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Industrial IoT (IIoT) for Manufacturing
fanufacturers are benefiting from a data-driven operations!
Objectives✓Introduction to Industry 4.0
✓Transition to Data-Driven operations
✓Increase communications across the business – machine-to-computer, machine-to-machine
✓Reduce operational cost and enhance quality
✓Improve Overall Equipment Effectiveness [OEE].
✓Anywhere, Anytime access to plant floor information through Web-enabled dashboard application
Industry 4.0
Industry 4.0 refers to the fourth industrial revolution where manufacturing uses computer networks and network connected equipment/devices to gather data, exchange and analyze information to improve process efficiency & decrease cost of operations!
What is involved?
Leverage Automation
Collect data and Analyze
Improve Operations
through insights
Reduce Operational cost
5 ways Data is impacting manufacturing
• Enhancing Plant performance by increasing production throughput and quality
• Improving demand forecasts
• Faster and improved customer service
• Managing supply chain risks
• Enhancing safety and security
Why IIoT in Manufacturing?
Predictive Modeling Will provide significant improvements in up-
time (predictive maintenance)
Will provide significant information on equipment
performance (real time)
Will provide data for continuous improvement
efforts – ever better efficiencies/utilization
Where in Manufacturing Operations is IIoT applied?➢Alerting unexpected equipment failures
➢Monitor worker negligence issues/accidents and preventsimilar incidents from happening in the future
➢Resource optimization by improving production workflowsand dynamic scheduling
➢Retrofitting legacy machines with needed sensors, cameras for monitoring
➢Enabling connectivity between legacy machines, new machines, communications and data processing infrastructure (Cloud computing)
➢Identifying product quality issues and correlating that info with equipment usage data
How IIoT Will Impact Operations-Improve Manufacturing
➢Analyze safety data and improve safe equipment operation
➢Analyze equipment performance and improve Overall Equipment Effectiveness [OEE]
➢Analyze manufacturing process and improve the procurement process
➢Reduce insurance costs as equipment performance increases and part manufacturing processes are streamlined
➢Improve employee performance as operation processes are made efficient
➢As manufacturing processes, equipment and personnel become more efficient overall shop-floor productivity increases
Business Cases
➢ Web-enabled dashboard application for plant floor visibility
➢Current state vs Future state (Networked operations)
➢Centralized vs Distributed Intelligence
➢Single point of failure vs Resilient operations
➢Predictive maintenance & OEE
Transitioning to Data-driven operations
➢Attaching smart devices to legacy machines
➢Capturing equipment data from automated assembly lines
➢Creating integrated network infrastructure for communication between machines, devices and personnel
➢Reporting data from various systems and plant equipment (dashboards)
Courtesy: Mazak USA
Measuring Overall Equipment Effectiveness (OEE)
Courtesy – Vorne Industries
Continuous Data and Distributed Intelligence
Present
Cell Controller
Future
Networked Communications
Courtesy: MTConnect.org
Business Value for Metal Works➢ Understand the process flow currently in use at Metal
Works for making parts
➢ Use Data points captured from CNC machines for shop-floor monitoring - Analytics & Reports
➢ A Web-enabled application dashboard to bring CNC &other machine data to display live production data
➢ Identifying ways to improve processes, workflow and overall equipment effectiveness
Manufacturing Examples
Courtesy – Memex Inc.
❖Smart Factory Simplified (with MTConnect):
www.youtube.com/watch?v=PMDTTDekW2Y&t=35s Image: Courtesy – Internet Royalty Free
3DES Team
• Nandu Vellal, Founder
• Rich Thall, Founder
• Satish Mantripragada, Business Lead
• 3D Educational Services,
• 84 Brick Kiln Rd.,
• Chelmsford, MA
• W: www.3desinc.biz
• P: 978-364-2728
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