nacfam: speeding up manufacturing through greater connectivity michelle pastel manager measurements,...

NACFAM:Speeding Up Manufacturing through Greater Connectivity

Michelle PastelManager Measurements, Controls &Systems Innovation

April 9th, 2015

Revised 2/2/2015

© 2015 Corning Incorporated 2

Corning Incorporated

Founded:1851

Headquarters:Corning, New York

Employees:34,800 worldwide

2014 Sales:10 billion

Fortune 500 Rank (2014): 343

• Corning is one of the world’s leading innovators in materials science. For more than160 years, Corning has applied its unparalleled expertise in specialty glass, ceramics, and optical physics to develop products that have created new industries and transformed people’s lives.

• Corning succeeds through sustained investment in R&D, a unique combination of material and process innovation, and close collaboration with customers to solve tough technology challenges.


Corning Market Segments and Additional Operations

• Optical Fiber and Cable

• Hardware and Equipment– Fiber optic

connectivity products

SpecialtyMaterials

OtherProducts

and Services

LifeSciences

Optical Communications

DisplayTechnology

EnvironmentalTechnologies

• Cell Culture and Bioprocess

• Drug Discovery• ADME/Tox• Genomics• Chemistry• Microbiology• General

Laboratory Products

• Emissions Control Products– Light-duty gasoline

vehicles– Light-duty and

heavy-duty on-road diesel vehicles

– Heavy-duty non-road diesel vehicles

– Stationary

• Corning® Gorilla® Glass

• Display Optics and Components

• Optical Materials• Optical Systems

• LCD Glass Substrates

• Glass Substrates for OLED and high-performance LCD platforms

• Optical Fiber and Cable

• Optical Connectivity Solutions

• Wireless Distributed Antenna Systems

• Optical Cables for Consumer Networks

• Copper Connectivity Components

• Emerging Innovations

• Equity Companies– Cormetech, Inc.– Dow Corning Corp. – Eurokera, S.N.C.– Samsung Corning

Advanced Glass, LLC (SCG)


Processes for mass

producing the television

bulb

Glass envelope for Thomas Edison’s light bulb

Heat-resistant PYREX® glass

Dow Corning

silicones

Innovation Timeline

Fusion overflowprocess

Ceramic substrates for automotive catalytic converters

Label-free screening platform for drug discovery

Environmentally consciousLCD glass

First low-loss optical fiber

Active matrix liquid crystal display (LCD) glass

Glass ceramics

Ultra-bendable fiber

Thin, lightweight cover glass with

exceptional damage

resistance

Ultra-slim, flexible glass for thin and lightweight applications

First EPA-registered antimicrobial cover glass

First all-optical

converged cellular

and Wi-Fi solution

1879

1934

1952

1970

1982

2007

2012

1915

1947

1964

1972 2006

2013


Growth Through Innovation

• Our culture of innovation is built on the foundation of research and development

• Our near-term growth will be fueled by several opportunities

– Glass substrates for LCD and OLED displays

– Ceramic substrates and filters for mobile emissions control systems

– Optical fiber, cable, and connectivity solutions for the world’s leading carrier, enterprise, wireless, and consumer networks

– Drug discovery tools and solutions

– Chemically strengthened, damage-resistant glass

– Other advanced optics and specialty glass solutions for the semiconductor, aerospace, defense, astronomy, and metrology industries


Research and Development (R&D)

• Our growth is fueled by a commitment to innovation and a passion for conquering complex material and technology challenges

• We invest approximately 10% of our sales in R&D

• We maximize the results of our R&D by engaging cross-functional teams and senior leadership at all stages of innovation

• Our technology leadership and R&D environment attract and enable the best scientific minds in the world


Deep Core Technology Capabilities – Science & Engineering

Corning’s strength is based on a broad portfolio of core technologies…

… and the ability to integrate

them.

Thin Filmsand

SurfaceSciences

BiochemicalSciences

andProcesses

OrganicMaterials

andProcesses

Engineering: - Materials - Optical - Process - Chemical - Electrical - Mechanical

Core Capabilities

NetworkIntegration

andConnectivity

Research

InorganicMaterials

andProcesses

MaterialsCharacterization

andProcesses

Modelingand

Simulation

OpticalPhysics

andNetwork

Technologies


Awards and Recognitions

• Four-time National Medal of Technology winner

• Institute of Electrical and Electronics Engineers (IEEE) Milestone Award for the invention of low-loss optical fiber (2012)

• Edison Award gold medal in Materials Science for Corning® Gorilla® Glass (2012)

• Thomson Reuters Top 100 Global Innovatorsm (2013, 2012, 2011)

• Massachusetts Institute of Technology’s list of disruptive innovators (2013)

• “Most Innovative Companies” (2013) and “Innovation All-Star” (2010) by Fast Company magazine

• The American Ceramic Society Corporate Technical Achievement Award (2010)

• One of Fortune magazine’s most admired companies (2010, 2009)


The Corning Values

Our Values are the historic strength of our company, guide our every move, and continue to set us apart from others.

