The Gulf Coast Regional Smart Manufacturing Centertexasiof.ceer.utexas.edu/PDF/Presentations/2015/Gulf Coast RSMC...The Gulf Coast Regional Smart Manufacturing Center ... • Pillar

The Gulf Coast Regional Smart Manufacturing Center

Texas A&M Energy Institute/Texas A&M Engineering Experiment Station University of Texas at Austin Energy Institute Tulane University Polymer Reaction Monitoring Center

The Gulf Coast RSMC Team

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Webinar Agenda Introductions Kathey Ferland, Texas Industries of the Future (2 min)

Welcome and Meeting Report (5 min) Satish Bukkapatnam, Director, TEES Institute for Manufacturing Systems, Texas A&M University

Smart Manufacturing and the Process Industries (10 min) Jim Davis, Vice Provost, Information Technology, University of California, Los Angeles

A National Framework: Smart Manufacturing Leadership Coalition (10 min) Denise Swink, CEO, Smart Manufacturing Leadership Coalition

Industry Perspective: Praxair Test Bed (10 min) Larry Megan, R&D Director, Praxair

TX-LA Regional Smart Manufacturing Innovation Institute: Future Plans and Priorities (10 min) Thomas F. Edgar, Ph.D., PE, Director, The University of Texas at Austin Energy Institute

Question and Answer (10 min) Moderator: Dr. Edgar

Wrap Up and Next Steps Dr. Edgar (3 min) 3

Clean Energy Smart Manufacturing

• DOE is seeking to establish a Smart Manufacturing Institute • Encompasses machine-to-plant-to-enterprise-to-supply-chain aspects of

- Advanced sensing and instrumentation - Real-time process monitoring, control, and optimization - Advanced hardware and advanced software platforms - Predictive modeling and simulation technologies

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Smart Manufacturing Leadership Coalition

• SMLC is the non-profit leader for the team • Consortium-sponsored open vendor-supported Smart Manufacturing (SM)

Platform and Marketplace • Creating a national organization with regional smart manufacturing

centers

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Clean Energy Smart Manufacturing Innovation Institute (CESMII)

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Gulf Coast RSMC Mission

• Apply Smart Manufacturing (SM) technologies to the high energy intensity manufacturing industries in the Gulf Coast Region

• Objective: reducing energy consumption through process measurement, control, and optimization

Workshop held in College Station on August 21

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Gulf Coast RSMC Strategy

• Pillar I – Training and outreach - Demonstrate value of SM and train industry in its application - Assist industry in implementation of SM technologies

• Pillar II – R&D for implementation of SM

- New sensors, controls, modeling & simulation, data analytics tools - Integration of components and tools into the SM Platform

• Pillar III – Test-beds and pilots to promote SM implementation

- First-of-a-kind implementations - Industry replication - Training and human-systems integration

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Gulf Coast RSMC

• Serving the Gulf Coast process industry’s needs for: - Process optimization and efficiency - Energy savings and emissions reductions

UT Austin Energy Institute Dr. Tom Edgar

Texas A&M Energy Institute Dr. Chris Floudas

Tulane Center for Polymerization Monitoring and Characterization Alex Reed

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www.smartmanufacturingcoalition.org



Smart Manufacturing, Real-Time Networked Information Workflows, Asset Management and

Value Chain Performance

Jim Davis UCLA & SMLC 10



Practitioner Landscape

U.S. manufacturing enterprises, value chains and ecosystems are turning to data and information – sensing, controls, analytics & modeling

– sensors and models to “see, manage and control” better – enterprise analytics – more value orientation and responsiveness to demand dynamic

markets – increased productivity, performance and agility – accelerated versatility with physical and cyber technology

adoption – radically better environment and energy productivity – stronger approach to zero field failures, incidents and

variations.

