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w w w . m a r k e t s a n d m a r k e t s . c o m 1w w w. m a r k e t s a n d m a r k e t s . c o m
SMART MANUFACTURINGMAKING AUTOMATION
INTELLIGENT
Jagdish Rebello PhDGlobal Vice President
MarketsandMarkets
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PRESENTATION AGENDA
WHAT IS SMART MANUFACTURING
KEY TRENDS IN SMART MANUFACTURING
DRIVING FACTORS AND KEY CHALLENGES
SMART MANUFACTURING ADOPTION
CASE STUDIES
KEY TAKEAWAYS
w w w . m a r k e t s a n d m a r k e t s . c o m 3
INDUSTRY 1.0
INDUSTRY 2,0
INDUSTRY 3.0Age of SteamEnd of 18th Century Water and steam power used to create
mechanical production facilities
Age of AutomationStart of 1970s Electronics and IT technologies
automated the production lines
Age of ElectricityStart of 20th Century Mass production line driven by electricity
1800 1900 1970
WHAT IS SMART MANUFACTURING
MORE PRODUCTIVITY
MORE FLEXIBILITY
IMPROVED SAFETY
SMART MANUFACTURING IS ALL ABOUT HARNESSING DATA Data will tell us WHAT TO DO and WHEN TO DO
INDUSTRY 4.0
An Era of Data driven ManufacturingSince 2010 Cloud technology & IIoT and many more
2010….
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RESPONSIVE TO SHORTER LIFE CYCLES
TRANSFORMING THE SHOP FLOOR
Every thing is connected on shop floor
• Machine
• Products
• Manufacturing Process
Any change in consumer preference will be
• Reflected in products
• Its manufacturing Process
• Machine which produces it
• Also reflect in supply chain
• Vendors
• Raw Materials
• Vendors
• Raw Materials
SUPP
LY S
IDE
• End Consumers
• Physical and virtual StoreDE
MAN
D SI
DE
Manufacturing Process Products
Machine
Data Communication
Data Communication
Data Communication
CONTINUALLY RESPONSIVE
w w w . m a r k e t s a n d m a r k e t s . c o m 5
SMART MANUFACTURING – TRENDS
IMPLEMENTATION OF SOFTWARE Implementation of Predictive maintenance
• Big data; Cloud computing; Analytical Software's
AUTOMATING AND CONNECTING Automating and connecting every vertical within the factory floor
• Process Flow
MATERIAL FLOW Helps us in knowing where every material and product is within the factory floor
• Preciously plan the production process • Place the right kind of tool at right place at right time
AUTONOMOUS MACHINE Autonomous machines and equipment's
• Automated Guided Vehicles (AGV)• Robots; Industrial Robots; Collaborative Robots
• Makes work place safer
AR AND VR Implementation of Augmented Reality (AR) and Virtual Reality (VR)
• Material Flow
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SMART MANUFACTURING – DRIVING FACTORS
IMPROVEMENTIN TECHNOLOGY
ROBOTICS SYSTEMS
GOVERNMENT SUPPORT
EMBEDDED SYSTEMS
• Machine manufacturer and developer has started embedding systems right at the concept phase
• Sensors• Communication Technology
• Huge improvement in the technology, especially with regards to data generation, communication, data collection, and computing power
• Cost of computing has decreasedto a large extent
• Drastic decrease in the cost of data storage
• Ability of connect and integrate has become much easier and simplerthan before
• Growth and implementation of Robotics systems in the manufacturing systems
• Industrial Robots; Collaborative Robots
• Government support with regards to the implementation of Smart Manufacturing
• China, South Korea, India, Germany, U.S.
