 3 rd party contribution Real-time systems across large time scales Workflow Based Architecture Composability & customization Design to manufacturing models Workflow libraries Technology insertion

35 SMLC Commitment to a Comprehensive Approach Enterprise Business System ENTERPRISE OPTIMIZATION & SUSTAINABLE PRODUCTION Higher value products Improved quality Suppliers AGILE DEMAND-DRIVEN SUPPLY CHAINS Higher product availability No inventory Product lifecycle management Factory Zero downtime Increased equipment life / utilization ENERGY, SUSTAINABILITY, EH&S Improved safety Reduced energy and emissions Highly sustainable Smart Grid Distribution Center OEM Machine Builders Customer

36 SM: An Enabling Technology National Network for Manufacturing Innovation (NNMI) sign.pdf Possible focus areas: Enabling Technology: Creating a smart-manufacturing infrastructure and approaches that integrate low-cost sensors into manufacturing processes, enabling operators to make real-time use of big data flows from fully instrumented plants in order to improve productivity, optimize supply chains, reduce costs, and reduce energy, water, and materials consumption.

37 The infusion of intelligence that transforms the way industries conceptualize, design and operate the manufacturing enterprise.