Smart Manufacturing, Manufacturing Intelligence and Demand-Dynamic Performance

Smart Manufacturing Leadership Coalition (SMLC)Jim Davis – UCLA February 6, 2011

http://smartmanufacturing comhttp://smartmanufacturing.com

National Modeling and Simulation Coalition

Jan 30 Wall Street Journal: The Coming Tech Led BoomMark Mills & Julio OttinoMark Mills & Julio Ottino

“The second transformation? Smart manufacturing. This is the first structural shift since Henry Ford launched the economic power of "mass production."

“We are just entering an era where the very fabrication of physical things is revolutionized by i t i l i E i ill d i d b ild f th l l l l emerging materials science. Engineers will soon design and build from the molecular level,

optimizing features and even creating new materials, radically improving quality and reducing waste.”

“The Internet is evolving into the "cloud"—a network of thousands of data centers any one of which makes a 1990 supercomputer look antediluvian.”

“From social media to medical revolutions anchored in metadata analyses, wherein astronomical feats of data crunching enable heretofore unimaginable services and businesses, we are on the cusp of unimaginable new markets.”

21st Century Smart Manufacturing

Data• Demand‐dynamic economics keyed on the intelligence of the ‘customer’

• Coordinated enterprise responses throughout the entire

AnalyzeApply

responses throughout the entire manufacturing supply chain

• Predictive, preventive 

Dramatically intensified application of manufacturing intelligence using 

advanced data analytics, modeling and simulation to produce a fundamental  ypp y

• Integrated computational materials engineering

transformation to transition/new product‐based economics, flexible factories and demand‐driven supply 

chain service enterprises 

• Performance‐oriented enterprise,  minimizing energy and material usage and 

i i i i t l

Modelmaximizing environmental sustainability, health and safety and economic competitiveness

Raising the Level of Abstractiong

Business (Collaboration, (Broader MetricsReal-time Decisions)

If Smart Manufacturing is such a smart idea why aren’t companies already doing it?

Already Investing in Information Organizational

Mindset

Already Investing in Information Technology, Automation and Controls for 40 years

Technology(Horizontal & VerticalPervasive)

Workforce(Innovation & Broad Based)Pervasive) Broad-Based)

SMLC Implementing 21st Century Smart Manufacturing

• Air Liquide• Alcoa

• American Council for an Energy Efficient EconomyA i I tit t f Ch i l

• Merck• Microsoft

O k id N ti l L b t• Applied Materials• CH2MHill• Cisco• Dow

• American Institute of Chemical Engineers

• Council on Competitiveness• Institute of Paper Science &

• Oakridge National Laboratory• Owens-Corning• Procter & Gamble• Pfizer• Dow

• DuPont• Eli Lilly• Emerson

pTechnology – Georgia Tech

• Manufacturing Institute• National Center for Manufacturing

Sciences

Pfizer• Praxair• Rockwell Automation• Sematech

• ExxonMobil• Ford• General Dynamics

Sciences• National Council for Advanced

Manufacturing• Putman Media

• Carnegie Mellon University• Purdue• Georgia Tech

RENCI/N th C li Ch l • General Mills, Inc.• General Motors• Honeywell International• Invensys

• Walt Boyes – Spitzer and Boyes • Jim Porter – President Sustainable

Operations Solutions - Chief Engineer and Vice President

• RENCI/North Carolina Chapel Hill

• UCLA• University of Texas Austin• Invensys

• KraftEngineer and Vice President Engineering and Operations DuPont Company (Retired)

• Denise Swink - Consultant

y• U. Wisconsin Milwaukee

School of Management

Smart Manufacturing is the Application of Networked-Based Manufacturing Intelligence & Integrated Performance MetricsIntelligence & Integrated Performance Metrics

Untapped degrees of Freedom: performance, efficiency & productivity

Actionablebusiness &operations

Business Systems, ERP

efficiency & productivityoperationstradeoffs Tracking &

traceability

Anticipate, plan,manage riskacross

li

Supply ChainDistribution Center

Customer

Smart Factory

suppliers

Smart Grid

Factory

New formsbenchmarking

ComputationalMaterials Engineering

6Courtesy of Rockwell Automation : Copyright © 2009 Rockwell Automation, Inc. All rights reserved.

benchmarking

Performance and Demand Dynamicsy

Mi i

New real-time globalPerformance metrics –•customization

Farming

Mining

• Less vertically integrated

•energy performance•reuse

Supply Chain

• More information driven• Workforce ecosystem

Manufacturing Plant• Customers “pushing” demands• Flexible production - smaller

Customer

Distributor

Courtesy of Rockwell Automation : Copyright © 2009 Rockwell Automation, Inc. All rights reserved.

pvolumes of custom products

Smart Manufacturing PlatformInfrastructure for Real-Time Data Driven

Modeling and Simulation

SMEsSmall & Medium 

SMLC Industry‐Driven 

Integrated  Performance 

Modeling and Simulation

Rapid EnterprisesNCMS, AIChE

MetricsNCMS, AIChE, NIST

Outreach

pEvaluation 

& Outreach

Real‐time Data & Modeling Workflow To& & Metric Toolkit/A D l t

Pre‐competitive& Competitive

Hub

Test BedManufacturer& SupplierCrosslinking Engagements

Apps StoreCloudServices

Community Source 

Resources

Standards and Reference

Key Development 

App Development EngagementsUCLA

Business CollaborationsBenchmarking Reference 

ArchitectureEmerson, Honeywell, Invensys Rockwell

pResources

Universities, SME’s Manufacturers, Labs Community Source Market Place

Benchmarking

11/1/11

8Real Time Collaborative Cloud Computing

Smart Manufacturing

htt // t f t ihttp://smartmanufacturing.com

http://smart-process-manufacturing.ucla.edu/