Ing. Giuseppe Viglialoro - PMP

Cisco Systems – Manager Connected Industry & Energy Group - IoT Manufacturing

“Fabbrica Futuro” – Bologna, 14 March 2017

From Traditional Factory to Connected Factory

Digital Manufacturing

Watch

Video

Off-LineFactory Network

Factory Security

Factory Wireless

Connected

FactoryAnalytics & Big Data

Virtualization & Compute

Connected Machines

Factory Collaboration

Location Services

Connected

Enterprise

Supply Chain Collaboration

(SXP)

Design Collaboration

Supply Chain

Orchestration

Digital Manufacturing Journey

+ 16% OEE

- 35% Inventory

+ 23% NPI

- 49% Defects

- 48% Downtime

Where Are You Today? Where in 2020?

50%

45%

40%

35%

30%

25%

20%

15%

10%

5%

0%

Off-lineFactory

ConnectedEnterprise

ConnectedSupply Chain

Orchestration

Today 2020Source: SCM World/Cisco “Smart Manufacturing and the Internet of Things 2015” survey of 418

Manufacturing Business Line Executives and Plant Managers across 17 vertical industries.

The Traditional Factory – The Purdue Model

• Separate Enterprise & Factory

Networks

• Manufacturing Processes not

Supported by IT Systems

• Proprietary Platforms

• Advanced Automation Through

Improved Security & Data

Virtualization

• Re-engineered Manufacturing

Processes Utilizing Industrial

Location & Collaboration

• Connected Supply Chain

TRADITIONAL FACTORY CONNECTED FACTORY

Connected Factory Approach

Connected Factory Architecture

Enterprise (Levels 4-5)

Controller Drive HMI Distrib. I/O

SCADA/MES Servers

Data Mgmt. Servers

Automation Security

iDMZ Network

Enterprise Applications

IE Switches

Level 3.5

iDMZ

Level 2.5

Fog

Advanced Automation

Asset Management Applications

Cloud

Wi-Fi Network Applications

Access Points Controllers

RFID Tags

Exciters

Smart Phones Laptops

Industrial Location

Video

Factory (Level 3)

Floor (Levels 0-2)

Unified Collaboration

Collaboration Applications

Collaboration Phones Video

Enterprise Network

Factory Network

Wireless Security

Fog Network

Distributed Applications

Advanced Automation Industrial Location Unified Collaboration

Production Automation

Workforce Enablement

Quality Control

Inventory Management

Product Enhancement

Cost Management

Sensors Robots Supply Chain Tracking Voice Video

Reduce Costs (Optimize Operations)

Increase Revenues (More Capabilities)

Meet Responsibilities (Environmental, Safety, Regulatory)

Applications & Analytics

Connecting the

Unconnected

Plant wide Security

Secure Operations

Predictive Maintenance

Wireless Automation

Locate Equipment

Locate Work in Process

Supply Chain Management

Connect AGVs

Quality Analytics

Video Analytics

Location Analytics

Energy Management

Worker Safety

Activity Based Costing

Time & Motion Studies

Worker Mobility

Employee Communications

Customer Communications

Worker Training

Locate Test Equipment

Connecting the

Unconnected

Device Security

Secure Operations

Predictive Maintenance

Connect Equipment

Locate Equipment

Digital Thread/Twin

Video Expert

Advanced Automation Industrial Location Unified Collaboration

Connected Factory Reference Model

Advanced Automation Approach: Security

TRADITIONAL FACTORY CONNECTED FACTORY

Industrial DMZ

Secure Automation

Basic Security

Segment

Network

Secure

Access

Identity &

Access

Threat &

Anomaly

Advanced Automation Industrial Location Unified Collaboration

• Challenge: Improve OEE

• Improve automation network reliability

& uptime

• Reduce costs through improved data

visibility

• Protect the factory from external

threats

• Drive Zero Down Time

• IoT Solution: 166% RoI

• Implemented the CPwE architecture

• Implement robust security (Level 3.5

iDMZ, etc) for factory & enterprise

network separation.

• Data Virtualization (Level 2.5 Fog, etc)

to support distributed applications for

predictive maintenance

Advanced Automation Architecture

Controller Drive HMI Distrib. I/O

SCADA/MES Servers

Data Mgmt. Servers

Automation Security

iDMZ Network

Enterprise Network

Enterprise Applications

Cloud

IE Switches

Factory Network

CONNECTED FACTORY

Enterprise (Levels 4-5)

Level 3.5

iDMZ

Level 2.5

Fog

Factory (Level 3)

Floor (Levels 0-2)

Fog Network

Distributed Applications

Advanced Automation Industrial Location Unified Collaboration

Cisco Confidential

REPLACE

BEARINGS

CELL 07

Big Data and Analytics at FANUC

Watch Video

• Data Collection

• Edge Compute

• Predictive

Analytics

• Proactive Part

Replacement

TRADITIONAL FACTORY CONNECTED FACTORY

Plant Floor Wireless

Material

Management

Asset

Management

People

Management

Enhanced Process

Plant Floor Wireless

Industrial Location Approach Advanced Automation Industrial Location Unified Collaboration

Challenge

Long Tire Assembly Search Times by Operators Increased Cycle Times, Decreased Labor Optimization, and Noncompliance with Production Schedules. High Scrap Rate Associated with Lost Carriers.

SolutionImplement LBS Solution to Track All Carriers in Real-time Using T2 Tags and Cisco Unified Wi-Fi network

Allow Material Handlers/Truckers and Managers to Search for Component by ID, Tread Number, Material Code (FIFO))

Business Outcomes

Continuous Real-time Visibility Across Entire Plant

20% Reduction of Breaker Component Tire Loss

Increase in tire machine utilization ensuring increased production and overall equipment efficiency (OEE)

Factory Wireless at Continental Tire

TRADITIONAL FACTORY CONNECTED FACTORY

Plant Floor Collaboration

Voice & Data Video Wearables

Process Integration

Plant Floor Telephony

Unified Collaboration Approach Advanced Automation Industrial Location Unified Collaboration

Efficient

Secure

Connected

Flexible

Human Connectivity & The Future of Work

Thank you.