©SMLC, Inc. and Rockwell Automation. All Rights Reserved. 11



Supply Chain Landscape

• Demand Dynamic Inventories

• Win-Win Optimization

• New Value Chain Opportunities

• Minimize Disruption

• Better products & Collaborative Innovation

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Provider Market Landscape

SM

Market drivers not aligned with

Software cloud system interoperability and best of breed solutions Rapid technology changes, Intersystem cyber security Low cost scaled infrastructure Low barrier software and services

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What got us here

Won’t get us there

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What is Smart Manufacturing?

Data as an Asset • Dynamic orchestration of activities

– Across time, and seams

• Multi vendor application interaction • Optimized decision making • Accessible, Available, Affordable, Agile and

Secure to all

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Applications

Context

Data

Calibration & Maintenance

Production Models

Sensor Data

In-production performance

Smart grid Interoperability

Smart machine operations

Sustainability & Safety

Open Platform & Marketplace For Industrial Data, Modeling,

& Metric Applications • For contributors and users

•Accessible Affordable, Flexible to SMMs

SM Value Proposition

Event Data Real-Time Data

Mapping

Smart Manufacturing Platform Bridging Seams Extending the Real Time

Infrastructure across Value Chains

Value chain Interoperability

Data as the key asset

Shift dependency of application from Infrastructure to

data-based outcome

Open Architecture – Vendor Agnostic Open Access – low cost & easy to use Open Market Place – composable software libraries & data Open Market Place - Innovation Trusted Data Broker

Secure I, P and SaaS

Secure Data Highways

Data & Device Integration & Orchestration

Smart Factory Manufacturing

Smart Enterprise Manufacturing

Manufacturing Health & Sustainability

Collective Innovation &

Practice

Converting Data to Information

Converting Information to Knowledge

Converting Knowledge to Wisdom

Data Valuation Collective vs. Proprietary

Practice Valuation Collective vs. Proprietary

IoT

Big Data

Smart

Collective Wisdom

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Internal & External Value Chain

Networked-Based Manufacturing

Supply Chain Distribution Center

Customer

Business Systems, ERP

Smart Grid

Smart Small Medium and Large Manufacturers

• Configurable high fidelity/statistical modeling and analytics • Dynamic plant configuration and readiness • Dynamic product component/material configuration • Faster changeovers & more variable order sizes • Dynamic inventory minimization & management

EDI transaction lot & quality certifications

Tracking & traceability

More customer freedom To customize

Minimum just in case inventory & corrective actions thru entire system

Chain of custody

Order adjustment Reduce premium shipments

Use Cases Mike Yost Mesa 18



Business Drivers for the SM Platform

New Industry Opportunities Opportunities with Trusted Data Sharing Easier Development, Deployment and Reuse Make multiple vendor applications and infrastructure systems a dominant capability Eliminate, simplify and/or automate the overall execution of real-time systems

Don’t make me deal with security every time I want collaborative business relation or multiple vendor system

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www.smartmanufacturingcoalition.org Advanced Manufacturing Drivers

©SMLC, Inc. and Rockwell Automation. All Rights Reserved.

ADVANCE SENSING, CONTROLS, PLATFORMS AND MODELING FOR MANUFACTURING

DOE FOA Clean Energy Manufacturing Innovation Institute on Smart Manufacturing

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FOA Issue Date: 9/15/15 Informational Webinar: 10/6/15 Submission Deadline for Concept Papers: 11/4/15 5:00pm ET Concept Paper Encourage/Discourage Notifications Sent 11/20/2015 Submission Deadline for Full Applications: 1/29/16 5:00pm ET Expected Submission Deadline for Replies to Reviewer Comments: 3/31/16 5:00pm ET Expected Date for EERE Selection Notifications: May 2016 Expected Timeframe for Award Negotiations August 2016

