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)

https://smartmanufacturingcoalition.org http://smartmanufacturing.com

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.

Technology Roadmap Report (2009)

3

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

4

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

Implementing 21st Century SM Report (2011)

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 low-

cost sensing and sensor fusion technologies Establish test beds for smart manufacturing concepts and make them

available to companies of all sizes

Industrial Gas Manufacturing

Steel

Energy

Bio/Pharma

Electronics

Healthcare

Energy Supply Production and Delivery Customers

Our customers demand capital discipline and high reliability Our goal is to meet their demands and maintain high energy efficiency

Smart Manufacturing Helps Meet Our Goals

• Hosted computing improves results at a lower cost

• Common infrastructure facilitates supply chain collaboration

Design Operations

• Low cost sensors and wireless enable real time decisions

Machine Operations & Line Management Trade-Offs

Machine Function Benchmarking & Integrated Line and Energy Management Managing Power from the Grid

General Dynamics

FORD In-Production Virtual Aluminum Castings

Aging temperature 240C for 5hrs

210 230

205

Aging at 250C for 3hrs

Optimized Heat Treatment Process Faster and Stronger !!

220

Initial Heat Treatment Process

Target Strength = 220 MPa

John Allison AIChE 2010

General Mills Farming

Distributor

Supply Chain

Customer

• Customers “pushing” demands • Tracking & Traceability

Manufacturing Plant

11

Supply Chain Distribution Center

Customer

Business Systems, ERP

Smart Grid

Smart Factory

Recipe Management Mapping formula into operating recipes

EDI transaction & quality certifications

FDA Tracking & traceability

General Mills Networked-Based Manufacturing

Intelligence & Collaborative Manufacturing

Green Light Analyze - to put into production Make – right ingredients – confirmation on recipe Release – meet requirements to release

Mapping SAP information Into operation

Master Data (BOM,Specs,Vendor,Ingredients,FP)

Dire

ct

Cons

umpt

ion

Core Systems

Data Input

Core Functions

Raw

Mat

’l In

vent

ory

Fini

shed

Pro

duct

In

vent

ory

Prod

uctio

n

Hist

ory

Plan

t Flo

or

Inve

ntor

y

Dem

and

Plan

Prod

uctio

n O

rder

Line

Sche

dule

MQIS MES SAP ERP Red Prairie SAP APO SAP PLM SAP MRP

Value Creation Green Light to Convert

Green Light to Ship

Demand Driven Supply Chain

Wor

kFlo

w

Lot T

rack

ing

Overusage

Opt

imiza

tion

Engi

ne

Trace/Recall BOM Validation Yard Mgmt

Optimized Inventory

Business Applications Directed Work

Supplier Managed Inv Line Supply Bin Mgmt

Allergen/Micro WorkFlow eCOA

GM’s ECO System of “ STUFF”

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

Industry Test Bed Strategy

Industry-Driven Defined from Test Bed systems

META 4 Interoperable Supply Chain

Network Control, Automation,

Optimization Management & Decision

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.

Meta 1 Integrated Workforce,

Cyber, Physical System Performance

Variability Reduction Benchmarking

Challenge 2 Integration of manufacturing enterprise data, control, automation, management and optimization infrastructures

Challenge 4 Precompetitive and competitive community source modeling innovation & simulation assimilation platform

Challenge 1 Factory and supply chain demonstrations sites of applied manufacturing intelligence

Challenge 3 Real-time syncing virtual models and physical operations

The Technical Basis for Collaborative Manufacturing and the SM Platform

Enabling New & Dormant Technologies

11/1/11

17

SMEs Small & Medium

Enterprises Manufacturing

Consortia

Standards and Reference

Architecture IT Providers

Key Development

Resources Universities, SME’s

Manufacturers, Labs

SMLC Industry-Driven Integrated

Performance Metrics

Micro, Meso, Macro

First Concept of the Smart Manufacturing Platform Infrastructure for Real-Time Data Driven

Modeling and Simulation

Community Source Market Place

Real-time Data & Modeling Workflow To& & Metric Toolkit/ App Development

Real Time Virtual Manufacturing Demonstration Facility (VMDF)

Pre-competitive & Competitive

Hub

Test Bed Manufacturer

& Supplier Crosslinking

Engagements UCLA

Apps Store Cloud

Services

Variability Management

Real-time Plan Passes

Community

Source Resources

Benchmarking

Rapid Qualification

ICME

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

Multi-Layer Smart Manufacturing (MLSM) Workflow Foundation

Design Data

MDSM Program “Host” Manufacturing

Initiatives

Virtual MDSM

Host • Dash Board •Collaboration

Product Manufacturing

Materials & Process Tech Prototype Qualification In

Service

Macro Layer • Product Volume • Scheduling • Supply Chain

Meso Layer • Management • Machine Flow • Optimization

Micro Layer

APP Store • Reference Flows • Process Models

• Control •Metrics

• Sensors/Actuators • Control/Optimization • Automation

People Involved Integrated Metrics & Decision Making

Conditional decisions Model building &updates Model insertion

Workflow Distinguished from Control & Automation

Check Table Optimal Machine

Usage

Calculate Machine, Energy,

Product Metric

Dashboard Recommend

Tradeoff Points

Process & Line Set Point

Conditions

Run Machine Usage Pattern-Based Analyzer

Update Machine Usage Model

Build Table Optimal Machine Usage Windows

New Machine Maintenance Process Data

Process & Line Data

Factory Data Control Automation Factory Workflow

General Dynamics

Benchmarking Model

Table Model Accepted

Workflow Service

Framework

Computational Resources Batch Scheduler

Machine Benchmark

Data

Multi-Layered Smart Manufacturing Management (MLSMM) Time Managed as Workflow Not Control

Transformational Machines – People - Materials Dynamic Manufacturing Ecosystem

Design Data

Product Manufacturing

Materials & Process Tech Prototype Qualification

In Service

Macro Layer

Meso Layer

Micro Layer 1000s of control loops Control points -

Manpower – 100X Time - minutes

100s of control loops Control Points - ? Manpower – 10X

Time -hours

10s of control loops Control Points - ?

