recommending a strategy

LINK

NE

T 3 -IIO

T

47 Years47 Years47 Years197219721972---201920192019

1

IIOT

IIOT (some slides courtesy of Balluff)

Michigan Safety

LINK

NE

T 3 -IIO

T


2

Improve safety

Improve reporting

Signing of documents

Reduction of Manufacturing Costs

Higher Machine Availability

OEE

Improved Asset Utilization

Traceability of products & parts

Improve Supply Chain

Easily integrate new technology

Improve product quality

Reduce Scrap rates

Reduce die crashes

Reduce unplanned downtime

WHAT ARE YOUR GOALS?

LINK

NE

T 3 -IIO

T


3

Predictive Maintenance – failures lead to injury

Quality Assurance

Condition Monitoring

Quick Die Change

Die Protection

Simplify Troubleshooting

Troubleshoot without entering control

Traceability- operators read and performed safety checks

Security / IT

Location Management

Analytics / Big Data

Press Setup

Part Bin / Cart Tracking

Poka-Yoke / Error-Proofing

ARE YOU TALKING ABOUT THESE THINGS?

LINK

NE

T 3 -IIO

T


4

THAT'S INDUSTRY 4.0

26. März 2019

LINK

NE

T 3 -IIO

T


5

WHAT IS INDUSTRY 4.0?

LINK

NE

T 3 -IIO

T


6

WHAT IS THE INTERNET OF THINGS (IoT)?

Network of physical objects or "things" which collect and exchange data.

LINK

NE

T 3 -IIO

T


7

Mass personalization

IoT CASE STUDY

LINK

NE

T 3 -IIO

T


8

INDUSTRIAL INTERNET OF THINGS (IIoT)

!!

!

!

!

!!

LINK

NE

T 3 -IIO

T


9

BUT WHY SHOULD I PAY ATTENTION TO THIS?

LINK

NE

T 3 -IIO

T


10

Closing The Loop

Requires someone to make a decision

LINK

NE

T 3 -IIO

T


11

Multiple loops

LINK

NE

T 3 -IIO

T


12

Closing The Loop

Machine controls

DRIVE CONTROLS

LINK net

LINK

NE

T 3 -IIO

T


13

Multiple loops

LINK

NE

T 3 -IIO

T


14

Multiple loops - Thermostat

LINK

NE

T 3 -IIO

T


15

MODERNIZATION IS OVERDUE

Projectinga 48% reduction in unplanned downtime!

48%

LINK

NE

T 3 -IIO

T


16

Morgan Stanley & Automation World,GE & Accenture

Expect the automation industry to grow at a faster pace than GDP

Capital budgets expected to grow 18% for IIoT type investments

73% of companies are already investing more than 20% of their overall technology budget on Big Data analytics.

INVESTMENT IN IIoT IS HAPPENING NOW!

LINK

NE

T 3 -IIO

T


17

YOUR COMPETITORS ARE INVESTING IN INDUSTRY 4.0

26. März 2019Balluff Inc | Marketing Management Director, Will Healy III @WillAutomate

LINK

NE

T 3 -IIO

T


18

1. Enhance worker safety2. Optimize asset utilization 3. Improve worker productivity

4. Create new business models/new revenue streams

5. Enhance customer experience 6. Reduce costs 7. Improve sustainability

WHY ARE MANUFACTURERS INVESTING?

LINK

NE

T 3 -IIO

T


19

Where is it?

Use Data?

Repair Data?

Setup Data?

Last Operator?

Maintained by?

Predicted Maintenance Date?

Recipe Data?

METAL STAMPERS & #2 ASSET UTILIZATION

26. März 2019 19

LINK

NE

T 3 -IIO

T


20

Maintenanceon the Shop Floor

Balluff Inc | Marketing Management Director, Will Healy IIII

LINK

NE

T 3 -IIO

T


21

Preventative MaintenanceTiming based on age or use.82% random failure pattern.When a failure occurs it can be a safety hazardPredictive MaintenanceEmploys condition monitoring and analytics to predict failure.Benefits:

Improved Uptime

Asset Longevity

Maintenance Cost Control

Safety

IIoT Enables Predictive Maintenance of Assets

MAINTENANCE ON THE SHOP FLOOR

21

LINK

NE

T 3 -IIO

T


22

THE USE OF MOBILE DEVICES IN INDUSTRIAL APPLICATIONS

Global market projections for industrial mobile applications(courtesy of IHS)

4x today!

SMART Machines: What they are and how they contribute to the future of the industry - by Dr. Rainer Beudert,

LINK

NE

T 3 -IIO

T


23

Using Historians and Data Logging

Visible globally across the organization in real time.

Laser focused information into individual operations

Share metrics of success and/or failures.

Diagnostics in the Cloud or Local Server


LINK

NE

T 3 -IIO

T


24

accurately measures safety parameters like temperature or vibrations and sends the data via smartphone to a cloud- based secure server

Software from ABB analyzes the data and recommends predictive safety failures measures.

reduce unplanned downtime by up to 70%, extend motor lifetime by up to 30% and improve the energy efficiency by up to 10% - a measurable added value amortized within less than a year.

