industry 4.0/smart manufacturing disrupting established ...the industry 4.0 business ecosystem...
TRANSCRIPT
Future of Nondestructive Testing
Industry 4.0/Smart Manufacturing Disrupting Established Products,
Technologies and Business Models
Mariano Kimbara
Measurement and Instrumentation
© 2015 Frost & Sullivan. All rights reserved. This document contains highly confidential information and is the sole property of
Frost & Sullivan. No part of it may be circulated, quoted, copied or otherwise reproduced without the written approval of Frost & Sullivan.
2
Focus Points—Agenda
• Understanding Industry 4.0
• The next Industrial Revolution is Around
the Corner
• The Vision
• Industry 4.0 and the NDT Industry
• Industry 4.0 Disrupting NDT
• Transformational Implications
• Smart Inspection
• Permanent Monitoring
• NDT Services 2.0
• Conclusion
4
Understanding Industry 4.0—The next Industrial
Revolution is Around the Corner
Industrial Market Evolution, 1800-2020
Year
Deg
ree
of
Co
mp
lex
ity a
nd
Ris
k
1800 2020 1900
High
Low
2000
1760s—1900
Use of steam and mechanically
driven production facilities
Industry 1.0
The steam
engine
1990—1970s
Electric Power driven mass
production based on division
of labor
Industry 2.0
Henry Ford’s
T-Model 1970s—Now
Extensive use of Controls, IT and
Electronics for an automated and
high productivity environment
Industry 3.0
IT-OT
Convergence
Future
Smart: based on integration
of virtual and physical
production systems
Industry 4.0
/IoT/IIoT
Cyber-physical
Production
Systems
5
Understanding Industry 4.0—The Vision
Industry 4.0
Technology
Processes
Collaboration
Wireless Intelligence
Big Data
Cloud Computing
Industrial Internet of Things
Integrated Industries
Social Innovation
IP Centralisation
Internet of Services
Sustainable Manufacturing
Lifecycle Assessment
• Mechanized Process
• Mass Production
• Production Automation
Industrial Revolution
1.0 – 3.0
• Production Innovation
• Increased Collaboration
• Operational Process Enhancement
• Cyber-Physical Production
Industrial Revolution 4.0 Pursuits
• Convergence of applications resulting in transformational advancements
• Energy efficiency and sustainability to gain greater business focus
• Greater presence of mobility and web-based information systems
Strategic Trends
The Industry 4.0 Business Ecosystem Industry 4.0 and NDT Industry
Industrial
Automation
ICT Vendors
Sensors, RFIDs
NDT Industry
Digital
Manufacturing
Virtual Reality
Advanced Analytics
The Industry 4.0
Ecosystem
Telecom Providers
Control
Systems
Motors &
Drives
PLM
Machine Tools
Key Attributes of the Industry 4.0
Ecosystem
Combined synergies of core NDT industry,
ICT, industrial automation technologies
supported by sensing for better tracking
Enterprise level quality process management
level software fostering high degree of
innovation across the value chain
Strategic shift in business approach towards
automation and monitoring driven by end-user
need for asset management
Ubiquitous
wireless
sensors
Production
tracking
The age of Industry 4.0 will reinvent
competitive dynamics across multiple
industrial verticals. The result will be a
grand new ecosystem where a mix of
companies from different background, co-
operate, co-opt and compete with each
other
Source: Frost & Sullivan
Robotic inspection
Robotic inspection
In Line NDT
7
Industry 4.0 Disrupting NDT
Cloud Computing Robotics Big Data Analytics
Smart Inspection NDT Services 2.0 Permanent Monitoring
Key Technological Pillars of Industry 4.0
Industrial Internet of
Things
Transformational Implications
9
Smart Inspection Real-time convergence of digital technology platforms with existing NDT techniques to give
rise to the smart inspection ecosystem where end user productivity is the central theme
Smart
Integrated
Testing
MiRA
Onsight
Connect
Smart
X-ray
Digital Technology
Platforms
Nondestructive Testing
Techniques
Visual
Inspection Augmented
Reality
Wearable
Computing
Ultrasonic and
Eddy Current
Testing
Robotics
Virtualization
Analytics
Radiography
Testing
Cloud
Computing
Cyber-physical
Systems
M2M
Real-time
streaming Remote
Collaboration
The vision of Smart Factories or Smart Manufacturing
will form the basis for an advanced Smart Inspection
ecosystem with new innovations enabled by
emerging disruptive digital technology platforms.
Despite evolving end-user needs, ROI or
productivity gains will push the adoption of
this advanced Smart Inspection ecosystem
where industry convergence and
collaboration will be central to success.
Potential New Product Innovation Existing Product
Key
10
Permanent Monitoring Convergence of condition monitoring and industrial automation with NDT technologies gives
rise to permanent monitoring because of inherent challenges in the NDT industry
Pre 2000s Early 2000s Post 2010
Periodic tests using PIGs,
ultrasonic scanners and
thickness gauges
Utilizing advanced sensor
technology through to monitor
assets
Periodic Testing Periodic Monitoring Continuous Corrosion Monitoring
Utilizing ubiquitous permanently installed
wireless sensor to not only monitor assets but
also detect small changes in pipeline wall
thickness, operate remotely, and send data
wirelessly to analysis stations.
Condition
Monitoring NDT
Industrial
Automation
Challenges:
•Lack of skilled technicians
•Aging workforce
•Increasing complexity of testing
•End-user demand for predictive
maintenance and preventive
maintenance
Permanent
Monitoring
11
NDT Services 2.0 The next generation of NDT services to transition from just inspection to engineering
decisions delivered from a remotely located office which houses NDT engineers (experts)
NDT Services 2.0: Vector of Business Transitions in the Service Landscape
NDT Services 2.0: Service Evolution for
the Future of NDT
Evolution from only
inspection services to
NDT inspection and
engineering services
1. Functional Core Strategic Partnerships
Forging relationships for
advanced service
capabilities with ICT
networking, communication
and analytics companies
Evolution from
field services to
remote services
2. Delivery Innovation
Time frame for Impact
(Years)
0
2
4 6
8
10
“If we can link simulation, rendering of assets in 3D with the data analysis and
report that–that’s a very powerful tool to work with. It will take time but we are
moving in that direction already”
- A pioneering company in the test and inspection business
Time frame for Impact
(Years)
0
2
4 6
8
10
Inspection and
Engineering Services Remote Services
13
What does this mean for NDT?—3 Big Predictions
2 While historically innovation has been incremental in the NDT
industry, going forward the model will be disruptive innovation
3 Organizations need to adapt and embrace the disruptive
business ecosystem to be relevant in the next 10 years
1
The current business model for NDT inspection services is
increasingly coming under threat and will change over the next
years.