All seven, All around the world. All the time.


Corning Summary Remarks

• We’ve succeeded for 160 years … few other U.S. companies have

• How have we done it?– Successive waves of innovation

– Deep understanding of glass and ceramic materials

– Strong process and manufacturing capabilities

– Collaboration with customers and partners

– An exceptionally talented and dedicated workforce

– A conservative financial structure and patient capital

`

Smart Manufacturing Leadership Coalition

www.smartmanufacturingcoalition.org



NACFAM - Speeding Up Manufacturing through Greater Connectivity

Michelle Pastel - Corning, Inc.



An Industry-Driven Open Architecture

Shared InfrastructureSMLC Partnerships

“Information that drives the next century’s structural shift in manufacturing.”

Smart Manufacturing

Smart Manufacturing Leadership Coalition (SMLC) – 501c (6)

Making real-time info available:•when it is needed, •where it is needed•and in the form it is needed throughout the Manufacturingecosystem

American Council for an Energy _Efficient Economy (ACEEE)AMP SocalAlcoaAmerican Institute of Chemical Engineers (AIChE)American Society of Quality ARCAssociation of State Energy Research and Technology Transfer Institutions (ASERTTI)CorningDepartment of Energy (DOE)EmersonElectric Power Research Institute General DynamicsGeneral Electric General MillsGeneral MotorsManufacturing Enterprise Solutions Association (MESA)MT ConnectNational Association of State Energy Officials (NASEO)North Carolina State University

Nimbis ServicesNISTNational Science Foundation (NSF)OSISoftOwens CorningPacific Northwest National LaboratoryPfizer Inc.PraxairPurdue UniversityRensselaer Polytechnic InstituteRockwell AutomationSavigent SoftwareSchneider ElectricSociety of Manufacturing Engineers Southwest Research Institute - SWRISustainable SolutionsTexas A&M Engineering Experiment Station (TEES - TAMU)Tulane - PolyRMCUniversity of California, BerkeleyUniversity of California, Los AngelesUniversity of Texas - AustinWest Virginia University



SMLC’s Industry-Driven Strategy

Roadmap: Operations & Technology for SM systems

Establish Work Groups: Identify & Drive Priority areas• Test Bed• Platform• People• Business

Infrastructure Specification: Increasing SM Platform Definition& Development

Action Plan: Implementing 21st Century Smart Manufacturing

SMLC Incorporates as 501c6:Building Capacity & Resources; Leveraging Resources; Advocacy for SM

DOE, NSF, NIST Awards: $13 million in Project Work to develop SM Platform Prototype

Implementation Plan: Review & Refine Collaboration Roles & Alignment

Membership Expansion Spin-off parallel activities

AMTechACCELERATE

DOE Workshop

SMLC Forum WorkshopNSF

Workshop

AIChE Workshop

Technical Meetings

Board Meetings, Calls, Advisory Groups, Focused Workshops, etc.



General Mills Networked-Based Manufacturing

Supply ChainDistribution Center

Customer

Business Systems, ERP

Smart Grid

Smart Factory

Recipe ManagementMapping formula into operatingrecipes

EDI transaction& qualitycertifications

FDA Tracking &traceabilityGreen Light

Analyze - to put into productionMake – right ingredients – confirmation on recipeRelease – meet requirements to release

Mapping SAP informationInto operation

Graphics courtesy of Rockwell Automation



Core Systems

Data Input

Core Functions

MQISMQIS MESMES SAP ERPSAP ERP Red PrairieRed PrairieSAP APOSAP APO SAP PLMSAP PLMSAP MRPSAP MRP

Value Creation

Business Applications

GMI’s ECO System of “STUFF”



EERE DOE “Project Smart Manufacturing”



Achievable Meaningful Use Goals and Magnitude of Impact

• Demand-driven efficient use of resources and supplies in more highly optimized plants and supply

