A2EP’–2xEP’Energy’Produc;vity’Summit’ 04?05 ... · MQIS$ MES$ SAP$ERP$ SAP$MRP$ SAPAPO...
Transcript of A2EP’–2xEP’Energy’Produc;vity’Summit’ 04?05 ... · MQIS$ MES$ SAP$ERP$ SAP$MRP$ SAPAPO...
Session 02 2xEP by 2030 by sector -‐ Manufacturing Michael Bellstedt Carmel Gillies Carl Duncan Denise Swink > presenta/on follows Chair: Paul Orton
A2EP – 2xEP Energy Produc;vity Summit 04-‐05 April, 2017 Australian Na;onal Mari;me Museum Darling Harbour, Sydney
2XEP PRODUCTIVITY SUMMIT, 04-05 APRIL 2017, SYDNEY
MANUFACTURING PANEL, DENISE SWINK, CEO,
SMART MANUFACTURING LEADERSHIP COALITION (SMLC)
SMARTMANUFACTURINGCOALTION.ORG
Who is SMLC
• A leader in Smart Manufacturing with 60+ national members
• Industry-driven 501c6, lowering barriers to access
• Developing an open platform and marketplace for Smart Manufacturing industrial applications
• Providing industry with easy, affordable, low-risk access to real-time data through a vendor-agnostic platform…
… when, where and in the form it is needed.
SMLC Membership ACEEE AMP Socal Alcoa AIChE American Society of Quality ArcelorMi=al ARC ASSERTI CMTC Carnegie Mellon Clear Peak Conn. Ctr. for Advanced Technology Corning, Inc. DOE Danfoss Drives Emerson EPRI General Electric
Rockwell AutomaJon Rutgers University Savannah Rivers NaJonal Lab Savigent SoMware Schneider Electric SME Southwest Research InsJtute Sustainable SoluJons Texas A&M Think IQ Tulane – PolyRMC United Technology Research Center (UTRC) UC Berkeley UC Irvine UConn UCLA USC -‐ EDC UT AusJn West Virginia University
General Mills General Motors Honeywell Manufacturing Enterprise SoluJons AssociaJon (MESA) MIT MT Connect NASEO NCSU Nimbis Services NIST NSF OSIsoM Owens Corning Pacific Northwest NaJonal Lab Pfizer Inc. Praxair Purdue University RPI
Industry-‐Driven Public-‐Private Partnership
2006-‐09 2010 2011 2012 2013 2014-‐15
Roadmap: OperaJons & Technology for SM systems
Establish Work Groups: IdenJfy & Drive Priority areas • Test Bed • PlaZorm • People • Business
Infrastructure SpecificaEon: Increasing SM PlaZorm DefiniJon & Development
AcEon Plan: ImplemenJng 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 PlaZorm Prototype
ImplementaEon Plan: Review & Refine CollaboraJon Roles & Alignment
Membership Expansion Spin-‐off parallel ac5vi5es
ACCELERATE
DOE Workshop
SMLC Forum Workshop NSF
Workshop
AIChE Workshop
Technical MeeEngs
Board MeeEngs, Calls, Advisory Groups, Focused Workshops, etc.
© SMLC, Inc. All rights reserved.
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Smart Manufacturing Leadership Coalition
www.smartmanufacturingcoalition.org www.smartmanufacturingcoali5on.org www.smartmanufacturingcoali5on.org
Supply Chain Distribution Center
Customer
Business Systems, ERP
Smart Grid
Smart Factory
Connected Supply Chain • Agile • Demand Driven • Raw Material to Finished Product
OpJmizaJon
• Asset UJlity/Zero DownJme • Quality/Zero Defects • Reliable results
Energy Efficient • Lower emissions • Less energy used • Green manufacturing
Safe ProducJon
• Improved safety • Fewer incidents • More user friendly
• Higher value products • Data for decision making • Product Lifecycle Management
Sustainable ProducJon
Affordable, Accessible, InnovaJve & CollaboraJve
Network-‐Based, Smart Manufacturing
© SMLC, Inc. All rights reserved. 5
Smart Manufacturing Leadership Coalition
www.smartmanufacturingcoalition.org www.smartmanufacturingcoali5on.org www.smartmanufacturingcoali5on.org
Smart Manufacturing:
Right Data, Right Time, Right Form Wherever Needed for the Business of
Enterprise
© SMLC, Inc. All rights reserved. 6
What got us here Won’t get us there
Smart Manufacturing Leadership Coalition
www.smartmanufacturingcoalition.org www.smartmanufacturingcoali5on.org www.smartmanufacturingcoali5on.org Ecosystem of “Stuff”
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Direct Con
sumpJ
on
Core Systems
Data Input
Core FuncEons
Raw M
at’l Inventory
Finished
Produ
ct
Inventory
Prod
ucJo
n History
Plant F
loor
Inventory
Demand Plan
Prod
ucJo
n Order
Line
Sched
ule
MQIS MES SAP ERP Red Prairie SAP APO SAP PLM SAP MRP
Value CreaEon Green Light to
Convert Green Light to
Ship
Demand Driven Supply Chain
WorkFlow
Lot T
racking
Overusage
OpJ
miza
Jon Engine
Trace/Recall BOM ValidaJon Yard Mgmt
OpJmized Inventory
Business ApplicaEons Directed Work
Supplier Managed Inv Line Supply Bin Mgmt
Allergen/Micro WorkFlow eCOA
© 2014 General Mills
Master Data (BOM,Specs,Vendor,Ingredients,FP)
• Complex • Fragile • Costly • Rigid • Built for Purpose
Layers of Interoperability
Technology § HW/SW § Infrastructure § ConfiguraJon § Methodology § Data § Product § Standards § Systems § Time § Cyber a=ack § Security
Ecosystem § B2B § Supply Chain § Market § Service Levels § Systems IntegraJon § CollaboraJve Data § Public/Private § Owner management § Tools § Standards § Cyber a=ack § Security