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$0.99per GB
$0.17per GB
2012 2013 2014 2015 2016 2017
SMART MANUFACTURING – DECREASE IN THE COST OF COMPONENTS
SOLID STATE DRIVE – DECREASE IN COST PER GB Declining IoT Sensor Cost
$0.7
$0.48
2012 2013 2014 2015 2016 2017
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SMART MANUFACTURING – CHALLENGES
HUGE INITIAL COSTHuge initial implementation cost, which will be compensated in the coming futures in terms of increased productivity
COMPATIBILITYCompatibility issues between technology, equipment, and communication protocol
SECURITY ISSUESSecurity is important, specially in the critical process; the companyisimplementing smart manufacturing at their production floor; technology gives access to deep dive into the data
POLITICAL ISSUESConstant pressure from government in many country to either maintain or add the manufacturing Jobs
MONUMENTAL TASKImplementation of sensors and other communication technology and its management may create huge IT glitches
IMPLEMENTATIONImplementation of smart manufacturing concept is major challenge –especially when manufacturing facility is old compared with the newer facilities
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INDUSTRIAL ROBOTS INDUSTRIAL 3D PRINTING AUGMENTED REALITY
BIG DATA, ANALYTICS, AND SOFTWARE
INDUSTRIAL INTERNET AND COMMUNICATION
CLOUD, CYBER SECURITY AND PLATFORM AS A
SERVICES
SMART MANUFACTURING
40.5 79.6
2016 2022
1.0
4.8
2016 2022
4.0
117.4
2016 2022
0.1
0.7
2016 2022
64.8 130.3
2016 2022
28.7
79.1
2016 2022
SMART MANUFACTURING – ELEMENTS OF THE ECOSYSTEM
Sensors
SensorsSensors
Sensors
System Integrator
System Integrator
Data Communication Data Communication
Data CommunicationData Communication
Dat
a C
omm
unic
atio
n
Dat
a C
omm
unic
atio
n
w w w . m a r k e t s a n d m a r k e t s . c o m 10Source: MarketsandMarkets
ENABLING TECHNOLOGIES – STRONG GROWTH
INDUSTRIAL ROBOTICS
INDUSTRIAL COMMUNICATION
ASSET MANAGEMENT
Industrial Robotics Market & Forecast (USD Billion)
Industrial Communication Market & Forecast (USD Billion)
Asset Management Market & Forecast (USD Billion)
40.38
0.12
75.99
3.59
Traditional Industrial Robots Collaborative Industrial Robots
2016
2022
37.7323.29
3.75
56.27 59.2
14.87
Fieldbus Industrial Ethernet Wireless
20162022
4.642.38 2.23 1.71
5.767.72
5.366.71
Barcode GPS RFID RTLS
2016
2022
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ENABLING TECHNOLOGIES – STRONG GROWTH
Augmented Reality Market
MANUFACTURING EXECUTION SYSTEMS
INDUSTRIAL 3D PRINTING
Augmented Reality Market & Forecast (USD Billion)
Manufacturing Execution System Market & Forecast (USD Billion)
Industrial 3D Printing Market & Forecast (USD Million)
Source: MarketsandMarkets
4.0
117.40
Augmented Reality Devices
2016
2022
5.263.23
11.59
6.63
Services Software
2016
2022
0.43 0.298 0.225 0.069
1.82 1.63
0.96
0.34
Printer Material Service Software
2016
2022
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SMART MANUFACTURING – VALUE CHAIN
Datalogic S.P.A. Honeywell International Inc. Sato Holdings Corp. Ubisense Group Zebra Technologies Corp.
ASSET MANAGEMENT
ABB LTD. Fanuc corporation Kawasaki Heavy industries Mitsubishi Electric Corporation Yaskawa Electric Corp.
INDUSTRIAL ROBOTICS
General Electric Company Hitachi Data Systems
Corporation Honeywell International Inc. Microsoft Corporation Siemens AG
3D PRINTING
ABB Ltd. General Electric Co. Rockwell Automation, Inc. Schneider Electric SE Siemens AG TE Connectivity Ltd.
COMMUNICATION
DMG Mori Komatsu NTC Mitsubishi Electric Corporation Okuma Corporation Samsung Machine Tools Schneider Electric Siemens TRUMPF
MACHINE BUILDERS
General Electric Co. Hitachi Data Systems
Corporation Honeywell International Inc. Microsoft Corporation Siemens AG
CLOUD AND BIG DATA
Infineon Technologies AG NXP Semiconductors N.V. Robert Bosch GmbH STMicroelectronics TE Connectivity Ltd. Texas Instruments Inc.