SMLC Membership

American Council for an Energy Efficient Economy (ACEEE) AMP Socal Alcoa American Institute of Chemical Engineers (AIChE) American Society of Quality ARC Association of State Energy Research and Technology Transfer Institutions (ASERTTI) Corning Department of Energy (DOE) Emerson Electric Power Research Institute General Dynamics General Electric General Mills General Motors Manufacturing Enterprise Solutions Association (MESA) MT Connect National Association of State Energy Officials (NASEO) North Carolina State University Nimbis Services

NIST National Science Foundation (NSF) OSISoft Owens Corning Pacific Northwest National Laboratory Pfizer Inc. Praxair Purdue University Rensselaer Polytechnic Institute Rockwell Automation Savigent Software Schneider Electric Society of Manufacturing Engineers Southwest Research Institute - SWRI Sustainable Solutions Texas A&M Engineering Experiment Station (TEES - TAMU) Tulane – PolyRMC United Technology Research Center (UTRC) University of California, Berkeley University of California, Los Angeles University of Southern California - EDC University of Texas - Austin West Virgina University

An Industry-Driven Open Architecture Shared Infrastructure

“Information that drives the next century’s structural shift in manufacturing.”

Smart Manufacturing

Making real-time info available: • when it is needed, • where it is needed • and in the form it is needed

throughout the Manufacturing ecosystem

Smart Manufacturing Leadership Coalition (SMLC) – 501c (6)

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Institute Mission - support the research, development and transition to industry the following technologies for Smart Manufacturing: advanced sensing and instrumentation; process monitoring, control and optimization; advanced hardware and software platforms; and real-time and predictive modelling and simulation technologies. Institute Goal - improved energy efficiency, equipment reliability, productivity gains - as well as, related improvements in safety, quality, and yield in manufacturing processes. Institute Strategy - development of energy management technology tools to achieve energy and cost savings through informed decision making and the implementation of energy saving practices for facilities, processes, equipment, and operations both in real time and over the life cycle of products from a manufacturing unit-process, facility, enterprise and supply chain. Energy intensive industries: petroleum refining, chemical processing, primary metals, food and beverage processing, forest products, glass, cement Energy dependent industries associated with clean energy applications: semiconductor solar cells, carbon fiber composites, corrosion resistant alloys, light emitting diodes; electric vehicle batteries

FOA

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Existing Institutes

America Makes – Youngstown, OH

Lightweight Innovations for Tomorrow (LIFT) – Detroit, MI

Power America - Raleigh, NC

Institute for Advanced Composites Manufacturing Innovation (IACMI) – Knoxville, TN

Digital Manufacturing & Design Innovation Institute – Chicago, IL Flexible Elextronics

- San Jose, CA

Integrated Photonics - Albany, NY

Next up: - Smart Manufacturing

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Clean Energy Smart Manufacturing Innovation Institute (CESMII)

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The Reality of Funding

• Not a grant • Leverage DOE funds for growth • State based “mini institutes” for operational projects

– DOE funds Test bed funding competitive – State cost share stays in state – Company cost share

• Hub – Administrative, cooperative agreements, IP, etc. – DOE R & D funding

• SM Platform infrastructure and training

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Praxair Test Bed Review

Larry Megan September, 2015

27 | Praxair Business Confidential | 9/29/2015

Praxair Global Analytics Strategy

Macro trends driving business transformations

Transform from reactive to proactive


Real time data driven decisions across the business

Descriptive

Diagnostic

Prescriptive Predictive

Sensor-Intense Control

Prescriptive Maintenance

Real-time Safety Alerts

Future Applications

Variety Velocity Volume − Smart Sensors

− Low Cost Communication

− Real Time Analytics

“Big Data” Trends

Information

Praxair Global Analytics Strategy


DOE test bed well aligned with strategy

Impact

Insight

Sensors and Wireless

Automated Monitoring

Dashboards

Closed Loop Control

Business & Supply Chain Tools

Mobile Data Collection

Electronic and accurate data collection From historical KPI’s to real time decision making Faster replication

Imaging System

Visual Display

“Closed Loop”

