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WatsonIoTComesToYou 6thOctober2017
IoTforManufacturing 1
Watson / IoT for Manufacturing / October 6th 20171
IoT for Manufacturing
Ton van Velzen, IBM (solution architect)
WatsonIoT
Watson / IoT for Manufacturing / October 6th 20172
IoT driven digital disruption of the manufacturing value chain is what brings us to transformation initiatives such as Industry 4.0
Digital transformation of production processes and systems that create new opportunities to achieve levels of productivity and specialization not previously possible
Industry 4.0 benefits:
• Versatile production process
• Higher specialization towards specific client needs
• Increased competitiveness across the value chain
• Ability to create new markets by establishing new services and business models
WatsonIoTComesToYou 6thOctober2017
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Cognitive Manufacturing applies cognitive capabilities to digitize and optimize previously inaccessible areas of manufacturing processes
collected manufacturing and enterprise data
Smarter Factory
Operations
Smarter EnergySmarter
AssetOperations
SmarterProductDesign
Smarter Employee
Safety
Smarter Quality
made into a transparent, comprehensive,
interactive, minable corpus of information
that makes visible new patterns in the data
to continuously monitor, predict, respond and
interact with humans and machines
To deliver
SmarterEquipment
Maintenance
Watson / IoT for Manufacturing / October 6th 20174
Gather the dataVisualize the patterns
Advance to analytics
Infuse with cognitive
Embracing Industrial transformation with cognitive through logical steps of value
• Instrument your equipment/assets to collect data
• Gather already existing data
• Visualize your data in meaningful dashboards
• Start to see patterns• Build with Bluemix
• Gain insights from the data
• Produce models, prediction recommendations
• Refine models with cognitive machine learning
• Utilize other cognitive functions to improve engagement
Asset needs to be connected, outfitted with sensor or data gathered
Use analytical models to predict equipment failures and provide recommendations
Use the platform to quickly build dashboards for data visualization
Use speech, video, image to diagnose complex problems
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IBM$Watson$IoT$Platform
Intelligent assets and equipment
Cognitive processesand operations
Smarter resource and optimization
Primary Use Case Asset Performance Management
Primary Use CaseManufacturing Performance & Quality
Primary Use CaseResource Optimization
Business MetricReliability, Downtime
Business MetricYield, Productivity
Business MetricSafety, Cost
34%Decrease in equipment downtime at
major global auto manufacturer
25%Increase in overall productivity at major
European automaker
8%Annual saving in energy cost at IBM
facilities
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
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.
Utilize IoT and cognitive insight to optimize resources (worker, energy, expertise) using geolocation data, individual data, usage data and environmental conditions along with analytics.
Prebuilt Predictive and Prescriptive Industry Models
Cognitive Processing of Structured and Unstructured Data
Personalized Learning based on User Engagement
IBM Watson IoT for Manufacturing focuses on driving improved performance and value to three fundamental pillars of manufacturing operations
Watson / IoT for Manufacturing / October 6th 20176
Intelligentassetsandequipment
Cognitiveprocessesandoperations
Smarterresourceandoptimization
IBM Watson IoT for Manufacturing focuses on driving improved performance and value to three fundamental pillars of manufacturing operations
Prescriptive Maintenance
Plant Performance Analytics
IoT Equipment Advisor
Prescriptive Quality
Prescriptive Warranty
Visual Inspection for Quality
Safety Analytics (coming soon)
Edge IntegratedTap into our ecosystem to find the
right edge or fog gateways for simple rules and filtering
Utilize manufacturing bus and MQTT messaging for advanced
rules and better integration MessageSight Integration Bus
AssetTap into our first mile shop floor integrators to connect to PLCs
and shop floor specific protocols
IBM Watson IoT Platform
IntelligentassetsandequipmentutilizesIoT andcognitivecapabilitiestosense,communicateandself-diagnoseissuessotheycanoptimizetheirperformanceandreduceunnecessarydowntime
Cognitiveoperationsandprocessesbringmorecertaintytobusinessbyanalyzingavarietyofinformationfromworkflows,contextandenvironmenttodrivequality,enhanceoperationsanddecision-making.