ABB's IoT Enabled Low Voltage Motors


26. März 2019 24

LINK

NE

T 3 -IIO

T


25

What goes in must come out!

Die Protection sensors are a must

Prevent crashes that cause injuries

Automate Setup & Change Verification

Reduce safety issues due to calling up the wrong part or tool

Safety & Die Protection need Control

Information that can assist in an accident or prevent an accident by not allowing operators to run equipment until they’ve done and checked off an inspection

ROI on an entire Die Protection Program is typically only 1 crash.

INDUSTRIAL IoT: VISIBILITY INSIDE THE TOOL

26. März 2019

LINK

NE

T 3 -IIO

T


26

PRESS CONTROLLERS

26.03.2019 26

Link Systems Die Interface

Link SystemsPress Controller

LINK

NE

T 3 -IIO

T


27

AUTOMATION CONTROLLERS

26.03.2019 27

LINK

NE

T 3 -IIO

T


28

Disadvantages

Difficult to repair

Hard to diagnose

High Cable Mgmt

Advantages

Low piece cost

Basic service skills

THE EVOLUTION OF I/O – HARDWIRED POINT-TO-POINT

26.03.2019 28@WillAutomate

LINK

NE

T 3 -IIO

T


29

Disadvantages

Hard to diagnose

Long downtimes

Advantages

Easier to repair

Basic service skills

THE EVOLUTION OF I/O – JUNCTION BLOCKS

26.03.2019 29

LINK

NE

T 3 -IIO

T


30

Disadvantages

Higher piece cost

Network skills

Advantages

Fast diagnosis

Fast repair

Low Cable Mgmt

THE EVOLUTION OF I/O – MACHINE MOUNT I/O BLOCKS

26.03.2019 30

LINK

NE

T 3 -IIO

T


31

Does it make sense to have every sensor

with an Ethernet connection?

VISIBILITY DOWN TO THE SENSOR

26. März 2019

LINK

NE

T 3 -IIO

T


32


26. März 2019

LINK

NE

T 3 -IIO

T


33


Capture vs Control – Analytics Driven Decisions!

26. März 2019

SE

RV

ICE

DA

TA

PR

OC

ES

S D

ATA

Logic ProcessInterpretation of the

supplied data

TransportingVarious systems

transport the data and make it available

CreatingCapturing the actual

process environment

Controlling

Transporting

Acting

Controlling

Transporting

Acting

Capture Cloud / Big DataAnalytics for Data Driven Decision Making

Logic Process

Transporting

Creating

LINK

NE

T 3 -IIO

T


34

Case Studies of IIoT & Industry 4.0


LINK

NE

T 3 -IIO

T


35

CASE STUDIES OF IIOT & INDUSTRY 4.0

Motivations

Flexible Manufacturing

Lot Size 1

Quick Die Change

Automated Press Setup

Efficient Production

Die Protection

Poka-Yoke / Lean

Error proofing also means that when there is an incident report, what are we doing to prevent it from happening again or never happening in the first place

Traceability / Error Proofing

Visibility

Operator / Supervisor

Corporate / Plant

26. März 2019 35

LINK

NE

T 3 -IIO

T


36

Traceability with RFID

A level of tracking- multiple sensors track tooling and personnel to verify it’s the correct tool and the correct operator using it.

Sensor & pushbutton I/O

96 variants on one line

CC-Link Masters

BIS M IO-Link RFID

BNI IO-Link I/O Hubs

Powertrain Assembly Conveyor

CASE STUDY: FLEXIBLE MANUFACTURING PALLETIZED ASSEMBLY

26. März 2019 36

LINK

NE

T 3 -IIO

T


37

Die crashes / lock-up

Costs the company

$80k per occurrence

3-4 times per year

plus torch work to cut out die sections.

Completely human error

Commonly wrong shut height or wrong recipe selected.

Crash can send parts exploding into the shop – Major safety incident

Manufacturer Problem

CASE STUDY: EFFICIENT PRODUCTION DIE IDENTIFICATION

LINK

NE

T 3 -IIO

T


38

UHF Long Range RFID System

Site Survey & Project Reviews

Software integrator required

Eliminate human error & paper documents

Benefits…

Eliminates damage to dies and press.

Substantially reduces downtime.

Application Solution


LINK

NE

T 3 -IIO

T


39

Application Installation


UHF Antenna can be mounted on one of the columns of the press

Customized mounting location and guard to suit the customers application.

BalluffRFID TagMounted on Die

LINK

NE

T 3 -IIO

T


40

Safety in the 4th Industrial Revolution


LINK

NE

T 3 -IIO

T


41

Most common in industry right now

"Add-on Safety"

Signal to PLC to stop but no control.

