Low Cost Adoption of Digital Capabilities

Sameer Savani, Head of Innovation & Engineering

ADS is the premier trade organisation advancing the UK Aerospace, Defence,

Security and Space industries. Farnborough International Limited (FIL) which

runs Farnborough International Airshow, is a wholly owned subsidiary.

The Organisation

Priorities for ADS

The industries represented by ADS are vital to the UK economy and are major drivers of growth and prosperity. The following priority objectives are designed to give focus to the work ADS undertakes:

• Improve the image and profile of our industries

• Influence the policy debates of most importance to our industries

• Support UK manufacturing and our industries’ supply chains

• Encourage investment in technology and innovation

• Support business development opportunities nationally and in priority international markets

• Increase Member value

Why Industrial Digitalisation is important to ADS

“Our review identified a £17.5

billion opportunity for the

aerospace sector over the next

ten years through the adoption

of currently known digital

technologies.

“Of all the sectors we examined,

aerospace offers the greatest

potential in terms of both cost

reduction and new business

models.”

This is what people think of as 4IR…

…looking through a technology lens

www.manufactringtomorrow.com

www.aethon.com/industry-4-0-means-manufacturers/

The technology isn’t flying in formation

• What are you actually trying to do?

• What skills and processes need to be in place for the technology to work?

• How much better is it than what it replaces?

• Are you over-engineering a solution?

• What are the connections between?

• Those who pay for it

• Those who have to implement it?

• Those that benefit from it?

• Those that will be disrupted by it?

Industry 4.0 goes way beyond technology

• Skills and Training

• Competency Frameworks

• Digital Mindsets and Culture

• Attractiveness to Talent

• New Business Models

• Risk Management

• Business Cases and Finance

• Business Transformation

• Security and Resilience

• Communication Networks

• Architecture and Integration

• ICT Services

• Data

• Analytics

• Digital-to-Physical

• Human-Machine Interfaces

TechnologySystems &

Networks

Skills &

Competencies

Business &

Strategy

Valu

e D

rivers

Technology isn’t even the starting point

Efficiency

Utilisation

Servitasation

Time-to-Market

Productivity

Inventory and Supply

Quality

Rapid prototyping and experimentation

Concurrent Engineering

Challenge-led Open Innovation

Agile Batch Sizing

Data-driven Demand Prediction

Additive Manufacturing

Robotics and Cobotics

Digital and Remote Performance M’gmt

Flexible Manufacturing

Predictive Maintenance (Factory)

Virtual and Augmented Reality

Smart Energy Consumption

Real-time OE Optimisation

Remote Maintenance

Predictive Maintenance (Product)

Data-enabled Business Models

Digital Quality Management

Sensor/Data-driven Process Control

Tech

no

log

ical c

ap

ab

ility le

vers

Risks with technology - centricity

• Transformation Strategy vs. Technology roadmaps

• Chasing the latest technology hype

• Numerous tactical projects of limited total-business value

• Bounded by a legacy systems and approaches – lack of vision

• Myopia - cross-impacts not understood by working in silos

• Scope constrained by technology, not what the customer wants

Never

Later

Tomorrow

NOW

Why now?

Learn Test Scale

Why now? Trends in capability

• Technologies are becoming far more affordable (and therefore, more available and accessible)

Why now? Trends in capability

• Discrete manufacturers starting to servitize – powered by connectivity

Why now? Trends in capability

• Larger companies are already getting on board

Why now? Trends in capability

• Data is getting Bigger…and Faster

Why now? Trends in capability

• Becoming increasingly affordable, available and accessible

• Larger companies (your customers) are doing this for themselves

• Data is getting Bigger…and Faster; analytics is already providing actionable insights

What’s Stopping Faster Adoption?

Awareness

Time

Ability to

invest

Expertise

Company

structures

Good

practice left

in silos

Not

knowing

where it fits

“Trying to change

the fan-belt while the

engine’s running”

Barriers

to

Adoption

for SMEs

Legacy

Case studies of low-cost adoption

• OEE (Overall Equipment Effectiveness) on a five-axis milling cell was <60%

– Getting to 80% would yield ~£27,000 per machine per year

• Engaged with CNC Data and CNC Connect; installation of £750 - £1500 per machine

• Return on Investment was less than two weeks once additional capacity was utilized; achieved through

– Operator awareness– Reduced setup times– Improved programme performance

through identifying machine stoppages

Case studies of low-cost adoption

• Created a demonstrator to showcase capability for SMEs to understand

– Data precision– Data accuracy

• Provenance and traceability

– Sensors calibrated by NPL– Measurements traceable to national standards

• End-to-end at low cost

– Multi sensor– Internet/Cloud enabled– Machine Learning– Introducing companies to servitisation models

Digitally Enabled Supply Chains• Enabling confidence in data

Case studies of low-cost adoption

• Digitally enabling a Cincinnati H5

• Fitted with a full range of sensors

Full Monty LLIVE – low-cost legacy informatics for value chain equipment

• Connected legacy machines across multiple companies

• Demonstrating

– Date validity– Interoperability– Trust and Cyber Security– Supply chain visibility to

OEMs

• 2x accelerometers for vibration measurement

• 1x thermocouple for temperature

• 3x Current transformer for power

• 1x NI 9211 for data acquisition

• 1x NI9230 for data acquisition

• 1x sbRIO 9627 – for edge analytics and visualisation

Bridgeport manual machine

Case studies of low-cost adoption

• Distributed intelligent monitoring architecture

– Utilising COTS IOT technologies– Easy to integrate with 3rd party systems

• Although this is a £2.5m programme over 3 years…

Case studies of low-cost adoption

• Affordable digitalised energy and site

management systems already available, which

often deliver far more than just a reduction in

energy bills.

• Monitor, manage and compare the performance

of assets and sites, helping it to spot

maintenance issues and optimise site resource

• Identify cost-effective opportunities for reducing

energy bills

• You can even make money by being more

flexible about the way the way you use energy

• Establish Farnborough as the home of showcasing Aerospace 4.0 solutions

• Demonstrate point solutions, integration and scale up

• Lead the narrative on the Aerospace sector’s approach to digital transformation

Aerospace 4.0

In Closing…

• Industry 4.0 doesn’t come in a box; different solutions will suit different companies

• Transformation needs to business-led and value-centric

• “Digital” is an enabler to business strategy; Technology is only part of the answer

• Large companies are already investing, but everyone will need to get on board

• Think big, start small, scale fast, act now

• Plenty of examples that you can touch and feel

• Digital transformation affects ALL parts of the business

• Come and find out more at Aerospace 4.0 at the Farnborough Airshow