Arconic Smart ManufacturingFOCAPO/CPC
January 9, 2017
Arconic: Transforming the way we fly, drive, build and power
2
2015 Revenue: $12.5B | Locations: 156 locations around the globe | Employees: 42,250
Arconic Engineered Products and Solutions
Arconic Fastening Systems and Rings
Arconic Titanium and Engineered Products
Arconic Forgings and Extrusions
Arconic Power and Propulsion
EPSArconic Global Rolled Products
GRP
Micromill Products and Services
Aerospace and Automotive Products
Brazing, Commercial Transportation and Industrial Solutions
Arconic Transportation and Construction Solutions
TCS
Building and Construction Systems
Latin American Extrusions
Arconic Wheel and Transportation Products
Source: Arconic
Arconic Technology Center: Core Competencies
Source: Arconic Technology Center 3
Alloy & MaterialDevelopment
Basic Science
Metal & Material ProductionTechnologies
End ProductManufacturing Technologies
EngineeredSurfaces Advanced Analytics &
Modeling
EnvironmentalTechnologies
Product Design,Development
and Manufacturing
Pilot Production/Product Prototyping
Source: Arconic Automation & Smart Manufacturing Team 4
Arconic’s vision for Automation & Smart Manufacturing
RecoveryQuality
Productivity
AnalyticsModelingSimulation
Optimization
PredictiveReal-timeFlexibility
Access VisualizationIntegration
Sensing
Data DrivenDecisions
Right dataRight timeRight form
Right people
Phase 2: Intelligence
Phase 1: Information
Smart Manufacturing
ITInf rastructure.& Applications
(ERP)
Data Historian, Manufacturing
Execution Systems (MES), Equipment Health Management
Advanced Control, Optimization, Operator Training Simulation,
Alarm & Event Management,
Controls – Distributed Control Systems (DCS), Programmable Logic Controllers (PLC),
Safety Instrumented Systems (SIS), Motor Drives
Supervisory Control & Data Acquisition
Field Devices – Control Valves, Pressure, Temperature, Level, Density, Analyzers, Motors, Variable Speed DrivesIn
fras
truc
ture
& S
ecur
ity
Automation
0
1
2
3
4
ISA-
S95
Auto
mat
ion
Leve
ls
Sensors
Real-time Control & Robotics
Advanced Control
Mfg Operations Management
Business Planning, Logistics
5
Competencies critical for developing Smart Manufacturing solutions
Source: Manufacturing Intelligence & Automation Technologies ATC
Process Modeling & Simulation
In-situ Sensing & NDE
Advanced Control & Automation Systems
Visualization
Advanced Analytics& Optimization
Physical Automation & Robotics
Smart Infrastructure
6
Using Advanced Analytics for Energy Forecasting
Source: Arconic Automation & Smart Manufacturing Team
Predicting peaks helpsoptimizeenergy usage
History Forecast
Ener
gy D
eman
d
Time
7
Leveraging internal and external research
RecoveryQuality
Productivity
AnalyticsModelingSimulation
Optimization
PredictiveReal-timeFlexibility
Access VisualizationIntegration
Sensing
Data DrivenDecisions
Right dataRight timeRight form
Right people
Phase 2: Intelligence
Phase 1: Information
Smart Manufacturing
ITInf rastructure.& Applications
(ERP)
Data Historian, Manufacturing
Execution Systems (MES), Equipment Health Management
Advanced Control, Optimization, Operator Training Simulation,
Alarm & Event Management,
Controls – Distributed Control Systems (DCS), Programmable Logic Controllers (PLC),
Safety Instrumented Systems (SIS), Motor Drives
Supervisory Control & Data Acquisition
Field Devices – Control Valves, Pressure, Temperature, Level, Density, Analyzers, Motors, Variable Speed DrivesIn
fras
truc
ture
& S
ecur
ity
Automation
0
1
2
3
4
ISA-
S95
Auto
mat
ion
Leve
ls
Sensors
Real-time Control & Robotics
Advanced Control
Mfg Operations Management
Business Planning, Logistics
Advanced Optimization Techniques
Simulation Tools
Physics BasedModeling
Advanced Analytics Methods
Advanced Visualization
MethodsAdvanced
Sensing/NDE
Advanced Process Control
Source: Arconic Automation & Smart Manufacturing Team
