journey to industry 4.0 and beyond with cognitive manufacturing
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Journey to Industry 4.0 and beyond with Cognitive Manufacturing
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We’re entering the fourth revolution of industry and it is fully differentiated from any that came before it
LineProduction
Electrification & Automation
Miniaturization & Global Scale
Cognitive ManufacturingComplexity
Era
1783
1870
1960
2020
Water, steam, and conveyors; modern materials handling
Assembly systems: Lighting, electricity and assembly lines
Embedded systems: Semiconductors, computers, information technologies and increase in trade
Cyber-physical systems: sensors, big data, predictive analytics, cognitive computing, cyber-physical systems, robotics, 3D printing
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collected manufacturing and
enterprise data
Smarter Supply Chain
Management
Smarter Energy
Smarter Factory
Operations
SmarterProductDesign
Smarter Employee
Safety
Smarter
Quality
made into a transparent,
comprehensive, interactive, minable
corpus of informationthat makes visible new
patterns in the data
to continuously monitor, predict,
respond and interact with humans and
machines
To deliver
SmarterEquipment
Maintenance
Cognitive Manufacturing applies cognitive capabilities to digitize and optimize previously inaccessible areas of manufacturing processes
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To capture the potential of the cognitive manufacturing transformation, we focus on three key pillars of manufacturing that drive the highest improvement
Intelligent Asset and Equipment
Smarter Resources and Optimization
Cognitive Process and Operations
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Intelligent Assets and Equipment
Intelligent assets and equipment utilizes IoT and cognitive capabilities to sense, communicate and self-diagnose issues so they can optimize their performance and reduce unnecessary downtime
Prevent production delays and improve line performance with better asset visibility
Reduce equipment downtime and increase process efficiency with industry models
Expedite equipment repairs through predictive and cognitive analytics
Decrease in equipment downtime at major global auto manufacturer
34%
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Auto manufacturers are utilizing the analytics capabilities of Watson IoT combined with new sources of real-time data to gain new predictions and prescription on improving equipment availability and performance. Using prebuilt industry models, manufacturer can spend less to analyzing and more time doing.
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Equipment downtime can be significantly reduced by combining the power of IoT with cognitive capability. Not only can Watson IoT predict what and when failures can happen, it can utilize cognitive capabilities to advise a user on exactly how to fix and resolve these failures.
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Cognitive Process and Operations
Cognitive operations and processes bring more certainty to business by analyzing a variety of information from workflows, context and environment to drive quality, enhance operations and decision-making.
Increase yield of your manufacturing operations and processes
Improve productivity of your manufacturing line with early quality detection
Expedite service calls and repairs and reduce warranty costs
Increase in overall productivity at major European automaker
25%
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With quality analytics from Watson IoT manufacturers can analyze hundreds of process variables, historic and real-time, to identify issues contributing to quality issues and resolve them before they occur. This drastically improves productivity and yield while reducing operation and material costs.
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By utilizing cognitive capabilities, Watson IoT can bring in unstructured data such as image and video which enriches the information around manufacturing processes. Combined with other IoT data, this information can produce more accurate predictions and better insights
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Smarter Resource and Optimization
Utilize IoT and cognitive insight to optimize the resources engaged around production, whether that’s keeping production line workers safe, improving the expertise of the entire workforce or optimizing energy consumption
Improve worker safety and gain better workforce management
Increase worker productivity and expertise Reduce energy consumption of your facilities
and buildings
Reduced energy and resource costs at manufacturing facility by
8%
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Industrial manufacturers are using Watson IoT to help employees stay safer in dangerous environments. The solution detects hazardous environments and provides real-time alerts to employees and employers enabling preventive measures if physical well-being is compromised or safety procedures have not been applied.
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Engineers are training Watson to collate 30+ years of engineering experience in managing liquid gas facilities to create a cognitive advisory service to help employees across the organization resolve problems faster, improve process flow and achieve better operational outcomes.
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Embracing cognitive manufacturing
Collect the Data
Collect and curate the right data— data on processes and operations you would like to improve, data across your systems, both structured and unstructured. Connect systems and sensors to bring in real-time data for more accurate insights
Visualize the Patterns
Visualize your data on a platform. Quickly build up dashboards and use simple analytics to determine patterns. Supplement with external sources of data and analyze variables that impact the process and operation you would like to improve.
Analyze with Purpose
Apply purpose driven analytics to gain new insights from you data Developed advanced models, process a combination of variables and utilize the prediction engine to generate the best recommendations the drive the most business results
Deliver with Cognitive
Whether it’s dealing with vast amounts of IoT data or dark and unstructured data, cognitive capabilities brings light and clarity. Take advantage of the processing power of cognitive to enable you to act, resolve, and deliver better
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Differentiating elements of Watson IoT technology and ecosystem
Partnered InnovationOpen ecosystemDevice partnershipsEmbedded securityEdge Analytics
Data IntegrationWeather dataSocial dataApplication dataPlatform of platforms
Advanced AnalyticsPredictive AnalyticsReal-time AnalyticsData MiningOptimization
Cognitive TechnologyNatural Language ProcessingMachine LearningTextual AnalyticsVideo/Image Analytics