Beginning the Smart Manufacturing Journey...Creating a New Generation of SM-Savvy Practitioners & Students A Vendor-Agnostic Roadmap & Strategy Industry-specific Innovation enters,

Copyright © 2020 CESMII - All Rights Reserved. 1

Beginning the Smart Manufacturing Journey

Institute overview

The Value of Smart Manufacturing

Smart Manufacturing Challenges

Transforming the Smart Manufacturing Ecosystem

Beginning Your Smart Manufacturing Journey

Panel Q & A

Copyright © 2020 CESMII - All Rights Reserved.

mission. strategy. role.

Driving the next wave of manufacturing productivity, energy productivity, sustainability and competitiveness through smart manufacturing innovation.

Fund the Innovation and R&D necessary to

dramatically reduce the cost & complexity of

using real time data from operations to drive

revenue & cost improvements and generate

cash.

How.

2017Founded by

the D.O.E.

$140M+Private/public

partnership over

5 year period

3Copyright © 2020 CESMII - All Rights Reserved.

Manufacturer

System Integrator

SW App Vendor

Academia, Labs

Machine Builder

Improve Energy

Productivity through

Sensing, Control,

Modeling, Analytics &

Platform Technologies

CESMII represents the voice of manufacturing;

engaging the smart manufacturing ecosystem through a membership model


Manufacturing business outcomes

unchanged for decades

QualityThroughput/YieldComplianceSafety

Increase

CostComplexityTime to ValueRisk

Decrease

4

Time to Money

Yield

Productivity

Energy Savings

Throughput

Cycle Time

Capacity

Scrap Rate

Etc.

BUT…


SMART MANUFACTURING

RIGHT INFORMATION –AT THE RIGHT TIME –IN THE RIGHT FORM –AT THE RIGHT PLACE –

WITH THE RIGHT TECHNOLOGY –FOR THE RIGHT PEOPLE –

TO ENABLE SMART DECISIONS

SMART MANUFACTURERS

REPRESENT A DATA-DRIVENCULTURE;

LEVERAGE TECHNOLOGY AND KNOWLEDGE MORE EFFECTIVELY THAN THEIR

PEERS

THE SM JOURNEY

A CATALYST TO INVEST IN DIGITAL TRANSFORMATION

AND BECOME A DATA-DRIVEN MANUFACTURER

WITH THE RIGHT EMPHASISON PEOPLE, PROCESS &

TECHNOLOGY

CESMII STRATEGY

DEMOCRATIZEFOUNDATIONAL❶ TECHNOLOGIES,❷ KNOWLEDGE &❸ INNOVATION FOR

MANUFACTURERS OF ALL SIZES AND ALL INDUSTRIES

5

Smart Manufacturing EssentialsChanging your Data into Intelligence can Transform your Business


Sources of Value from Smart Manufacturing

McKinsey’s Digital Compass

Time to

market

Design

Resource

Process

Asset

utilization

LaborSupply chain

& Inventories

Quality

Ad

va

nce

d p

roce

ss

co

ntr

ol (A

PC

)

Automation of

warehousing &

logistics flows

10-30% reduction of design

engineering costs

20-50% reduction in

time-to-market

Forecasting accuracy

increased to 85+%

Cost of quality reduced by

10-20%

Cost of inventory holding

decreased by 20-50%

45-55% increase of productivity in

technical professions through

automation of knowledge work

30-50% reduction of total

machine downtime

Productivity increase by 3-5%

❶

❷

❸❹

❺

❻

❼

6


VP, Operations

Operations View

Current Investments Are Not Sufficient

Internal Plants

Outsourcers

Contract Mfg’ers

Suppliers

VP, Supply Chain

Supply Chain View

Plant Manager

Internal Plant View

Sales &

Marketing

Supply

Planning

VP, R & D

Design View Portfolio

Management

Innovation

Management

New Prod Dev

Manufacturing Delivery Logistics

After Sales Service

Demand Sensing

SourcingInformation Black Hole

7


Status Quo - Purdue Model

PhysicalPlant L0

ProcessControls L1

SupervisoryControls L2

ManufacturingOperations L3

BusinessPlanning L4

Production

Maintenance

Quality

Engineering

OperationsQualityScheduling

FinanceSupply ChainIT

The Smart Manufacturing JourneyEnabling Digital Transformation at Scale

Optimizing/Eliminating Proprietary Information Flows, Data Architectures & Business Processes

Smart Manufacturing Model

PhysicalPlant L0

ProcessControls L1

SupervisoryControls L2

ManufacturingOperations L3

BusinessPlanning L4

SM Platform Infrastructure

Production

Maintenance

Quality

Engineering


Access to SM is essential for all Manufacturers!Secure, sustainable & sanctioned isn’t just important for the F1000