SENSORS
Daqri LLC EON Reality, Inc Google Inc. Infinity Augmented Reality Inc. Microsoft Corporation Oculus VR, LLC Qualcomm Inc. Samsung Electronics Co., Ltd.
AR AND VR
ABB Ltd. General Electric Co. Mitsubishi Electric Corporation Rockwell Automation, Inc. Schneider Electric SE Siemens AG Yokogawa Electric Corporation
SMART MANUFACTURING
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SMART MANUFACTURING ADOPTION TRENDS
MAJOR COUNTRIES RAPIDLY ADOPTING AND DEPLOYING SMART MANUFACTURING
PROJECTED GEOGRAPHY AND INDUSTRY VERTICAL MARKET FOR SMART MANUFACTURING
TOP ADOPTERS: INDUSTRY VERTICALS
Chemical
Machine Manufacturing
Oil and Gas
AutomotiveManufacturing
Food and Beverages
Electronics and Semiconductor
CPUMexico
U.S.
Canada
Brazil
U.K.
Germany
Poland
Saudi Arabia & UAE India
Japan
South Korea
VietnamTaiwan
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45.57 49.85 54.38 59.15 64.18 69.19 74.8
0
10
20
30
40
50
60
70
80
2016 2017 2018 2019 2020 2021 2022
SMART MANUFACTURING –ROBUST GROWTHU
SD B
illion
Note: Market size is based on Technology and component implemented in a smart manufacturing facility. Technology segment includes PLM, MES, PLC, SCADA, ERP, DCS, and HMI; and component segment includes sensors & actuators , communication technologies, industrial robotics, machine vision, control devices, and control valves
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CASE STUDY – SMART MANUFACTURING
FEW INITIATIVES TAKEN BY MAJOR MANUFACTURING COMPANIES
Facility is considered to be the one of the most advanced automobile manufacturer facility It is expected to help in optimizing the entire process chain and its operation 30% faster
Smart factory equipped with modern equipment and highly efficient logistics will help to achieve annual production volume of 150,000 Audi Q5 vehicles
Audi has started its advanced manufacturing plant in Mexico
“
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CASE STUDY – SMART MANUFACTURING
Important feature of the said facility is the implementation of 3D printing to develop next generation fuel nozzles This technique will develop fuel nozzle 25% faster and will be five time stronger
Anticipated to develop 100,000 next generation fuel nozzles by 2020 Helps GE to develop approximately 44,000 fuel nozzle per year
General Electric recently opened smart manufacturing facility (2nd phase) in Chakan near Pune in India
“
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SUMMARY & CONCLUSIONS
• Data will command the entire manufacturing operation
• Will create flexibility and customizability in manufacturing environment
• Implementation of smart factory will not happen in few days
• Will need various technologies to come together in order to complete the ecosystem
• New set of trained workforce is required at the smart manufacturing facility
• Skills required will be changes in software engineering, data management, and IT
networking
• Government is emphasizing either retain or add the workforce
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SMART MANUFACTURING CURVE AND MNM’S COVERAGE
HORIZON ASCENT ZENITH PLATEAU
TEC
HN
OLO
GY
MAT
UR
ITY
Advanced Process Control Market
Digital Substation
Industrial Communication
Industrial IIoT
Industrial Safety
Intelligent Flow Meter
Internet of Robotic Things (IoRT)
Manufacturing Execution System
Supervisory Control and Data Acquisition
Water Automation
Leak Detection
Immersive Training Simulator
Level Transmitter
Machine Safety
Digital Manufacturing
Control ValveMicro Nano PLC
Industrial PC
Plant Asset Management
Industrial Augmented Reality
Industrial 3D Printing
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THANK YOU!
Jagdish Rebello [email protected]
&Pankaj Raushan
