Industrial IoT (IIoT) for Manufacturing

fanufacturers are benefiting from a data-driven operations!

Objectives✓Introduction to Industry 4.0

✓Transition to Data-Driven operations

✓Increase communications across the business – machine-to-computer, machine-to-machine

✓Reduce operational cost and enhance quality

✓Improve Overall Equipment Effectiveness [OEE].

✓Anywhere, Anytime access to plant floor information through Web-enabled dashboard application

Industry 4.0

Industry 4.0 refers to the fourth industrial revolution where manufacturing uses computer networks and network connected equipment/devices to gather data, exchange and analyze information to improve process efficiency & decrease cost of operations!

What is involved?

Leverage Automation

Collect data and Analyze

Improve Operations

through insights

Reduce Operational cost

5 ways Data is impacting manufacturing

• Enhancing Plant performance by increasing production throughput and quality

• Improving demand forecasts

• Faster and improved customer service

• Managing supply chain risks

• Enhancing safety and security

Why IIoT in Manufacturing?

Predictive Modeling Will provide significant improvements in up-

time (predictive maintenance)

Will provide significant information on equipment

performance (real time)

Will provide data for continuous improvement

efforts – ever better efficiencies/utilization

Where in Manufacturing Operations is IIoT applied?➢Alerting unexpected equipment failures

➢Monitor worker negligence issues/accidents and preventsimilar incidents from happening in the future

➢Resource optimization by improving production workflowsand dynamic scheduling

➢Retrofitting legacy machines with needed sensors, cameras for monitoring

➢Enabling connectivity between legacy machines, new machines, communications and data processing infrastructure (Cloud computing)

➢Identifying product quality issues and correlating that info with equipment usage data

How IIoT Will Impact Operations-Improve Manufacturing

➢Analyze safety data and improve safe equipment operation

➢Analyze equipment performance and improve Overall Equipment Effectiveness [OEE]

➢Analyze manufacturing process and improve the procurement process

➢Reduce insurance costs as equipment performance increases and part manufacturing processes are streamlined

➢Improve employee performance as operation processes are made efficient

➢As manufacturing processes, equipment and personnel become more efficient overall shop-floor productivity increases

Business Cases

➢ Web-enabled dashboard application for plant floor visibility

➢Current state vs Future state (Networked operations)

➢Centralized vs Distributed Intelligence

➢Single point of failure vs Resilient operations

➢Predictive maintenance & OEE

Transitioning to Data-driven operations

➢Attaching smart devices to legacy machines

➢Capturing equipment data from automated assembly lines

➢Creating integrated network infrastructure for communication between machines, devices and personnel

➢Reporting data from various systems and plant equipment (dashboards)

Courtesy: Mazak USA

Measuring Overall Equipment Effectiveness (OEE)

Courtesy – Vorne Industries

Continuous Data and Distributed Intelligence

Present

Cell Controller

Future

Networked Communications

Courtesy: MTConnect.org

Business Value for Metal Works➢ Understand the process flow currently in use at Metal

Works for making parts

➢ Use Data points captured from CNC machines for shop-floor monitoring - Analytics & Reports

➢ A Web-enabled application dashboard to bring CNC &other machine data to display live production data

➢ Identifying ways to improve processes, workflow and overall equipment effectiveness

Manufacturing Examples

Courtesy – Memex Inc.

❖Smart Factory Simplified (with MTConnect):

www.youtube.com/watch?v=PMDTTDekW2Y&t=35s Image: Courtesy – Internet Royalty Free

3DES Team

• Nandu Vellal, Founder

• Rich Thall, Founder

• Satish Mantripragada, Business Lead

• 3D Educational Services,

• 84 Brick Kiln Rd.,

• Chelmsford, MA

• W: www.3desinc.biz

• P: 978-364-2728