Asset Line Plant Supply ChainEnterprise

9

99.6%SMM’s US Manufacturers

0.4%Fortune 1000

US Manufacturers

Start small, knowing you can scale up or…Start with an enterprise strategy, knowing you can scale down to your smallest sites


‘Hidden’ Costs of Manufacturing System ImplementationA significant barrier to the adoption of SM/digital transformation – for all manufacturers

SM solutions at scale are justifiable primarily by large

manufacturers

SM solutions don’t scale down well to small

and medium plants

Enterprise roll-outs almost always stall

No economy of scale –from Site 1 to Site N

SME’s struggle to justify SM Solutions

Value CreationStart From a ‘Blank Slate’ Every Time (little/no reusability)Costly, Complex & LegacyOn Premise

Compute& Storage

Physical Infrastructure& Networking

SystemImplementation SW License

today

Crowd-Sourcing SMEDefacto Standards

Low cost sensors5G, Etc.

IncludesCloud

SW LicenseApp Developmenttomorrow 50% cost reduction

…and accelerated time to implementation

Implementations become justifiable for small/medium plants & businesses

Significant re-usability creates economies of scale

Outcome:


Accelerate the Democratization of Smart ManufacturingEnable frictionless movement of information – data and context – between real-time

operations and the people & systems that can create value for your organization

TechnologyPlatform infrastructure

de facto standards for industry

KnowledgeData-driven culture, education

citizen technologist

InnovationBusiness practices

safe harbor collaboration


How can CESMII

realistically impact this

entire ecosystem?

12


3 421

13

Manufacturer

Enabling technology

for ASCPM*,

SMIP, Marketplace…

National SM Learning

Infrastructure to equip

the entire SM ecosystem

National SM presence

& market engagement

for ALL manufacturers

Vendor-neutral,

agile innovation &

collaboration framework

System Integrator SW App Vendor Academia, Labs Machine Builder

Strategies that enhance the business models

for each of the stakeholders in this ecosystem

Direct, broad and significant impact on Manufacturing & Energy Productivity

*ASCPM = Advanced Sensors, Controls, Platform & Modelling for Manufacturing


PLATFORM & CAPABILITY PROJECTS

Develop core technologies:

Innovation Platform, Profile Designer,

Marketplace and tools

ENABLING R&D PROJECTS

SM technology gaps: sensors, AI/ML,

controls, modeling, 5G…

SM INNOVATIONPROJECTS

Implementation of SM innovations leveraging the SMIP, Profiles and

Apps…

APPLICATIONPROJECTS

Free, pre-production use of CESMII

capabilities for Proof of Concept development

EDUCATION & WORKFORCE

DEVELOPMENT

Develop SM education content: train, equip &

certify SM practitioners, citizen technologists…

Ops Research Ops Research Ops Research Ops Research Ops Research

CESMII Vision: Smart Manufacturing is manufacturing in 2030 CESMII Strategies

Democratize

Smart Manufacturing

CESMII Roadmap:Optimize Manufacturing, Increase Energy Productivity


❶ Enabling Technology: The SM Innovation PlatformStandardized infrastructure that drives OT/IT CONVERGENCE and enables repeatable Innovation and R&D

Openness, Interoperability, Standards Based

Smart manufacturing API - Streaming & Historical Data via Model

Data store - time series, relational, blob, data lake…

Detect SM Edge systems, federate all profiles & fragments & assemble data model

Edge - connect, monitor, manageSM P

latf

orm

(En

able

r)A

pp

s

Homegrown Apps

1 2 3 Etc.

PLM Integration

SAP IBM SAS Etc.

Workflow

SAP IBM SAS Etc.

AI Engines

SAP IBM SAS Etc.

Enterprise Integration

SAP IBM SAS Etc.

COTS OT Apps

SAP IBM SAS

Mfg

Syst

ems

SENSOR CONTROLLER NETWORK HW SoftwareROBOTMACHINE TOOL HMI MANUAL DATA Existing SystemFIELD EQUIPPLANT EQUIP

Smart ManufacturingMarketplace

Member Apps

SM Profiles(Device, Machine, Process)

SM Innovation Platform

Profile Designer

SM Services – IT/OT

SM Tools


❷ SM Ecosystem and Workforce Development - Goals

• Engage at scale

Virtual – regional – national

• Deliver formal and informal education

Social, expert networks, collaboration, crowdsourced experiences and knowledge bases

SM curriculum and SM learning centers

• Address entire SM ecosystem

Students, integrators, manufacturers,

practitioners and business leaders

• Offer open-source access to education, best practices, tools, methodologies, benchmarks…

• Scale national pool of SM Workforce and SM Professionals

• Empower and engage executives

• Breakthrough Transformational Thinking!