FOCAPO-CPC Smart Manufacturing in Energy Intensive Industries
January 2017
Praxair at Glance
A Fortune 300 company with sales of $10.8 billion in 2015
One of the largest industrial gases companies
Operations in more than 30 countries
26000 employees
One million customers worldwide
Presence Service Industries
Praxair Business
200+ air separation plants worldwide
• A large air separation plant can consume
60+ MW of power/hr
40+ hydrogen plants
Hundreds of smaller plants
Large distribution business
• 500+ trailers in USA alone
Large packaged gas business
• 10MM+ cylinders in USA alone
$1B+ expend in electricity & NG/year
Praxair Strategy on Smart Manufacturing
Faster replicationKPI’s to real time decision making
Descriptive
Diagnostic
PrescriptivePredictive
Variety Velocity Volume“Big Data”
Reactive to proactive business
Information ImpactInsightSensors and
wirelessAutomated monitoring
Intelligent platforms
Advanced control
Business & value chain tools
Mobile data collection
IIoT and Big Data
1 Billon+ measurements per year for a single compressor
Vibration
Pressure/volume
Rod runout
RPM
Data logger
Sensors
500K+ measurements per second
Server per plant & lack of analytics!
Advanced Analytics& visualizationInefficient system
Steam Methane Reformer
Good Partnership with UT & SMLC !
Before balancing
After balancing
Each camera collects millions Ts/min
Model based algorithms to recommend burner fuel valve positions to balance the reformer
Embedded algorithms into a user-friendly, web-based interface
Design TWTAvg TWT (lower level)
17001650 17501600
TWT distribution Max TWT
1550Temperature oF
Next Generation Product Allocation System
Enable integrated production and distribution planning
Network of plants, customers, and 3rd party sources
Site BCompetitor
Supply
Power supply
Pipeline customers
C2
Site A
C3
C1
Liquid customers
Next Gen PAMS Objective: Minimize total merchant liquid network costs by better coordinating sourcing, production, and distribution decisions
Optimizeplant-customer
assignments
Optimize production
plans
Next Gen PAMS Key Challenges
Key Modeling FeaturesProduction: energy contracts and production modes/slates
Distribution: driver contracts and vehicle capacities
Market: electricity and demand forecasts
Horizon: One week to one month at various granularity
0 H(Horizon)
Time interval = hours / days / weeks4 hr 1 day
Key DecisionsElectricity demand & liquid production at plants
Liquid sourcing & transfers to existing / new customers
Liquid inventory targets at plants and liquid depots
Response to outages & spot sales
Resource plan (# trailers & #drivers)
Strategic analysis (e.g. competitor swap, fleet sizing)
Technical ChallengesComputational time bounded by 15 min
Decisions that impact groups with conflicting metrics
Plant vs Cluster Unit production cost
Production vs Distribution
Gaps in production and routing scheduling
Holistic approach to merchant liquid sales and operations
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Providing manufacturing context to the research community
Process Expertise
Source: Arconic Technology Center, Praxair
Production Facilities
Materials
Talent& Tools
ExperimentalFacilities
ExploratoryFreedom
Industry Academia
InnovativeSolutions
Awareness
Talent Marketplace
Collaboration
Environment
ManufacturingChallenges &Opportunities
Research Areas of Interest for Arconic & Praxair
Using technology to maintain competitive edge
• Integrated Computational Materials Engineering (ICME)
• Multi-physics simulation for metals solidification, deformation processes
• Prediction of surface topography in metals manufacturing operations
• Multi-variate optimization for multi-production center flow paths
• Model based process control with uncertainty quantification
• In-situ property & surface sensing in metals manufacturing operations