UtilizeIoT andcognitiveinsighttooptimizeresources(worker,energy,expertise)usinggeolocationdata,individualdata,usagedataandenvironmentalconditionsalongwithanalytics.
Plant Advisor
Predictive Maintenance and Optimization
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Watson / IoT for Manufacturing / October 6th 20177
Estimated ranges of benefits of Predictive Maintenance
maintenancecosts
unexpectedfailures
repairandoverhaultime
sparepartsinventory
uptime
costofunplanneddowntime
assetlife
maintenance costs
equipment downtime
capital investments
0%-50% +50%
PlantEngineer’sHandbook- KeithMobleyNucleusResearchROIworkdonewithIBMMcKinsey&Co.TheInternetofThings:MappingtheValueBeyondtheHype
Watson / IoT for Manufacturing / October 6th 20178
PredictiveMaintenanceandOptimizationexampleapplication
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Watson / IoT for Manufacturing / October 6th 20179
IntegrationBus
End-userReports,Dashboards,Drill-downs
AnalyticDatastore
Predictive&StatisticalAnalytics
DecisionManagement&Optimization
Reporting&Dashboarding
EnterpriseAssetManagementSystemHigh-volumeStreamingData
Telematics,ManufacturingExecutionSystems
LegacyDatabases,DistributedControlSystems
MasterDataManagement
Predictive Maintenance and Optimization architecture
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Physical & 3rd
Party Models (Optional)
Ad Hoc DashboardsData Science Tooling &
Authoring
IBMAna
lytics
Platform
Apps
EAM
DataSou
rces
Optimization System
Platform Services
IBMPredictiveMaintenance&Optimization
Math Rules
Optimization
ReportsCustom Applications
Predictive System
SOP Alarm & Alerts
Models Prediction & Forecasting
Text Analytics Feature Extraction
Integration ( Real time and Bulk load)
HortonWorks Data Platform for IBM
DataLakeSpark MapReduceOperationalDataStore
SCADA
SDK
BI SystemReports
Ad-hoc Query
Client Applications
Hosted/ On-premise
Client Systems
Vibration data analytics
Material prognostic analytics
WeatherService
Cloud services
Operation Engineer Engineering Manager Analyst
Stakeh
olde
rs
Users
Reliability Engineer
Historian MES
Watson IotPlatform(Optional)
Cognitive System
Content Insight
Data Insight
Visual Insight
Speech Insight
Partner ServicesIoT
Emotional Insight
Predictive Maintenance and Optimization big picture
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Watson / IoT for Manufacturing / October 6th 201711
Usage in various Industries along with demonstrated benefits
97% ability to predict delays & cancellations within 12 weeks aviation – analysis of terabytes of jet engine performance data
87% accuracy within 48-hour regarding potential equipment failures
oil & gas exploration - identify situations that lead to equipment outages; improve production forecast
45.5% ¯ in unplanned maintenance steel – analyze production data; detect impending machine malfunctions; implement preventive maintenance
$44M+ savings from reduced maintenance
aviation - reduce # of tail rotor gearbox removal maintenance procedures34% accuracy predicting machine failures 2+ hours in advance
automotive – analyze robotic assembly line failure data
30% chiller efficiency
electronics – assess operational parameters that lead to sub-optimal performance
Watson / IoT for Manufacturing / October 6th 201712
Utilize purpose driven advanced analytics dedicated to industrial use cases or generate custom analytical models with Predictive Maintenance and Optimization
IBM Watson IoT for Manufacturing
Manufacturing Analytics
Plant Performance
AnalyticsPrescriptive Maintenance
Prescriptive Quality
Prescriptive Warranty
• Prebuilt industry models• Role specific user interface
• Proven algorithms• Cognitive extension
• Packaged analytics tools• Custom build and
execute models• BI customizable interface
Predictive Maintenance and Optimization
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Watson / IoT for Manufacturing / October 6th 201714