Create a national learning infrastructure

& drive competitiveness through

broad-scale adoption of Smart Manufacturing and

development of SM Workforce and SM Professionals


UCLA

TAM

NCSU

RPI

• Aligned around Industry Segments or Technology Verticals

• A World-Class Network of Manufacturing Assets Connected to our SM Innovation Platform

• Academia or Industry Partners

HQ & SM Innovation Center

SM Innovation Centers

SMIC Satellites

Other SMICs or Satellites (directional)

SMIC Industry/Technology Focus Areas

Existing SMICs

• NCSU – Pulp/Paper, Nonwoven, Bio Mfg• TAMU – Energy (O&G)• UCLA – Aerospace• RPI – Advanced Mfg, Pharma

Additional SMICs Funded in Q4 2020

• Metals• Robotics• Food & Beverage• Consumer Packaged Goods• SMMs• Automotive• Chemical• AI/ML• 5G

❸ National Presence – Smart Manufacturing Innovation CentersEngage Manufacturing & Supply Chains where they are - local presence, test beds, training…


A Smart Manufacturing Innovation Center in ActionBringing Industry & Academia Together, Driving Research & Innovation @ Scale

SM Innovation Platform - Interoperability, Open, Scalable, Secure

TSI TrendMaterial Flow & Genealogy Workflow ERP & EAM

SM API

Visualization & ProfitAdvisorPredictive Maintenance

NWI - Nonwovens Factory

SM Edge - Connector

BTEC - Bio Manufacturing

SM Edge - Connector

Forest Biomaterials - Pulp & Paper

SM Edge - Connector

Advanced Manufacturing

SM Edge - Connector

Future: Siemens, PTC, IBM, Tulip, Rockwell, SAP,

Amazon, AT&T, etc.

18

NCSU-SMIC: Powerful Educational Platforms to Promote Active and Immersive Learning for Workforce Development

24

Simulated cGMP Labs

Training for Chromatography Skids Contemporary, Smart Manufacturing

Concepts, Training & Interaction

Hands-on Automation TrainingAutomation Controllers

NetworksOT SoftwareIT Software

(Allen Bradley, Emerson, ABB…)

19


Manufacturer

System

Integrator

SW App

Vendor

Academia,

Labs

Machine

Builder

Smart

Manufacturing

Innovation

Project

❹ Agile Innovation & Collaboration

Manufacturer defines a target asset/process based on specific problem/need

Form an IntegratedSM Innovation Project team

The team builds SM profiles of the assets and/or processes

The SM IP Team develops the Application and/or Predictive Models that address the problem/need

CESMII sanctions and publishes the profiles and apps on the SM Marketplace™

SM Innovation ProjectRapid Funding - $50k - $200k

(50% CESMII, 50% Cost Share)

20


Innovation Project Framework

Pre-defined Areas of Value

Energy Consumption and/or Energy Productivity

Precision, Productivity and

Performance

Asset Monitoring, Asset Management & Predictive

Maintenance

Profiles and applications that address improvement

in energy consumption and/or energy productivity

for unit operations or process flow paths through use of Smart Manufacturing

technologies

Profiles and applications that address improvement in precision, performance

and/or productivity for unit operations or process flow paths through use of Smart Manufacturing technologies

Profiles and applications that enable real-time asset monitoring, management

and predictive maintenance for unit operations or

process flow paths through use of Smart Manufacturing

technologies


Democratizing SMART MANUFACTURING

www.cesmii.org

[email protected] – ask to be put on our SM Innovation Project RFP list

[email protected] – questions about engaging

22

Engage with us!

mailto:[email protected]

mailto:[email protected]


Engage with CESMII, the SM Institute

Accelerate Your SM / Digital Transformation Journey

Access to FUNDING for YOUR SM Innovation

Access to the Brightest SM Practitioners and Innovators in the Industry

Creating a New Generation of SM-Savvy Practitioners & Students

A Vendor-Agnostic Roadmap & Strategy

Industry-specific Innovation Centers, Affinity Groups, Nat’l Labs

A Channel to Amplify your Business Objectives

Contribute to the TRANSFORMATION of the ManufacturingEcosystem – OT & IT

Drive the Democratization of SM – for SMM’s

23Copyright © 2020 CESMII - All Rights Reserved.

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Beginning the Smart Manufacturing Journey...Creating a New Generation of SM-Savvy Practitioners & Students A Vendor-Agnostic Roadmap & Strategy Industry-specific Innovation enters,