Smart Manufacturing Leadership Coalition (SMLC)

The infusion of intelligence that transforms the way Industries conceptualize, design, and operate the manufacturing enterprise.

Denise Swink, CEO - SMLC

https://smartmanufacturingcoalition.org http://smartmanufacturing.com

Continuous

Batch

Motion Drive

Discrete

Safety

2

Most plants use multiple separate manufacturing control and information technologies

Combined

Heat &

Power

(CHP)

Energy-efficient

Motors

Distributed

Control

Systems

(DCS)

Programmable

Logic

Controllers

(PLC)

Smart

Machines

& Robots

Manufacturing Today

30 Years of IT & Islands of Efficiency

Courtesy of Rockwell Automation : Copyright © 2010 Rockwell Automation, Inc. All rights reserved.

Copyright © 2009 Rockwell Automation, Inc. All rights reserved.

Continuous

Batch

Motion Drive

Discrete

Safety

3

End-to-end data and information connectivity across the plant floor

e.g., Ethernet/IP

• Networked sensors & information

• New forms of benchmarking

• Untapped efficiency opportunities

• Integrated, global performance metrics

• New forms of production management

Industrial Energy Management

Smart Manufacturing 101 Networked Information & Integrated Decision-Making

Test Beds - General Dynamics, General Mills, General Motors, Praxair,

Corning, Pfizer, NETL, Alcoa, Center for Advanced Technology Systems/RPI

Design/Manufacturing Platform Providers – JPL/NASA, UCLA,

Rockwell, Honeywell, Emerson, Invensys, Nimbis

Modeling & Simulation Materials, Design, Manufacturing –

Caltech/JPL, NETL, Argonne, UCLA, UT Austin, Tulane, NCSU, CMU, Penn,

Purdue

Smart Manufacturing/Smart Grid – EPRI

Global Metrics/Outreach – AIChE, ASQ, ACEEE, NCMS, MESA, Sustainable

Solutions, Spitzer & Boyes

Agency partners – NIST, NSF

Regional/National Partners – ASERTTI, Center for Smart Manufacturing

Innovation in CA (CMSI), NASEO, Wisconsin Manufacturing Institute

S M L C 501c (6)

P A R T N E R S H I P S

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

S M A R T

M A N U F A C T U R I N G

(S M)

Modernized factory base

Bolder design of new plants

Accelerated manufacturing

innovation

Radical Sustainability

New skilled-workforce

New technology insertion

Zero incidents

Aggressive increase in SMEs

New high-tech jobs

Global competitiveness

“Making real-time information available when it is needed, where it is needed, and in the form it is needed throughout the Manufacturing ecosystem.”

S M

P L A T F O R M

Shared, scaled, open

architecture infrastructure

Manufacturing apps store

Knowledge-enabled, model

rich enterprises & supply

chains

Real-time, networked,

sensor-based modeling &

simulation

Manufacturing on the

internet

S M L C

O B J E C T I V E S

Develop a standards-based reference architecture based on

industry-driven collaboration with IT suppliers

Create and provide broad access to next-generation sensors, including low-cost sensing and sensor fusion

technologies

Lower cost barriers for applying advanced data analysis, modeling, and

simulation in core manufacturing

processes

Build pre-competitive infrastructure including

network and information technology,

interoperability, and shared business data

Ensure multi-level cyber security and

protection at a scalable level

Integrate requirements of

small, medium and large enterprises

Facilitate efforts to secure funding through public-

private and private-private partnerships to address priorities

Establish an industry-shared SM Platform that includes an open

architecture software development framework

Implement R&D projects for joint investment and

execution of SM Systems

Operate industry test beds for Smart Manufacturing System

concepts and make them available to companies of all sizes

8

Supply Chain Distribution Center

Customer

Business Systems, ERP

Smart Grid

Smart Factory

Recipe Management

Mapping formula into operating

recipes

EDI transaction

& quality

certifications

FDA Tracking &

traceability

General Mills Networked-Based Manufacturing

Intelligence & Collaborative Manufacturing

Green Light

Analyze - to put into production

Make – right ingredients – confirmation on recipe

Release – meet requirements to release

Mapping SAP information

Into operation

Graphics courtesy of Rockwell Automation

Master Data (BOM,Specs,Vendor,Ingredients,FP)

Dir

ect

Co

nsu

mp

tio

n

Core Systems

Data Input

Core Functions

Raw

Mat’l

Inve

nto

ry

Fin

ish

ed P

rod

uct

In

ven

tory

Pro

du

ctio

n

His

tory

Pla

nt

Flo

or

Inve

nto

ry

Dem

and

Pla

n

Pro

du

ctio

n

Ord

er

Lin

e Sc

hed

ule

MQIS MES SAP ERP Red Prairie SAP APO SAP PLM SAP MRP

Value Creation Green Light to Convert

Green Light to Ship

Demand Driven Supply Chain

Wo

rkFl

ow

Lot

Trac

kin

g

Overusage

Op

tim

izat

ion

En

gin

e

Trace/Recall BOM Validation Yard Mgmt

Optimized Inventory

Business Applications

Directed Work

Supplier Managed Inv Line Supply Bin Mgmt

Allergen/Micro WorkFlow eCOA

GMI’s ECO System of “ STUFF”

