A Perspective on Industrial Internet of Things (IIoT) for Paint Shop Operations

Painting Technology Workshop PTW2016

October 18-19, 2016 Lexington, KY

Agenda

• What is Industrial Internet of Things (IIoT)? – Industry Perspective – My Perspective

• What are some of the foundational technologies? • What are example use-cases for IIoT in Paint Shop

Applications? • Discussion Topic: How does IIoT enable Monozukuri &

Hitozukuri? • Q & A

IIoT – Industry Perspectives

Sample Quotes: • Market Analysts

• Greg Gorbach, Vice President, ARC Advisory Group: • "IIoT more accurately described as: The transformation of industrial products,

operations, value chains, and aftermarket services that is enabled through the expanded use of sensors, digitization, networking, and information systems.“

• Technology Providers • Sujeet Chand, SVP and Chief Technology Officer, Rockwell Automation: • “Rockwell Automation’s vision of Connected Enterprise is focused on connecting the

multiple silos of information in a manufacturing enterprise and helping them to extract business value from connecting these silos.”

• Manufacturers (End-Users) • Tim Platt, Toyota Group VP and Chief Divisional Information Officer: • "Toyota sees a huge IoT opportunity in putting sensors on equipment…even the older

equipment. We were talking about an example we had in paint. Our engineers were manually collecting data, it was taking weeks and weeks to validate a problem, we brought in one of our strategic vendors, put in a predictive maintenance tool to show proof of concept. One of the paint engineers came back and said you know it’s taken me eight weeks to figure out that was a problem; you guys did it in two hours.”

Common Theme: Digital Thread, Connect Info Silos, Smart Solutions, IT / Ops Collaboration

My Definition

IIoT enables: (a) Transition from 1-Dimension problem/solution paradigm to multi-D paradigm (b) Put people (Workers and Customers) are at the center of focus…not just the technology.

• IIoT is an umbrella theme – not a single “Thing”

• IIoT is the integration of Processes, Industrial Automation & IT Systems to Continuously Improve Operator skills across the value-chain with the objective of delivering high-quality products to customers cost-effectively.

• Because of its real-time capability IIoT also enables manufacturers to improve responsiveness to new fashion driven and fluctuating customer demands.

My Definition

Technology: As-Is Emerging

• Is IIoT the same old, or is there something new?

• What are the new dynamics? – Dramatic reduction in communications, sensors, analytics costs

– Thousands/millions of sensors, wide-area communications, Terabytes of data

– Edge / Web / Cloud Computing Technology

– Enterprise IT / Factory Operation-IT / Consumer Interface Systems Integration

• What does it mean for new value creation? – Highly flexible manufacturing: Just-In-Time, Individual Customization

– Proactive instead of Reactive: Condition Based, Prognostics Maintenance

– Expand production capacity without additional capital investment

IIoT is the new opportunity to create new business models, enabled by the democratization (dramatic cost reduction) of technologies Better (User) Experience

$4.99

Amazon Dash Button

IoT Node with WiFi: < $5

Very low cost

Instant Comms.

Paint Shop Operations: IIoT Examples

Painting Robot Prognostics / Diagnostics Energy & Environmental Management

Supports: Facility Management, Sustainability Supports: Production, Maintenance, Quality

Paint Shop

Real-Time Sensor & User Input Data

Fusion

Multi-Objective Optimization (Big Data Analytics)

Objective Vector

Mathematical Model & Algorithm

Quality

Electricity

Natural Gas

Weather: Now & Forecast

Savings

Emissions

Temp, Humidity, etc. Image so

urces: V

W, Fan

uc A

merica

• Unplanned downtime in a factory can cost automakers $15,000 – 50,000 per minute

• As-Is: Scheduled Maintenance New: CBM, RCM, Predictive

Discussion: Philosophy & Strategy

• Monozukuri & Hitozukuri Concepts – Meaning

– Why the focusing on worker is most important? • Why do we say employees are the most important asset?

• Automation cannot learn or be creative – only people can

– Can it work in high-turn over environments? • Deskill the work or Develop the Skills of the Workers?

• What are the Pros & Cons?

• Example of Creative Thinking - Kaizen – Removing doors prior to Vehicle Assembly

• How IIoT can empower people involved in the manufacturing process? – Amplify Human Awareness and Capabilities

• Provide real-time feedback on quality – upstream & downstream of the process

• Visibility to parameters beyond human sense

• Wide-area awareness – Global supply chain coordination – especially for JIT

• Real-time data visibility shop-floor to board-room, with source of truth

• Coordination across functional silos

• Q: Do you agree? If so, how can we accomplish this approach in the US or in any high turnover manufacturing environment?

IIoT should be designed and implemented with Human Centricity in mind - assisting humans, enabling them to learn & develop smart problem-solving skills

Image source: TMMK YouTube Video

“Whatever products and services you supply to your customers, the main purpose of your business is to train and develop your people.” – Peter F. Drucker

Questions / Discussion

Thank You!

Ram Shetty OPEX Systems E: ram.shetty@opexsolutions.com P: (404) 268 5522 Atlanta, GA

About OPEX Systems We are a technology Research, Development and Consulting firm based in Atlanta, GA. We specialize in industrial automation, factory-IT and smart energy management technologies. We assist manufacturing and government customers to identify and implement cutting-edge IIoT technologies and business processes . We have helped them to improve productivity, quality, efficiency and overall operational excellence in their operations.

References

• Digital Innovation - How IIoT is Transforming the Industrial Space, ARC Industry Forum, February 2016, Orlando

• Rockwell Automation – Connected Enterprise – http://www.rockwellautomation.com/global/innovation/connected-enterprise/overview.page#tab3

• IoT at M&T: An Inside Look at Toyota Operations Technology, Industry Week, May 2016 – http://www.industryweek.com/industryweek-manufacturing-technology-conference-expo/iot-mt-inside-look-toyota-operations-technolog

• IIoT Technology Applications in Automotive Robotics – https://www.youtube.com/watch?v=BHhLTTuDqTY&feature=youtu.be

– http://blogs.cisco.com/manufacturing/general-motors-prevents-factory-downtime-with-connected-machines

• Book: “Automotive Painting Technology – A Monozukuri-Hitozukuri Perspective” – Kimio Toda, Abraham Salazar, Kozo Saito

• White Paper: “How to Implement a Kanban System” – Ram Shetty, OPEX Systems (contact me for an e-copy: ram.shetty@opexsolutions.com)

• Blog Post: “Monozukuri Through Hitozukuri”, Michael Ballé – http://www.lean.org/LeanPost/Posting.cfm?LeanPostId=168