ImageAnalytics
Enablesmonitoringofunstructureddatafromimagessnapshotstoidentifyqualitydefectsandfailurepatterns
MachineLearning
Automatesdataprocessing,identifies thebestmodelforthedata andcontinuouslymonitorsnewdatatolearnandimproveresults
Textual Analytics
Enablesminingoftextualsourcestofindcorrelationsandpatternsin structuredandunstructuredtextsuchaslogsandnotes
AcousticsAnalytics
Utilizesaudioasanadditionalsourceofunstructureddatatoenableanomalydetectionandpatternrecognition
EquipmentAdvisor
VisualInspectionforQuality
AudioInsights
PlantAdvisor
Begin the journey to cognitive manufacturing with use case driven application for value
Watson / IoT for Manufacturing / October 6th 201715
IBM Visual Inspection for Quality utilizes deep learning to improve quality processes• New offering in the IBM IoT for Manufacturing solution suite• Cognitive capabilities classifies product image against defect
patterns • Quickly identify and classify defects in manufacturing process• Works in conjunction with IBM Prescriptive Quality • Optional integration with the IBM Watson IoT Platform• Available NOW
passfail
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Watson / IoT for Manufacturing / October 6th 201716
IBM IoT Equipment Advisor delivers Cognitive Prescriptive Insights
Equipment Advisor consumes varied sources of data and provides insights & visualization for problem diagnosis and resolution to help technicians identify the right repair
Watson, through interaction with Field Technicians, learns over time to become an expert on the specific equipment
Aggregated Data Views
Cognitive Learning Point of Impact Insights
Watson Explorer (WEX)PMO
Equipment Advisor Solution Components
Watson / IoT for Manufacturing / October 6th 201717
IBM Plant Advisor optimizes throughput, energy cost and quality in Process Manufacturing Plants
Physical ManufacturingOperations
Process Automationand Control
Ø On-line Operator Actions
Ø Real time Process Inputs
Ø Real time Process Outputs
Ø Maintenance History
Ø Historical Operators Actions
Ø Historical Process Inputs
Ø Historical Process Outputs
Historian Systems
Continuously learn from all dataAugments operator performance
Captures and retains company expertiseEnables manufacturers to achieve high performance
IBM Plant Advisor
Optimize KPIsOffers the flexibility to optimize costs, quality, throughput, or any identified variable at any given point in time
Recommend ActionsProvides meaningful recommendations at appropriate intervals which the operator can implement or reject
Optimize ProcessesCan be trained and applied in multiple plant processes
Link Actions to PerformanceOffers a closed-loop mechanism to link specific actions with actual performance and predict outcomes
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IBM Plant Performance Analytics
TransactionsEAMCMMProduction Plan
Cycle timePositionalParametricEvents
ISA 95 Info Model
Industry Analytical Models
Pred
ictio
ns Probability of Occurrence
Time to Occurrence
Root Cause
Probable Time to Recover
Issue prediction
Recommended Repair PlanRecommended Action
Pres
crip
tions
Plant Operational Effectiveness (OE)
OvertimeMaintenanceMaterial
Integration
Watson / IoT for Manufacturing / October 6th 201719
Overall Equipment Effectiveness (OEE) of Manufacturing Plants is Impacted by 3 Big Losses
IBM Plant Performance Analytics predicts potential OEE losses, prescribes remedies, and maximizes OEE
bottleneck – machine # 1 is delaying production
Downtime loss
Quality loss
Performance loss
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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
Critical differentiators• Partnered Innovation – Edge Analytics and IoT Connectivity Integration
• Cognitive Technology – Unstructured data analysis and insights
• Advanced Analytics – Purpose driven and Industry specific models
Watson / IoT for Manufacturing / October 6th 201721
Thank you