No managed shutdown

can damage automation

unknown shutdown states

Lead to crashes

Basic light curtains, estops, door switches

Dominated by safety relays

Hardwired Safety Architectures

EVOLUTION OF SAFETY ARCHITECTURES

26. März 2019 41

Safe processing

Safety sensors/actuators

Balluff Inc | Marketing Management Director, Will Healy III

LINK

NE

T 3 -IIO

T


42

Most users are not here yet.

Can provide controlled shutdown

Known device shutdown states

Safety & Motion enabled PLC

Integrates into LINK control

Remote I/O

Cabinet Slice I/O

Machine Mount I/O

Event Data & Process Data

Status Parameters

Controlled Safety Architectures

EVOLUTION OF SAFETY ARCHITECTURES

42

Safety sensors/actuators

Standard sensors/ actuators

Fieldbus with IO-Link

interface

IO-Link devices

Safety PLC

LINK

NE

T 3 -IIO

T


43

Smart Devices Report Data

Device Events

Process Data

Status Parameters

Downtime from device switching

"Why door 6 vs doors 1&5?"

"How often are safety devices being switched?"

"Why are they being switched?"

Downtime & Incident Analytics

SAFETY & IIOT

26. März 2019 43

LINK

NE

T 3 -IIO

T


44

flow of daily work

shift changes

known violators

adapt to operator habits

preemptively slow down work in the area to not cause a hard shutdown

Anticipatory control of the Workcell

PREDICTIVE PRESENCE

26. März 2019 44

LINK

NE

T 3 -IIO

T


45

Most have software safety

Zone limited control

Improved human access to the machine

Improved robot utilization

6Axis Robots

HUMAN / MACHINE COLLABORATION

26. März 2019 45

LINK

NE

T 3 -IIO

T


46

Increased Human & Robot Efficiency

Human idle reduced 85%!

Applicable to Small to Midsized Mfgr

Increased ROI (<1yr)

Greater Flexibility in the Human Environment

Safely Handle Complex & Dangerous Tasks (prevent unwanted motion)

Simpler, more effective, less expensive safety

Collaborative Robots

HUMAN / MACHINE COLLABORATION

26. März 2019 46

LINK

NE

T 3 -IIO

T


47

Collaborative

Better Safety

Better visualization

Safety with a mobile device is not a new topic.

More Mobile Devices

NEW TECHNOLOGY AWARENESS

26. März 2019 47

LINK

NE

T 3 -IIO

T


48

Collaborative

Remote maintenance

Better visualization

Distracted walking?

Distracted working?

Virtual Reality & Augumented Reality (VR & AR)


26. März 2019 48

LINK

NE

T 3 -IIO

T


49

Assisted lifting, positioning, moving

Machine & Man are one collaborative unit.

Machine/Man Safety is going to get more complicated.

Operators & Bystander Safety.

Huge safety benefits, reduced or eliminated back injuries

Exoskeletons


26. März 2019 49Balluff Inc | Marketing Management Director, Will Healy III

LINK

NE

T 3 -IIO

T


50

SAFETY IN THE 4TH INDUSTRIAL REVOLUTION

Recommendations for the Press Shop

Create a Manufacturing Automation Safety Strategy & Program

Start with Basics like:

Light curtains on presses

Press control for controlled shutdowns

Die Protection Program

Have a strategy for addressing new technologies brought into the plant

26. März 2019 50Balluff Inc | Marketing Management Director, Will Healy III

LINK

NE

T 3 -IIO

T


51

Industry 4.0 –What do I doNow?


LINK

NE

T 3 -IIO

T


52

BULLDOZE THE FACTORY!

26. März 2019@WillAutomateBalluff Inc | Marketing Management Director, Will Healy IIII

LINK

NE

T 3 -IIO

T


53

Build a Team

INDUSTRY 4.0 – WHAT DO I DO NOW?

26. März 2019 53

LINK

NE

T 3 -IIO

T


54

Who needs what data?Interviews

Plant Mgr, Line Mgr, Engineers, Production Mgr, Quality Mgr, Operators, Maintenance, IT

Questions to ask

What do you want to know?

What information would make you more productive?

What don't you need to know?Build a strategy & action plan

FIRST BUILD A TEAM!

26. März 2019

LINK

NE

T 3 -IIO

T


55

Build a Team

Research Data

Identify Strategy

Buy-In & Budget

Daily Action

INDUSTRY 4.0 – WHAT DO I DO NOW?

26. März 2019 55

LINK

NE

T 3 -IIO

T


56

What data do we have?

What are we trying to accomplish?

Specify what you want.

Order the right thing, not the cheapest.

What data do we need?

DAILY ACTION

26. März 2019 56

LINK

NE

T 3 -IIO

T


57

RESULTS & VISIBILITY

26. März 2019 57

LINK

NE

T 3 -IIO

T


58

Thank You!!

Questions?

Your Time Is Very Important, Thank You

Thanks to all of you who made this training possible.

Free 3 Day OSHA training www.linkelectric.com

Dean Phillips, LINK [email protected]

(615) 714-4442

http://www.linkelectric.com/

recommending a strategy

Documents