Building a Smart Manufacturing Experimental Factory in Anna University

Some Initial Thoughts…

December 21st 2017

Ananth Seshan & Sumitra SeshanFifth Generation Technologies (5G)

Introducing 5G

• A niche and innovative software product company focusing on providing unique digital solutions.

• Product foot prints in 13 countries around the globe.• Clients include

– Major Global Automotive company– Major Tractor Manufacturer– Partner to largest global Automation company– Many Indian manufacturers

The Smart Manufacturing Landscape

© Copyright 2016. Fifth Generation Technologies. All Rights Reserved.

Unified Visibility

Smart Logistics

Smart Shipping/ReceivingSmart Customer Integration Processes

Sales Order Processing

ERP

Demand

Design

Tooling

Production Engineering

Production Planning

CA

D/C

AE

Smart Production Processes

Smart Quality Processes

SPC

/ SQ

C

Smart Reliability/Maintenance Processes

Smart Purchasing Processes

Smart Supply Chain

Finance & Administration Processes

Smart Supplier IntegrationProcesses

Internet ConnectionWhere the role of every stakeholder in the manufacturing ecosystem has transformed from being isolated to connected, from being uninformed to informed, from being passive to active,

And where information flow does not lag material flow and the boundaries between the physical and the cyber worlds are indistinguishable,

And where the human worker is elevated from the drudgery of mechanical work, stress and laborious monotony and empowered to contribute using his mental faculties with the help of intelligent machines, devices and systems to co-create value..

The Four Dimensions

Empowered Human

Smart Business Processes

Smart Technologies / Infrastructure

Smart Solutions

Smart Manufacturing Value Frame of Reference

Value is co-created by all human

stakeholders of a Smart Business

Process

The experience of the value is

manifested in Smart Solutions

The enabler of the experience is Smart

Technology

The experiencer of the value is the

Human Stakeholder

Cohesive, active, inter-disciplinary, collaborative interaction is the core of

value co-creation

Contextual intelligence & Awareness implicit in the solution outcomes present an opportunity for timely interaction

Inter-operability, security and reliability in the

connection of disparate systems allows for

experiencing varied contexts.

Personalization of the experience improves the quality of inference of a context and therefore

the quality of co-creation

Frameworks/environments for co-creating

Smart Processes

Innovative design of actionable outcomes

Use of open standards, Peer-to-Peer networks,

wireless, internet , cloud augmented reality and machine intelligence

technologies

Training and empowerment of human to continuously improve

in co-creating and experiencing value.

Value Concept

Value Definition

Value Presentation

Dimension 1 Smart Business Processes

Dimension 2Smart Digital Solutions

Dimension 3Smart Technology

Dimension 4The Human Stakeholder

SM Use Case 1 – Smart Quality Integration between Supplier and OEM

Measu

re Wid

th

Measure Inner Diameter

Real-Time Wi-Fi Transmission of Calliper Measurements to Mobile Device

Automated storage of part data in Supplier QA Repository Server (Web/Cloud)

Parts Dispatch

SUPPLIER PREMISES

Part 1 _____________Part 2 _____________Part 3 _____________Part 4 _____________Part 5 _____________

Automated alerts/updates of errors in part quality

1

1

2

3

Real-Time remote access to Supplier QA server by OEM

4

Part(s) Accepted/Rejected

5

6Parts OK

7

OEM Quality Approved Parts Dispatched

OEM PREMISES

Qu

alit

y C

on

tro

l Ch

eck

SM Use Case 2 – Smart Energy and Asset Intelligence

Centrifugal Compressor

Real-Time Energy Consumption Profile

Asset Performance Profile from Plant/EAM System

Compressor 101 –SR00345 – Loud Vibration

Lift Station 03 Generator – Oil Change – SR00456

Wet Well – Rag Removal – Inspection

Compressor Cycling Energy Signature Observed

<Compressor 101 Location/Fault ID from EAM, Energy Usage Alert

from eC4>

WORK ORDER DETAILS

Type

Status

Priority

Create

Proactive Intervention Driven by Intelligence

Predictive Maintenance W/O

Generated & Dispatched

Proactive Intervention to Prevent Unplanned Downtime and Drive Asset Performance of Compressor using Combined Intelligence from Energy and Plant/EAM Systems

13

Database

Traceability System

Part sub-assembly

Instructions from CAD/CAMOperator sends picture of

the assembly for

future traceability

Carries out assembly operation

with the guidance provided by

the wearable

2

SM Use Case 3 – Smart Sub-assembly

Our Past Experience

• 5G and Ferguson College, Pune – School of Automation

• 50:50 Partnership between both entities

• Governed by a Steering Council

• Offered Masters Diploma in Automation Application

• Industry Sponsored Program

• Facilitated real practical Industry oriented Automation projects

Purpose

This document is an articulation of some initial thoughts to start off a brainstorming discussion on developing a

Smart Manufacturing Experimental Factory

at Anna University, as a “strategic partnership” between 5G and Anna University.

Initial Stakeholders

• Anna University & 5G (Principal Founders)

• Students and Faculty of Anna University

• Select OEMs in and around Chennai.

• Select Suppliers of OEMs in and around Chennai

Mandate

• Educate students on Smart Manufacturing by involving them in practical developmental projects. Build and include topics of Smart Manufacturing in the engineering curriculum.

• Educate the industry personnel by conducting seminars, practical workshops and programs on Smart Manufacturing.

• Create an ecosystem of OEMs and their Suppliers – to potentially mimic real world scenarios and challenges.

• Pilot new Smart Manufacturing ideas and initiatives within the ecosystem. Become the “joint” R&D arm of the concerned participants.

• Do research on how the concept of Smart Manufacturing must be shaped according to the “Indian context” for large scale adoption in India, especially, within the purview of “Make in India” initiative.

• Develop a roadmap for the “next generation worker” and a curriculum fortraining the trainers of the industry.

Vision

ACT Ceramic Technology

Nano Particle Size Analyzer

High-Temperature MOR

PCE Temperature

High Temperature Dilatometer

High Temperature Furnace

Thermal Conductivity Equipment

CNC Vertical Machining Centre

Hydraulic Press 60 Tons

EDM

Hydraulic Surface Grinder

Central Workshop Division

ANSYS Academic Research

Institute for Energy Studies

CEG Mechanical Engineering

CNC Bench Milling Machine

Digital Micro Height Gauge

FANUC LR Mate 100 iB Robot

CNC Wirecut EDM

CNC Micromachining System

CNC Micromachining System w. Software

CNC Turning Centre

Abrasive Water Jet Machine

Vacuum Metal Melting Furnace

LD D-Tech Injection Moulding Machine

Twin Screw Plastic Extruder

MIT: Rubber & Plastics Technology

CNC Slant Bed Lathe

Wire Cut EDC

ECM

Abrasive Water Jet Machine

CNC Machines

Stand-Alone Robots

Autonomous Mobile Robots

Industrial Engineering

MIT Production Technology

Polyjet Rapid Prototyping Machine

FDM Rapid Prototyping Machine

AU-FRG Institute of CAD/CAM

Centre: Institute for Energy Studies

Non-IBR Steam Boiler Package

ANSYS Academic Research – 5 Users

Big Data AnalyticsCloud Based MESCloud Based EMSCloud Based EAMCloud Based ERP

Dedicated Network

Pee

r-to

-Pee

r C

on

nec

tivi

ty Dimensional Measurement Tools Retrofitted withwireless connectivity

Wearbles, Intelligent localProcessing units inerfacingwith IIoT sensors

Peer to Peer ConnectivityInter-Departmental Integration to mimic

an Experimental Factory

Thank You!