Courtesy of General Mills

What is Smart

Orchestration- achieve optimal actions across specific environment at the speed of business

CONTEXT - give raw data meaning to do something effective with the information

DATA - retrieve related data, communicate to multiple sources, map it for RICH context

Multi-Layered Smart Manufacturing Workflow Management

Time Managed as Workflow Machines – People - Materials Dynamic Manufacturing Ecosystem

Design Data

Product Manufacturing

Materials & Process Tech

Prototype Qualification In

Service

Macro Layer

Meso Layer

Micro Layer 1000s of control loops

Time - minutes

100s of control loops

Time -hours

10s of control loops

Time – days

Focus: 10x Multiple

Pass Variability

Reduction; Supply

Chain Information

Focus: 100x Event

Variability/Tradeoff

Adjustment; Dynamic

Performance Mgmt.;

Integrated Metrics

Focus: Insertion,

Qualification, ICME,

High Fidelity Dynamic

Operations

Workflow, Data, Time & Cost

Smart Manufacturing Open Architecture

Platform

Control & Automation Propriety Optimized

Automation Workflows

Data Partnership Workflow

Orchestration

Toolkits

Sensor Data

Apps Store

Data collection, modeling & Synchronization multi-scale time requirements embedded

Data collection, modeling & synchronization defined by workflow

Single scale time requirement in workflow

Decision

Composability Design to manufacturing Workflow libraries

Separate Data & apps Data to apps paradigm

Test Bed Generated SM Systems

Smart Machine Operations

• In production machine-product management

• Benchmarking machine-product interactions

• Integrated dynamic management of machine-electrical power interactions

• Adaptable machine configurations

In Production Use of High Fidelity Modeling and Simulation

• High fidelity modeling for better management

• Rapid qualification of components and products

In Production Decision Making with Global Integrated Metrics

• Dynamic Business and Operational Tradeoff Decision-Making

• Dynamic performance management of global integrated metrics

• Untapped cross factory degrees of freedom for optimizing efficiency and performance and compressing time

Supply Chain Management

• Supply chain variability reduction and management of risk

• Tracking and traceability

Machine Function Benchmarking & Integrated Management

Design Operations Supply Chain

DOE Project SM - Test Beds

Dynamic energy management & cross unit performance

Praxair

General Dynamics

SM Platform

Implementation

Working Groups

Platform • Validation • Cyber security • Definition of open architecture • Standards requirements • Define a near-term demo • App store functions • Webinar

Business Development Group • Research study to develop business

case • Funding • Problem definition • SME outreach • Support service structure • Elevator speech for various audiences • Communications Package, Advocacy

Test Bed • Metrics • Domains w/diversity • Applications identification • Mock ups • Smart Grid interface • Problem categories • Sharing and Exchange of protocols • Skills identification

People & Training • Education & training (k-12, higher

education, existing workforce) • Existing workforce • Lead the paradigm shift • Test beds • Public-policy & advocacy for

workforce development

Member Benefits - 1

• Gain access to the “best and brightest”

SM resources from many disciplines

(esp. ME and ChE)

• Find opportunities to fuel innovation

• and access talent, knowledge and expertise

• Establish R&D implementation teams for specific projects

• Participate in the deployment of projects to address industry hurdles.

• Form partnerships to pursue new commercial opportunities

16

Member Benefits - 2

• Manage risks and uncertainties of deployment through R&D and test bed opportunities

• Avoid high cost development of one-off, local solutions

• Develop engineering standards, define initial test beds, and target applications of prototypes

• Gain insight into early market opportunities and add commercial value

• Provide input and guidance for the design of the platform structure while it is under development

17

18

Smart Grid

Customer

Enterprise Business

System

Suppliers

OEM Machine Builders

Distribution Center

Factory

• Higher value products

• Improved quality

• Zero downtime

• Increased equipment

life / utilization

• Improved safety

• Reduced energy

and emissions

• Highly sustainable

• Higher product availability

• No inventory

• Product lifecycle

management

18

ENTERPRISE OPTIMIZATION &

SUSTAINABLE PRODUCTION

ENERGY,

SUSTAINABILITY, EH&S AGILE DEMAND-DRIVEN

SUPPLY CHAINS

Courtesy of Rockwell Automation : Copyright © 2010 Rockwell Automation, Inc. All rights reserved.

The commitment to comprehensive design-manufacturing life cycle

T H E

V I S I O N

Websites: https://smartmanufacturingcoalition.org

http://smartmanufacturing.com