Manpower - X Time – days

Current Practice – One Pass per Day per

Event; Too Late, Stale Data, Slow Responsive

Manufacturing

Goals: 100x Event Variability Adjustment Capability & Dynamic

Certification Improvement

Focus: Integrated metrics, Qualification,

Computational Materials Engineering, High Fidelity Dynamic

Operations

The Concept of Data-to-Applications

Ref Arch

Data Collection Manufacturer

Manufacturer Real-time

Manufacturer Data Warehouse

Performance Management Data & Modeling Workflow

Data Validation

App

Local/Global Integrated Productivity

Metric Dash Board

Process sensor data

Ref Arch Data Collection

Supplier

Data and Computation Management Dashboard

EPM App from

Toolkit

Risk Scenarios App

Reduced Order Model

Scenarios App

Real-time Action & Risk

Support App

SM Platform Workflow, Data and

Computation Services

Encrypted links

Linked Apps to Form Function

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)

ENGINEERING THE PLATFORM FOR THE USE CASES

Implementation

Process Data Transfer

Process Data

Data Control Automation Proprietary Workflow

Praxair SMR Example

ROM Validation

Local Storage

ROM Accepted

Rerun ROM

Workflow Control Server

Data Validation and filtering

Local Web Server

Workflow Service

Framework

Computational Resources

Validated Data

Batch Scheduler

New ROM Transfer

CFD Runs Update ROM

using CFD Output

Offline Simulation with ROM

CFD Preprocessing

Workflow (WFaaS)

SMLC Concept Workflow as a Service (WfaaS)

Factory Data Control & Automation Workflow

Proprietary Workflow

Provisioning

State Tasking

Orchestration

Security Provenance

Application Instances

Workflow (WfaaS)

WfaaS Integrated with SaaS, PaaS, IaaS

Compute Platform (IaaS)

Cycles Software / Licenses Storage

Technical Computing Marketplace

Seller/Provider (PaaS)

Seller Dashboard Dev Tools Software

Images

Buyer/User (SaaS)

Buyer Dashboard

Buyer Catalog

Portal Apps

Factory Data Control & Automation Workflow

Proprietary Workflow

Provisioning

State Tasking

Orchestration

Security Provenance

Application Instances

/UCLA Services

Web Browser / Desktop Application

Caching URL Dispatcher

View

Model

Template

Tasks

Asynchronous Task Queue

Message Queue Database

Compute Provider Interface (CPI)

HTTP / REST / SOAP

Nimbis Ecommerce

Subsystem (NES)

Nimbis Broker

Subsystem (NBS)

Compute Platform

Shared Storage

Browse, Configure, Price, Purchase

OAuth-OpenID

PBS

Job/Session Management Resource/License Metering

Remote Access Node

HTTPS / SSH VPN / VNC

License Manager

Application Images

Nimbis Secure Cloud Portal Architecture Data and Application Management Foundation

Nimbis Services Inc. Proprietary

Open Architecture Workflow Construction & Management

SM Platform Apps Store, Shared Market Place & Distribution Hub

Multiple Service Environments

“Apps” Store

Check Table Optimal Machine

Usage

Calculate Machine, Energy, Product Metric

Dashboard Recommend

Tradeoff Points

Process & Line Set Point Conditions

CFD Runs Update ROM

using CFD Output

Offline Simulation with ROM

CFD Preprocessing

CFD ROM

Template for SMR

Apps as a Service Apps as code module

CFD Runs CFD Preprocessing

Machine, Energy, Product Metric

App Toolkits Workflow Components

Library of Workflows

Machine energy usage

calculation

ROM Sync

Integrated Metric

Data Definition

Maps

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 3rd party contribution

• Real-time systems across large time scales

Workflow Based Architecture

• Composability & customization

• Design to manufacturing models

• Workflow libraries

• Technology insertion

Smart Grid

Customer

Enterprise Business

System

Suppliers

OEM Machine Builders

Distribution Center

Factory

SMLC Commitment to a Comprehensive Approach

• Higher value products • Improved quality • Zero downtime • Increased equipment

life / utilization

• Improved safety • Reduced energy

and emissions • Highly sustainable

• Higher product availability • No inventory • Product lifecycle

management

ENTERPRISE OPTIMIZATION & SUSTAINABLE PRODUCTION

ENERGY, SUSTAINABILITY, EH&S AGILE DEMAND-DRIVEN

SUPPLY CHAINS

• National Network for Manufacturing Innovation (NNMI)

• http://manufacturing.gov/docs/NNMI_prelim_design.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.”

SM: An Enabling Technology

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

https://smartmanufacturingcoalition.org http://smartmanufacturing.com