smart manufacturing for smm opportunities and challenges

Dr. Thorsten Wuestthwuest@mail.wvu.edu

Smart Manufacturing for SMM Opportunities and Challenges

SmalltoMediumManufacturing(SMM)NeedsandCaseStudies- Presentations&PanelSession -

NISTIndustryForumMay8,2018

Gaithersburg,USA

WestVirginiaUniversityBenjaminM.Statler CollegeofEngineering andMineralResourcesDepartmentofIndustrialandManagementSystemsEngineering

Dr. Thorsten Wuestthwuest@mail.wvu.edu

1. SmartManufacturing

2. SmartMfg SurveyofSMEsinWestVirginia

3. Projects&CaseStudies

4. Recommendations

Agenda

Dr. Thorsten Wuestthwuest@mail.wvu.edu

Youmayhaveheardof

Allthesetermsdescribeasimilardevelopment!

SmartManufacturingIndustrialInternet

Industrie 4.0Cyper-Physical(Production)Systems

FactoryoftheFuture

…andmanymore!ManufacturingIntelligence

IMS

IntelligentManufacturing

CloudManufacturing

Industry4.0SmartFactory

SMART MANUFACTURING PRINCIPLES/ CONNECTIVITY/ VIRTUALIZATION/ DATA UTILIZATION

Schmid &Wuest,2017

Dr. Thorsten Wuestthwuest@mail.wvu.edu

Smart Manufacturing VisionFully Connected Smart Factory

I need morematerials

Alertsmonitor:Problemwithmachine#2.Please check

I’mcustomer order#312 and want tobered colored.

End of line test: Machine#1, Pleaseadjustmachineparameters

Source: http://smartamerica.org/teams/smart-manufacturing/

Control center:Aggregated data revealimprovementareas

Packingmaterial islow. Please releaseorder.

Cogwheel will break in fivedays. I haveordered spareparts and scheduled externalserviceprovider.

Schmid &Wuest,2017

Schmid &Wuest,2017

SMART MANUFACTURING MARRIES TECHNOLOGY, DATA AND HUMAN INGENUITY

Smart Manufacturing in Small- and Medium-sized Enterprises (SMEs)

Dr. Thorsten Wuestthwuest@mail.wvu.edu

Dr. Thorsten Wuestthwuest@mail.wvu.edu

Status of Industry

Source:Jinwoo Park,2015

Dr. Thorsten Wuestthwuest@mail.wvu.edu

Siemens Digital factory

• Siemens’plantinAmberg,Germany

• Productscommunicatewithmanufacturingmachines

• ITsystemscontrolandoptimizeallprocesses

• Productionqualityisat99.99885%

Dr. Thorsten Wuestthwuest@mail.wvu.edu

SMEs vs MNEs – Different requirements

Dr. Thorsten Wuestthwuest@mail.wvu.edu

Upgrade existing systems• BoschupgradedLathefrom1887tobeSmartManufacturingready

• Newcapabilities:• processmonitoringforconstantqualityassurance

• anotherisconditionmonitoringinordertopreventunplanneddowntimes

• Extremeexamplebutshowcasesthepotential

http://www.bosch-presse.de/pressportal/en/69632.html

http://www.bosch-presse.de/pressportal/en/69632.html

Dr. Thorsten Wuestthwuest@mail.wvu.edu

Background§ Internet of Things is changing the industrial landscape§ Manufacturing is undergoing a major transition§ Large corporations aredealing with this topic intensively

⇒ But how to apply Smart Manufacturing in small companies?⇒ How can small manufacturers takeadvantageof it?

Objectives§ Examinethecurrent stateofmanufacturingwithasurvey§ Understandthemanufacturinglandscapeanditsspecific

challenges andconcerns byconducting interviews andplantvisits§ Support small manufacturersinadoptingSmartManufacturing

technologies bysettingupatrainingworkshop

Work Packages1. Online survey2. Interviews&plantvisits3. Analysis ofresults&report4. Trainingworkshop

Schmid &Wuest,2017

Project Scope

Survey Report

Availableforfree

Downloadhere:https://t.co/8uTam5lQtl

Dr. Thorsten Wuestthwuest@mail.wvu.edu

Dr. Thorsten Wuestthwuest@mail.wvu.eduSchmid &Wuest,2017

Survey Method

0

2

4

6

8

10

12Subsectors inManufacturing

Total#ofrespondentsfrommanufacturing53

Company sizeby#employees

lessthat20

100 - 499

20 - 99

500andmore

Who participated in the survey?