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Business § Investment § IP § Risk § Service Levels § Systems integraJon § Engineering § Data/IP Security § Time § Cyber a=ack § Security
People § OrganizaJon § IT/OT § Trust § Skills § Change § Roles § Cyber a=ack § Security
Cloud & Enterprise VirtualizaEon Services Data to ApplicaEons
Physical & Cyber reusability
ApplicaEons Context
Data
Mapping
CalibraJon & Maintenance
ProducJon Models
Sensor Data
Time Series
Event Data Tradi&onal Manufacturing
Automa&on Environment and So7ware Tools
Private Smart Manufacturing Pla[orm Appliance
Paper Steel
Metals Glass Food
Micro electronics Industrial gas
CoaJngs PlasJcs
Composites
Smart Manufacturing Pla[orm Open Infrastructure
• SM SoMware Marketplace • APPs & Toolkits
• Compose Workflows • Cloud Deployment • Private/Public IaaS
SM Value ProposiEon
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Industry Hosted Test Bed Structure
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First Steam Methane Reformer Furnace Port Arthur, TX
• Already efficient
• Distributed sensing
• Distributed actuaJon
(96 burners) • High fidelity
model & reduced order models
Simple Model
HPC Model
Burner Controls Reduce
Cameras
reducJon wasted energy
reducJon wasted energy
Halve capital cost Dynamic energy management
Metrics
Extend
to 20 U.S. SMRs
Praxair
IntensificaJon through Measurement &
OperaJonal IntegraJon
© SMLC, Inc. All rights reserved.
QualificaJon, ProducJon on Demand, IntensificaJon
Part Tolerances
Improved gas flow control RecuperaJon
Part ProperJes 3D RadiaJon
Dynamic machine configuraJon
Reduce idle Jme
Reduce defects
destrucJve tests
Integrated line management of part precision, materials/metallurgical properJes, dynamic part movement, defect reducJon, energy management
General Dynamics Scranton, PA
PredicJve Maintenance
Part quality
Part quality
Part quality
Reduce defects
© SMLC, Inc. All rights reserved.
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Variable Contracts
Billet quality
The Flow of Oats
• Bin Number
• Grain Type
• Grain Quality
• Bin Fill
• Time Filled
• Rail Car
• Grain Source
Multiple Sources of
Information People, Sensors,Suppliers,
Transporation
Not knowing…creates Gridlock
CESMII Smart Manufacturing – USA
MISSION: Radically save time and costs of improving US manufacturing performance –
developing and deploying tool sets of advanced sensors, controls, analytics and information
technologies – supplying a highly skilled workforce – serving companies of all sizes.
VISION: Smart Manufacturing is manufacturing in 2030
Key Metrics for CESMII: • First of kind live commercial test beds in the US.
• Cost and time to develop and deploy solutions halved.
• U.S. energy productivity doubled every 10 years
• US SM workforce capacity increased five-fold by 2030.
• 40% ↗ in SM supply chain participation by 2030
Strategy: Bringing the institute to the manufacturers
• ~200 partners from industry, academia, NGOs and state/local : $70M federal funding, more than matching from partner’s cost share.
Northeast Hub: Rensselaer Polytechnic Institute
Southeast Hub: North Carolina State University
HQ: University of California Los Angeles California Hub: California Manufacturing Technology Consulting
Northwest Hub: Pacific Northwest National Laboratory
Gulf Coast Hub: Texas A&M University
Midwest Hub: Building Team
Affordable, Accessible, InnovaJve & CollaboraJve Network-‐Based, Smart Manufacturing
Focused Efforts Key Markets
Energy Intensive Markets • Petroleum Refining • Chemicals, PlasJcs, Rubber • Wood Pulp and Paper • Primary Metals • Food Processing • Glass and Cement
Energy Dependent Markets: • Solar PV, Carbon Fiber Composites, Light Emirng Diodes, Electro-‐
Chromic CoaJngs & Corrosion resistant alloys, Advanced texJles for fashion, ExoJc materials for space, Nano materials for healthcare, Membranes, Computers & Electronics, EV Ba=eries, MulJ-‐material joining, Other Industries that have a 25% or greater cost of energy as part of the total cost of manufacturing
April 18, 2017 CESMII Kick-‐Off PresentaJon – Los Angeles, CA 19
Regional Manufacturing Centers We followed the data
April 18, 2017 CESMII Kick-‐Off PresentaJon – Los Angeles, CA 20
MidWest COMING SOON
CESMII PERFORMANCE METRICS
To achieve what end results?
CESMll Performance Metrics include:
• Energy Productivity - in U.S. manufacturing will double every 10 years
• Energy Efficiency - a 15% improvement in energy efficiency in first of a kind Testbeds will be achieved within 5 years
• Deployment Costs - of SM systems will be reduced 50% relative to state of the art within 5 years
• Adoption Costs - of SM systems will be recovered from improved energy use in less than 10 years
• Workforce - SM workforce will be increased two-fold by 2020, and five-fold by 2030
• Supply Chain - value and participation will increase over 40% by 2030