Embed Size (px)
Citation preview
Technology Convergence Enabling Factories of Technology Convergence Enabling Factories of
the Future the Future Smart and Sustainable Manufacturing key for Industrial Revolution 4.0Smart and Sustainable Manufacturing key for Industrial Revolution 4.0
Sumit Kumar Pal, Research Analyst
Technical InsightsTechnical Insights
10 April, 2014
© 2014 Frost & Sullivan. All rights reserved. This document contains highly confidential information and is the sole property of
Frost & Sullivan. No part of it may be circulated, quoted, copied or otherwise reproduced without the written approval of Frost & Sullivan.
Today’s Presenter
Functional Expertise• Detailed oriented analytical and research skills which includes market and technology analysis
within the Automation and Electronics domain.
• Generating research service reports and technical alerts.
Industry Expertise• Experience base covering a broad range of sectors, leveraging long-standing working
relationships with leading industry participants’ Senior Executives in
• Sensors
• Microelectronics
2
What I bring to the Team• Technical expertise in Electronics and Instrumentation
• Strong Problem Solving and Analytical Skills
• Presentation Skills
Career Highlights� Research Associate in Automation & Electronics – Technical Insights group of Frost & Sullivan
since April 2012
Education� Post Graduate Programme in Business Management from Praxis Business School, Kolkata, India
� Bachelor of Technology from Future institute of Engineering and Management, West Bengal
University of Technology, Kolkata, India
Sumit Kumar PalResearch Analyst
Technical Insights
Frost & Sullivan
GIC
Chennai
The Industrial Revolution Timeline
1st Industrial Revolution
2nd Industrial Revolution
3 Industrial Revolution
1818thth CenturyCentury
1919thth CenturyCentury
2020thth CenturyCentury
3
2025
3rd Industrial Revolution
Industry 4.0
2020 CenturyCentury
2121stst CenturyCentury
Focus on Cyber-
Physical Systems
Agenda
Factories of the Future – Focus on 3P’s
Smart, Connected & Virtual factories
Key DriversTechnology Enablers
4
Convergence Scenario Notable Developments & initiatives
Global Footprint & Funding
ScenarioImpact on Megatrend
Future Factories – 2025 OutlookTechnology Convergence and
Innovation Opportunities
Factories of the FutureFocus on 3P’s – People, Process, Production
� Customization
� Decrease in
Production Time
Workforce Management� Condition Monitoring
People Process
Production
5
� Plant-wide Optimization for
Manufacturing Intelligence
� Flexibility
� Reduce Wastage
� Worker Safety
� Collaboration
� Workforce Management
� Supply Chain
Management
� Plant and Enterprise
wide Integration
� Predictive
Diagnostics
� Condition Monitoring
Progressive Outlook of Future FactoriesSmart, Virtual & Connected Factories
Smart Factories
• Maximize Resource Utilization
• Sustainable Manufacturing
• Reconfigurable Processes and Systems
• Minimal Downtime
• All devices are connected to each other
6
Connected Factories
Virtual Factories
• All devices are connected to each other
• Components include Sensors, Actuators, Transducers, Controllers,
Display, Computers, Workstations
• Integration with Business Decision Making
• 3D Modelling of Entire Plant
• Access to all processes from a workstation
• Real world simulation prior to
implementation
Key Driving FactorsTowards Realization of Smarter Factories
Short Medium Long Comments
Sustainability
•Efficiency, Waste Reduction, Energy Consumption
reduction
Flexibility
•Shorter Product life cycles
•Multiple products in the same factory
Drivers
7
Flexibility •Multiple products in the same factory
Low Downtime •Non stop production to maximize output
Return on Investment•Smart factories promise high ROI even though capital
investment can be high
HighLow Medium
Impact
Technology EnablersICT – A Key Enabling Technology
ICT – A Key Enabling
Technology
Sensors – The Source
of Data
• Big Data
•Cloud Computing
•Augmented Reality
•Wireless Communication
•Visualization
•WSN
•Smart Sensors
• Condition Monitoring
Sensors (Vibration,
Temperature, etc)
•Machine Vision
Electronics
•Processors
•Microcontrollers
•LED
•MEMS
•Displays
Advanced
Manufacturing
•Mobile Robots
•Collaborative Robots
•Additive
Manufacturing
8
•Machine Vision
•RFID
•M2M Communication
•Remote Monitoring
•Real Time Information
•Virtual Factory
•Condition Monitoring
•Process Monitoring
•Product Testing
•Product Tracking &
Accountability
•Internet of Things
•High Performance
Terminals
•Demand based
lighting
•Human-Robot
Collaboration
•Rapid Prototyping
Convergence Scenario 1The Power to Remotely Control a Plant Using Your Hands
Augmented Reality
Big Data
Analytics
Cloud Computing
Data ServerData Server
Industry Initiatives
�British Oxygen and Linde
have ventured into
Wireless monitoring of
process plants located in
remote locations
Ubiquitous Wireless
Sensors
9
Remote Monitoring of the
Industrial Plant
Highly reliable, fool proof
sensors and data
communication will be
made a possibility in the
next 6-7 yearsSmartness and Greenness Prevails in
setting up Industrial Plants
(Infrastructure) facilitated by:
• Efficiency in Plant Management
• Personnel-Free Location Monitoring
• Downtime Reduction
• Safety
• Reduction in Operational
Expenditure
2013 20202014 2016 2017 2018 20192015
YOI – 2019-2020
Convergence Scenario 2Demand based Lighting: Energy Savings by Switching Off Light When Not Needed
