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Reducing and Eliminating Downtime in Robots Using Predictive Analytics
Scott Melton
FANUC AMERICA Corporation
Transformation
“Transformation is not from new technologies but transforming your organization to take advantage of the possibilities…”
- MIT Center for Digital Business
What is IoT ? The Internet of Things (IoT) is the network of physical devices and other items
embedded with electronics, software, sensors, actuators, and connectivity, which
enables these things to connect and exchange data creating opportunities for more
direct integration of the physical world into computer-based systems, resulting in
efficiency improvements, economic benefits, and reduced human exertions”. Source: Wikipedia
How / Why did we get here ?
Four Phases of Industrialization
Where is the IoT?
Smart Phones – Proximity
ads, traffic patterns, fuel
prices, etc.
Wearable Tech – Apple
watch, Fitbit, Google
glass, Nike+, etc.
Home Automation – Nest,
Echo, Wink, Arlo, Z-
Wave, etc.
Medical Devices –
Glucometers, blood
pressure, etc.
Agriculture – Smart
irrigation, optimized
seeding, etc.
Smart Cities –
Parking apps,
Intelligent lighting
Connected Logistics
Systems
Professional
Sports
Wildlife Tracking
Jet Engine
Monitoring
Here are some examples of the IoT outside of manufacturing…
And companies are investing in it… PWC surveyed 2,000 senior executives in 26 countries:
• Industrial companies around the world are expected to invest more than 900 billion dollars per year in Industry 4.0 through 2020.
Reference: pwc 2016 Global Industry 4.0 Survey
And why are companies are investing in it…
http://www.forbes.com/sites/louiscolumbus/2018/03/18/where-iot-can-deliver-the-most-value-in-2018/
• Harley Davidson – reduced BTO ratio by factor of 36
• Rolls Royce – 1% reduction in fuel usage – savings of 250K per plane, per year
• Royal Dutch Shell - $1M return on $87K investment.
IIoT = Industrial Internet of Things The IoT and IIoT both rely on sharing and using data to provide value, but…
• IIoT targets Industry - producers of goods and services
• The IIoT is expected to revolutionize manufacturing by creating new value streams through the collection, analysis and sharing of data to improve uptime, reduce scrap, optimize processes, etc.
• IIoT solutions require long term support and rugged design considerations
• IIoT solutions need to work with existing (legacy) equipment
• IIoT solutions MUST BE SECURE
IIoT
Why is connectivity so important?
Because Connectivity
Enables Access to
Data & Data Drives Value
Creation
Some Facts about Data Collection
Data storage is growing 4X FASTER THAN THE WORLD ECONOMY
Increasing quantity of data allows for
MORE QUALITATIVE APPROACH
EVERY DAY WE CREATE
2,500,000,000,000, 000,000 (2.5 QUINTILLION) BYTES OF DATA
That is enough data to Fill 10 million Blu-ray discs, the height of which when stacked, would measure the height of 4 Eiffel Towers one on top of another.
Source: Adient / Adient Industry 4.0/ May 11, 2017
Alphabet Soup… Industry Terminology
• IoT = Internet of Things
• IIoT = Industrial Internet of Things
• SCM (Supply Chain Management) = software to execute supply chain transactions, manage supplier relationships, and control associated business processes.
• MES (Manufacturing Execution System) = software to understand how current conditions on the plant floor can be optimized to improve production output.
• ERP (Enterprise Resource Planning) = business management software that tracks resources (cash, raw materials, production capacity) and the status of business commitments (orders, purchase orders and payroll).
Industry 4.0
• Digital to Physical Conversion
• Reconfigurable Mfg Systems
• Cyber-Physical Systems
• ICT (Info & Comm Technology)
• “Smart” Products
Industry 4.0
• Interoperability
• Connectivity
• Human-Machine Collaboration
• Additive Machining
Connecting Smart Manufacturing FANUC has been investing in connectivity and Smart Manufacturing for many years.
Connecting Smart Manufacturing We have been creating features that produce useful data at the Robot & Machine tool
• Maintenance Reminder
• Process Logger
• Operation Logbook & History
• I/O Signal Information Operation
History
Signal and CNC
information
Connecting Smart Manufacturing
Today we have smart phone apps to view data outside plants
• Data produced on CNC & Robots using existing software.