– 25% reduction in safety incidents– 25% improvement in energy efficiency– 10% improvement in overall operating efficiency– 40% reduction in cycle times– 40% reduction in water usage

• Product safety – Product tracking and traceability throughout the supply

• Sustainable production processes for current and future critical industries

– 10x improvement in time to market in target industries– 25% reduction in consumer packaging

• Maintain and grow existing U.S. industrial base– Environment for broad innovation– 25% revenue in adjacent industries– 25% revenue in new products and services– 2x current SME’s addressing total market– More highly skilled sustainable jobs created

• ROI constrained or prohibitive- Requires broader infrastructure investment to scale- Incremental investment difficult- Requires IT investment with 70% of cost non-value- Depends on other companies - supply chain- Need 80% lower cost implement modeling/simulation- 10x reduction in cost of sensors/sensor infrastructure

• ROI opportunity comprehensive– Multiple systems– Integrated global performance metrics– Aggregating data

• Installed base of serviceable manufacturing facilities– $60 B in IT investment– Retrofit

• Risk– Major change & New business model– Uncertain about technology, security & IP

• Organization– IT capability lacking or IT not talking to operations– Workforce skills – Collaboration

Issues Beyond Individual Company

Technical and Business Drivers for Shared Infrastructure



Manufacturing Health & Sustainability



What is SMARTTest Bed Smart Systems

Smart Machine Line

Operations

In-Production High Fidelity

ModelingDynamic Decisions

Enterprise & Supply Chain

Decisions

Design, Planning & Model

Development

Machine product management

Better management complex behaviors

Performance management global integrated decisions

Variability reduction

Design models in production

Benchmarking machine-product interactions

Rapid qualification components products materials

Untapped enterprise degrees of freedom in efficiency, performance time

Risk and compliance management

Product/material in-production ability

Machine-power manage management

Integrated computational materials engineering

Business operational tradeoff decisions

Tracking traceability genealogy

New product, material technology insertion

Adaptable machine configurations

External partner integration into business process

Configurable data and analyses for rapid analytics and model development



Smart Manufacturing: Multi-Layered Seams, Time, Data & Action - Materials

Dynamic Manufacturing Ecosystem

Product Manufacturing

Materials & Process TechPrototype Qualification In

Service

Macro Layer

Meso Layer

Micro Layer1000s control loopsTime - minutes

100s control loopsTime -hours

10scontrol loopsTime – days

Focus: 10x Multiple Pass Variability

Reduction; Supply Chain Information

Busi

ness

Sys

tem

sBu

sine

ss S

yste

ms

Cont

rol &

Aut

omati

onCo

ntro

l & A

utom

ation

Focus: 100x Event Variability/Tradeoff

Adjustment; Dynamic Performance Mgmt.;

Integrated Metrics

Focus: Insertion, Qualification, ICME, High

Fidelity Dynamic Operations

DesignData



ApplicationsApplications

ContextContext

DataData

Calibration &Maintenance

Production Models

Sensor Data

Suppliers

Heating & Forging

Power Mgmt & Energy Grid

Line Operations

Customers

DistributionSustainability

& Safety

Open-Architecture Infrastructure & Marketplace

• APPs & Toolkits•Composable Systems• Cloud Deployment• Private/Public IaaS

SM Value Proposition

Event Data Real-Time Data

MappingMapping

Smart Manufacturing PlatformBridging Seams Extending the

Real-Time Infrastructure



Building InfrastructurePowering Smart Decisions



US Mfg Needs Smart Sensors & SystemsNeed to Overcome Adoption Barriers

• Low Initial Cost- open• Low Cost to Install- robust wireless• Easy to Maintain- high uptime, increase mfg

efficiencies• Secure• Information- Respect What’s Not Yours• Bridge Workforce Generation Expectations• Make Smart Manufacturing a Prudent Risk

with <2 yrs. ROI



US Mfg Needs Mindset Changes to Win in a Global Economy

• Expect Information- expect interoperability • Think Eco-system Broadly- physical and cyber• Integrate Existing Organization Silos- IT & engr• Place Increased Value in Data- knowledge• Automate What We Know- opens time to

solve the next problem • Re-Evaluate Roles- expanded skills required• Expect Lifelong Learning- facilitate achieving it



Institute Structure

nacfam: speeding up manufacturing through greater connectivity michelle pastel manager measurements,...

Documents

corning incorporatedfounded

samsung corning advanced

corning market segments

flexible glass

specialty glass solutions

lcd platformsoptical

optical physics

road diesel vehiclesheavyduty