DOE Project

Leading industrial process for hydrogen production


Design TWT Avg TWT (Lower Level)

1700 1650 1750 1600

TWT Distribution

Max TWT

1550

Temperature oF

Steam Methane Reforming

𝐶𝐶4

𝐶𝟐

Furnace Imaging System


State of the Art Smart Manufacturing

New Data New Insight Improved Operations

SMLC Value Proposition – Reduce Friction

Efficient Deployment Platform – Quickly deploy new apps – System agnostic – Significantly reduce replication costs

Drive competition through SME’s

– Lower barriers to entry – App diversity

Enable Collaboration

– Crowdsource new ideas – Cross-org supply chain optimization


Foundation for Next Generation applications

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Industrial Scale Demonstration of Smart Manufacturing Achieving Transformational

Energy Productivity Gains DE-EE0005763

AIChE, General Dynamics, Emerson, NCMS, Nimbis Services, NIST, Praxair, Schneider Electric, SMLC, UCLA & University of Texas

September 1, 2013 through November 30, 2016

Thomas F. Edgar, Ph.D., Principal Investigator

University of Texas at Austin Austin, TX

U.S. DOE Advanced Manufacturing Office Peer Review Meeting Washington, D.C. May 28-29, 2015

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Project Objectives

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• Develop a prototype open architecture Smart Manufacturing (SM) Platform to facilitate extensive application of real-time sensor-driven data analytics, modeling and comprehensive performance metrics

• Accelerate the development, deployment and reuse of smart system applications while halving the cost

• Demonstrate SM Platform applicability, interoperability and operational security on two diverse commercial test beds at Praxair and General Dynamics. Employ new sensors, models and operating strategies to reduce waste heat.

• Develop plans to commercialize, sustain, and grow SM technology through the SM Open Platform deployment services and application libraries (apps), alignment with provider involvement, and trusted brokering of data and applications in an industry-defined Marketplace aligned with small, medium and large manufacturer requirements

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Average Temperature

1150 1100 1050

Tube Temperature (K)

Num

ber o

f tub

es

Steam-Methane Reformer Furnace SMR Temperature Distribution

Technical Approach-Two Test Beds • Install image-based temperature measurements on Steam-methane reforming (SMR) unit so that

real-time model-based decisions can reduce energy use and increase productivity in an SMR unit. SM Platform provides configurable, multi-vendor modeling and big data management, high performance computation and storage resources, and enables high fidelity modeling and interoperability with SMR controls.

• Install measurements and software to reduce energy use and increase productivity in heat

treatment and machining of artillery shell casings and commercial metal parts. Deploy real-time data analytics and modeling to optimize heating and forging together with CNC machine operation. Integrate energy and product performance metrics for an entire line operation, where materials property targets are influenced by furnace/machine conditions. Interface with ISO 50001 program.

GD Production Line

Summary Report on the Gulf Coast Regional Workshop of the DOE Smart

Manufacturing Institute at Texas A&M University August 24, 2015

• 28 attendees from industrial companies

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Discussion Summary 1. Gulf Coast Regional Value Proposition/Objectives

– Decision Support tools/services for the Process Industry and its supply chain – Data-driven Risk Management – Common Data structures and software reuse for data acquisition, control, optimization,

human interfaces, and data security

2. Regional Needs and Issues – Human Performance Models – Performance Metrics – Relationship of DOE energy metrics to plant operational metrics – Process models – Costs of implementation – Intellectual Property- framework must be agreed upon in advance

3. Potential Test beds/Projects

– Emissions Reduction – Human Systems Integration – Mixing monitoring and optimization – Wireless data security – Process Design – Process Integration

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Documents

The Gulf Coast Regional Smart Manufacturing Centertexasiof.ceer.utexas.edu/PDF/Presentations/2015/Gulf Coast RSMC...The Gulf Coast Regional Smart Manufacturing Center ... • Pillar