Dr. Thorsten Wuestthwuest@mail.wvu.eduSchmid &Wuest,2017

Survey ResultsHow aware are companies of the transition towards Smart Manufacturing?

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

Industry4.0

SmartManufacturing

IndustrialInternet

InternetofThings(IoT)

SmartFactory

Cyber-physicalsystem

Ihavealreadyheardabout...0% 20% 40% 60% 80% 100%

Mycompany isdealingwith...

Dr. Thorsten Wuestthwuest@mail.wvu.eduSchmid &Wuest,2017

Survey ResultsHow prepared are companies for Smart Manufacturing?

0% 10% 20% 30% 40% 50% 60% 70%

Slightlyprepared

Moderatelyprepared

Veryprepared

Towhatextentisyourcompanyandyouremployees prepared?

0% 10% 20% 30% 40% 50% 60% 70%

Notrelevantatall

Moderately relevant

Very relevant

HowrelevantisSmartManufacturingforyourcompany?

Dr. Thorsten Wuestthwuest@mail.wvu.eduSchmid &Wuest,2017

Survey ResultsWhat are the needs of manufacturers when it comes to Smart Manufacturing?

Dr. Thorsten Wuestthwuest@mail.wvu.eduSchmid &Wuest,2017

Interview MethodWho participated in the interview sessions?

Manufacturing Experts

Intervieweesinmanufacturingcompanies

10Expertsinacademia,associations&state

agencies

Manufacturers

8

Smart Manufacturing in SMEs

Lack of opportunity

Resources & cost

Knowledge & awareness

Skilled workforce

Missing ‘success stories’

Dr. Thorsten Wuestthwuest@mail.wvu.edu

‘Capability creates Opportunity’

Dr. Thorsten Wuestthwuest@mail.wvu.edu

Craig Hartzell, Azimuth Inc., 2017

SMART MANUFACTURING IS NOT ONLY FOR THE BIG GUYS.

Schmid &Wuest,2017

Opportunities for entrepreneurs

Brave new world

‘Low’ initial investment

Dedicated ‘Apps’ (Platform solution)

Scalable solutions (interoperable & extensible)

Fast deployment

Dr. Thorsten Wuestthwuest@mail.wvu.edu

Dr. Thorsten Wuestthwuest@mail.wvu.edu

Boiler Revision Project (1/2)

Provided by : EagleManufacturing, jmcknight@eagle-mfg.com

at Eagle Manufacturing

Concepttoreviseboiler controlsPlant maintenance cancontrol and monitor the steamboilersfromoutside of the plant instead of coming to the plant toschedule and check on themphysically

Before

Schmid &Wuest,2017

Dr. Thorsten Wuestthwuest@mail.wvu.edu

Boiler Revision Project (2/2)at Eagle Manufacturing

Provided by : EagleManufacturing, jmcknight@eagle-mfg.com

AfterSolution• Using newertechnology• PLCs with integratedEthernetandSMTP (email) protocol• along with advanced HMIand smarthubnetworkfunctionality

Benefits• Better control& schedulingof system

• Real-time alarm monitoring(throughmobile devices)

Schmid &Wuest,2017

at Homer Laughlin China Company

Problem• Compressed Air Systemwas experiencing unacceptable pressurevariationsduringpeak demand hours

• Current systeminefficient consuming 80%of full load energywhile producing 20%capacity

Solution• Balancesystem(compressorrelocation,pipingimprovements,andincreasedstoragecapacity• Changecontrolmethodtoaload– noloadsystemmanagedbyacomputersystem