• Live updated information in real-time
• Data sent via e-mail messages to an in plant mail server
Cisco Security
ZDT Service Center Portal Alert Monitoring, Schedule Parts and Maintenance, Enhanced Customer Service Tools
ZDT Customer Portal Track alerts, View ZDT network status, Access ZDT reports, Authorize users, etc.
Web Services
Business Intelligence/
Reporting Area
Plant 1 Plant 2 Plant X Data
Receive
FANUC CLOUD
Persistent, Secure Encrypted
ZDT D/C Customer
Cisco Customer Security
Data Analytics
Machine Learning
Data Visualization
ZD
T D
ata
C
olle
ctor
@
Challenge
Solution
Business Outcomes
Save estimated $40M in machine downtime Provide visibility on machines are utilized and increased the Overall Equipment Effectiveness (OEE)
No visibility on how machines are utilized Machine downtime cost millions Data collection and edge compute Cloud managed service across plants
ZDT data collector with UCS on-premises Streaming machine data to Cisco Cloud service and perform data analytic with Cloudera cluster
We have cases where downtime is costing over
$20,000 per minute. With Cisco, I saw a
potential for the solution that could change our
entire go to market strategy… This has the
potential to have the biggest impact of anything
I’ve seen in my 35-year career.
--- Rick Schneider, former North America CEO
”
“
ZDT – A Transformational Tool • Started from 10 robots in 10 factories • Grown to 17,200 robots around the
world
• Already detected and avoided 360 failures
• Estimate $40M+ saved by avoiding downtime
Component changed during weekend
-ZERO DOWN TIME-
Replacement component automatically sent to customer
ZD
T
Data analysis detects failing component from historical data and notifies customer.
-Action Required-
ZDT Data Storage
FANUC Analytics
ZDT Data Collector
Alert message sent to customer and FANUC Service team Partnered with Cisco for Network
Security and Reliable Cloud Services
ZDT - The Big Picture
ZDT is deployed on more than 17,200 robots
Global Installed Base
Europe 1,570 Canada 1,789
China
Europe
Africa
USA
Brazil 698
Japan 64
USA 10,700
Mexico 1,850 Taiwan 48
Australia
India 13
S. Korea 205
China 8
Thailand 51
If downtime costs $500/minute, the total savings is $47,370,000
Total # of robots : 17,252 Total # of plants : 71 Total # of countries : 17 Total # of alerts confirmed : 363 Total downtime avoided: 1,579 hours In production since : May, 2015
Downtime Avoided by ZDT Notifications:
Downtime Avoided by ZDT
• Even though FANUC robots are highly reliable, we are not always kept up to date on how they are used or applied.
• With ZDT we can continually monitor the use and performance of our robots to predict failures before they happen.
• ZDT and FIELD System enhance our support strategy from ‘improving our ability to quickly react’ to ‘predicting and addressing issues before they occur.’
Drive Replaced
Normal
Alert
DOWN TIME PREVENTED BY
ZDT
ZDT is Re-Defining Robot Support Strategy
ZDT Provides Additional Value
Advantages of Cloud Connectivity • Increases awareness of how our
products are being used after shipment
• Connects our service team to our robots for improved response time
• Speeds the deployment of new and refined analytic functions
• Enhances technical support capabilities
• Provides a foundation for future value added services
SECURE
Cisco IE-4000 Hosts FANUC Adapter and MTConnect Agent
Cisco & FANUC IoT Machine Integration 1) IOT Fog Node hosts Adapter + Agent 2) Extracts Machine Data Securely 3) Managed at Scale 4) IOT Ready Machine 5) Factory integration that IT Supports 6) POE+ for Sensor support
IOT Fog Node
MTConnect with FANUC’s CNC (FOCAS)
adapter
FIELD system
Edge Heavy
Open Platform
An open platform that links
all devices at the edge of
the network to make their
data available to intelligent
applications that drive
Smart Manufacturing
systems.
FANUC Intelligent Edge Link and Drive
How ”Open” is FIELD system? Connect Any Device • FIELD system is designed so network
enabled devices from FANUC or any other company can connect, including competitor products.
3rd Party App Development • FIELD system is designed so Apps can
be written and sold by FANUC or any company that wants to be a FIELD system App development partner.
How does FIELD system work? Key Components… • FIELD system Server • Device Converters • FANUC FIELD Apps • 3rd Party FIELD Apps • FIELD system Manager
& Store
Edge Heavy
Open Platform
FANUC FIELD Base Pro
Cisco UCS Server
Thank You