Journey to Industry 4.0 and beyond with Cognitive Manufacturing

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We’re entering the fourth revolution of industry and it is fully differentiated from any that came before it

LineProduction

Electrification & Automation

Miniaturization & Global Scale

Cognitive ManufacturingComplexity

Era

1783

1870

1960

2020

Water, steam, and conveyors; modern materials handling

Assembly systems: Lighting, electricity and assembly lines

Embedded systems: Semiconductors, computers, information technologies and increase in trade

Cyber-physical systems: sensors, big data, predictive analytics, cognitive computing, cyber-physical systems, robotics, 3D printing

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collected manufacturing and

enterprise data

Smarter Supply Chain

Management

Smarter Energy

Smarter Factory

Operations

SmarterProductDesign

Smarter Employee

Safety

Smarter

Quality

made into a transparent,

comprehensive, interactive, minable

corpus of informationthat makes visible new

patterns in the data

to continuously monitor, predict,

respond and interact with humans and

machines

To deliver

SmarterEquipment

Maintenance

Cognitive Manufacturing applies cognitive capabilities to digitize and optimize previously inaccessible areas of manufacturing processes

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To capture the potential of the cognitive manufacturing transformation, we focus on three key pillars of manufacturing that drive the highest improvement

Intelligent Asset and Equipment

Smarter Resources and Optimization

Cognitive Process and Operations

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Intelligent Assets and Equipment

Intelligent assets and equipment utilizes IoT and cognitive capabilities to sense, communicate and self-diagnose issues so they can optimize their performance and reduce unnecessary downtime

Prevent production delays and improve line performance with better asset visibility

Reduce equipment downtime and increase process efficiency with industry models

Expedite equipment repairs through predictive and cognitive analytics

Decrease in equipment downtime at major global auto manufacturer

34%

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Auto manufacturers are utilizing the analytics capabilities of Watson IoT combined with new sources of real-time data to gain new predictions and prescription on improving equipment availability and performance. Using prebuilt industry models, manufacturer can spend less to analyzing and more time doing.

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Equipment downtime can be significantly reduced by combining the power of IoT with cognitive capability. Not only can Watson IoT predict what and when failures can happen, it can utilize cognitive capabilities to advise a user on exactly how to fix and resolve these failures.

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Cognitive Process and Operations

Cognitive operations and processes bring more certainty to business by analyzing a variety of information from workflows, context and environment to drive quality, enhance operations and decision-making.

Increase yield of your manufacturing operations and processes

Improve productivity of your manufacturing line with early quality detection

Expedite service calls and repairs and reduce warranty costs

Increase in overall productivity at major European automaker

25%

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With quality analytics from Watson IoT manufacturers can analyze hundreds of process variables, historic and real-time, to identify issues contributing to quality issues and resolve them before they occur. This drastically improves productivity and yield while reducing operation and material costs.

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By utilizing cognitive capabilities, Watson IoT can bring in unstructured data such as image and video which enriches the information around manufacturing processes. Combined with other IoT data, this information can produce more accurate predictions and better insights

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Smarter Resource and Optimization

Utilize IoT and cognitive insight to optimize the resources engaged around production, whether that’s keeping production line workers safe, improving the expertise of the entire workforce or optimizing energy consumption

Improve worker safety and gain better workforce management

Increase worker productivity and expertise Reduce energy consumption of your facilities

and buildings

Reduced energy and resource costs at manufacturing facility by

8%

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Industrial manufacturers are using Watson IoT to help employees stay safer in dangerous environments. The solution detects hazardous environments and provides real-time alerts to employees and employers enabling preventive measures if physical well-being is compromised or safety procedures have not been applied.

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Engineers are training Watson to collate 30+ years of engineering experience in managing liquid gas facilities to create a cognitive advisory service to help employees across the organization resolve problems faster, improve process flow and achieve better operational outcomes.

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Embracing cognitive manufacturing

Collect the Data

Collect and curate the right data— data on processes and operations you would like to improve, data across your systems, both structured and unstructured. Connect systems and sensors to bring in real-time data for more accurate insights

Visualize the Patterns

Visualize your data on a platform. Quickly build up dashboards and use simple analytics to determine patterns. Supplement with external sources of data and analyze variables that impact the process and operation you would like to improve.

Analyze with Purpose

Apply purpose driven analytics to gain new insights from you data Developed advanced models, process a combination of variables and utilize the prediction engine to generate the best recommendations the drive the most business results

Deliver with Cognitive

Whether it’s dealing with vast amounts of IoT data or dark and unstructured data, cognitive capabilities brings light and clarity. Take advantage of the processing power of cognitive to enable you to act, resolve, and deliver better

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Differentiating elements of Watson IoT technology and ecosystem

Partnered InnovationOpen ecosystemDevice partnershipsEmbedded securityEdge Analytics

Data IntegrationWeather dataSocial dataApplication dataPlatform of platforms

Advanced AnalyticsPredictive AnalyticsReal-time AnalyticsData MiningOptimization

Cognitive TechnologyNatural Language ProcessingMachine LearningTextual AnalyticsVideo/Image Analytics