Microchips
Occupancy
Detection
Sensors
10
Communication
TechnologyDemand Based Lighting
on the Work floor
Convergence Scenario 3Condition Monitoring Using Self-Powered Wireless Sensor Networks
Energy
Harvesting
Sunlight/Thermal
/Vibration
11
Sensors
Condition Monitoring
Using Self-Powered
Wireless Sensor
Networks
Notable Developments & Initiatives
Cisco Connected Factory
� Designed for industrial applications
� Complete IT integration (OT and IT)
Rockwell Automation: Factory Talk® Services Platform
� Integration of Factory Floor
� Live Data
� Central Administration of Key Functions
� Multi-vendor ConnectivityIntel
� Collaboration with Cologne University ofApplied Sciences and Computacenter
� Developing Solutions for Smart ITInfrastructure
Siemens
� Siemens electronics factory in Amberg, Germany
12
Infrastructure
Ford Motor Company
� Plans to enable more flexibility and reducedowntime
� Adoption of advanced techniques such as 3Dprinting LG CNS: Smart factory Solution
� Provides one-stop services from factory design consultingto software/hardware establishment and operation
� Optimizes the entire software-based factory
� Siemens electronics factory in Amberg, Germany
� PLM Software
� Virtual Simulation of Machines
� Intelligent control of Manufacturing Process
Hidalgo: BlackGhost ISAW
� Worker monitoring solution
� Integrates real-time worker health data,sensor data and other information
Global Footprint & Funding ScenarioEurope Focusing Heavily on Factories of The Future
North America Europe APAC
• Funding for Smart
manufacturing not as
• 150 R&D Projects
under the 7th
• JSCA (Japan Smart
Community Alliance)
13
Intensity of Technology Development & Adoption
Very High High Medium
Source: Frost & Sullivan
manufacturing not as
intense as Europe
• Major scope in
Automotive
manufacturing
under the 7th
Framework Programme
• Factories of Future
Project of EU
• Indicative budget
within Horizon 2020:
EUR 1.15 billion
Community Alliance)
established in 2010
• Focus in Public-Private
Partnership and
University
collaborations
• Developments in the
field of Smart
manufacturing
prominent in South
Korea
Impact on MegatrendsHighest Impact on ‘Innovating to Zero’
Smart is the New Green Connectivity and Convergence Innovating to Zero
Medium
Term
Long Term
Medium
Term
Long Term
Medium
Term
Long Term
14
• Reduction of negative impacts
to zero levels
• Companies to shift focus and
develop products that
“Innovate to Zero”
• E.g. Zero Emissions, Zero
breaches of security, Zero
Defects, and so on
• Convergence of Products (E.g.
Electric cars)
• Convergence of Industries (E.g.
Healthcare IT)
• Convergence of Technologies
(E.g. Smart Home Hub)
• Intelligent Sensing Technology
• Smart Products replacing
Green Products
• Smart products being
connected to the internet
• Products react and
communicate to changing
environments, optimizing
operations, and improving
efficiency
Future Factories – 2025 Outlook
Flexible
Manufacturing
Zero Defect
Products
Near Zero
Downtime
Remote Control of
�Multiple Products on Same Production Line
�Accurate production technologies as well as efficient product testing can help
companies achieve zero defects in products
�Demand based integration of workstations and production
�Controlling and monitoring of processes from remote location using
15
Remote Control of
Processes
Human – Robot
Collaboration
Green
Manufacturing
Mass
Customization
�Controlling and monitoring of processes from remote location using
visualization and cloud based services
�Sharing of workplace between humans and robots in a safe manner
�Energy efficient manufacturing that has minimal effect on the environment
�Meeting every customer’s demand while manufacturing in mass scale
Technology Convergence and Innovation Opportunities
Homalnd security4
7
56
1
4
3
3
2
16
Factories of
Future
Factories of
Future1
2
3
4
4
7
51
62
2
Cloud Computing
Additive Manufacturing
Big Data AnalyticsWireless Sensors
NanosensorsEnergy Harvesting
Condition Monitoring
Collaborative Robots
Product Testing
Manufacturing
Environment Monitoring5
1
1
2
34
5
3 MEMS
1
1
4
1
3
1
Remote Controlling Solutions
Solution Providers
Plant management Software
Miniaturized Sensors2
1
Remote Control6
6
8 High Speed
Communication
Next Steps
Develop Your Visionary and Innovative SkillsGrowth Partnership Service Share your growth thought leadership and ideas or
join our GIL Global Community
17
Join our GIL Community NewsletterKeep abreast of innovative growth opportunities
Phone: 1-877-GOFROST (463-7678) Email: [email protected]
Your Feedback is Important to Us
Growth Forecasts?
Competitive Structure?
What would you like to see from Frost & Sullivan?
18
Emerging Trends?
Strategic Recommendations?
Other?
Please inform us by “Rating” this presentation.
Follow Frost & Sullivan on Facebook, LinkedIn, SlideShare, and Twitter
http://www.facebook.com/FrostandSullivan
https://www.linkedin.com/groups/Technical-Insights-3197215
19
http://twitter.com/frost_sullivan
https://www.linkedin.com/groups/Technical-Insights-3197215
http://www.slideshare.net/FrostandSullivan
For Additional Information
Britni Myers
Corporate Communications
Industrial Automation & Process
Control
(210) 477.8481
Sumit Kumar Pal
Research Analyst
Technical Insights
+91-44-66814101
20
Kasthuri Jagadeesan
Program Manager
Technical Insights
+44-(0)-1865-398-625
Bernard Weber
Sales Director, Technical Insights
(Europe)
+44 207 343 8352