System operation• Compressorsaremonitored&systemismonitoredforpressure• Compressorsarestartedandstoppedwithsystematicmethodbasedondemand• Operatingsequenceisdeterminedtomaintainpressureandequalcompressorrun-time

Provided by : Homer Laughlin, sadkins@homerlaughlin.net

CompressedAir System Monitoring (1/2)

Dr. Thorsten Wuestthwuest@mail.wvu.eduSchmid &Wuest,2017

Provided by : Homer Laughlin, sadkins@homerlaughlin.net

CompressedAir System Monitoring (2/2)at Homer Laughlin China Company

System benefits• Annual energy savings over $100,000• Real time information allows personnel to quickly identify problems• Run time of compressors is reduced extending theiroperatinglife• PreventativeMaintenancetracking and scheduling• Consistent system operatingpressure

Next steps• Vibration and airend temperature monitoring to improvepredictive maintenance of system• Investigating use of Bosch CISS (Connected Industrial Sensor Solutionmulti-sensor device)

Further benefits• One device type can be used in a variety of applications• CISS connects existing machines without intervening to the machine control• Visualize live and historicdata• CISS integrates easily to various platforms

Dr. Thorsten Wuestthwuest@mail.wvu.eduSchmid &Wuest,2017

Problem

• Howtoprovidethebestpossible service formanufacturingequipmenttocustomers?

Approach

• Collaborate&Innovate

Solution

• I4.0Platfrom thatprovidesinterfaceandcloudaccesstomachinedataincl.visualization

• Allowsmonitoringallequipmentsetpointsandactualsincl.feedbackonperformance

• UptimeGuaranteedTM withSmartServices

at Conair Group (IPEG Inc.)

Smart Services Project

Dr. Thorsten Wuestthwuest@mail.wvu.edu

Source&moreinformation:https://www.conairgroup.com/product/smart-services/

• ProvideeducationalresourcesonSmartManufacturingandIndustry4.0(‘spreadtheword’inanaccessibleway)forindustrialpartners.

• Jointlydevelopcurriculumfor1)professionalstoequipthemwithrequiredknowledgetoinnovateandoperatewithinaSmartManufacturingenvironment,and2)includeSmartManufacturinginexistingengineeringcurriculaacrossinstitutions(‘highschooltomasters/Ph.D.’),departmentsandmajors.

• Communicatesuccessesbroadlyandencouragepeer-to-peerexchange(acrossindustries)ofbestpracticesandlessonslearned.

Recommendations (1/2)for Smart Manufacturing in SMEs

Dr. Thorsten Wuestthwuest@mail.wvu.edu

• Buildstrongandsustainablepartnershipsbetweencompanies,academiaandindustryassociations.Forexample,leverage(local)technologystart-upstoteam-upwithestablishedmanufacturersandacademia.

• Startwithsmall‘lighthouse’projectstargetingspecificpainpointstolearnandachievequickwins.

• LeveragestateandfederalfundingtocomplementthelimitedrecoursesavailabletomanufacturingSMEs.

Recommendations (2/2)for Smart Manufacturing in SMEs

Dr. Thorsten Wuestthwuest@mail.wvu.edu

SMART MANUFACTURING CANNOT BE BOUGHT. THE SUCCESS HAS TO BE EARNED.

Schmid &Wuest,2017

Dr. Thorsten Wuestthwuest@mail.wvu.edu

My take on this issue:

• SolutionsmustbetailoredtoSMEs’(real!)needs&requirements!

• Createrealvalue(shortANDlongterm)!

• Fitthestrategy/vision!

TodosoSMEsneedto:• Assess theircurrentprocessescritically

• Identify theircorecompetencies• Build onthoseand• Developaroadmapwithspecificmilestones/objectives

• (keep80/20ruleinmind!)

Contact:

ThorstenWuest,Ph.D.AssistantProfessor SmartManufacturingWayneandKathyRichardsFacultyFellow

WestVirginiaUniversityIndustrialandManagementSystemsEngineering347EngineeringSciences BuildingMorgantown,WV26506-6070,USA

+1(304)293-9439thwuest@mail.wvu.eduwww.thorstenwuest.com

Thank You!