Dr. Thorsten Wuest [email protected]
Smart Manufacturing and Industry 4.0 - Opportunities and Challenges for SMEs
1stIndustry4.0School&IndustryNightFebruary18,2018
Kelonwa,Canada
WestVirginiaUniversityBenjaminM.StatlerCollegeofEngineeringandMineralResourcesDepartmentofIndustrialandManagementSystemsEngineering
Dr. Thorsten Wuest [email protected]
1. SmartManufacturing
2. SmartManufacturingTechnologies
3. SmartMfgSurveyofSMEsinWestVirginia
4. RecommendaCons
Agenda
Dr. Thorsten Wuest [email protected]
“Manufacturingcreateswealth”Prof.RonaldG.Askin,ArizonaStateUniversity(USA)
hPps://s-media-cache-ak0.pinimg.com/736x/38/92/57/389257d7b42e9a9bc34df0a5d00ae87e.jpg
“Obamaplansexecu?veac?onstostrengthenU.S.manufacturing”(h#p://www.reuters.com/ar2cle/2014/10/27/us-usa-obama-industrialoutput-idUSKBN0IG0UR20141027)
“Obamaconfirmsfundingformanufacturinginnova?onhubs”(Skiba,K.,ChicagoTribune,Feb,25th2014)
“Obamapushesforhigh-techmanufacturing”(Pace, J., June, 24th 2011, NBCNews)
“We’rebuildingIronman–ManufacturingInnova?on”(Obama,Feb,2014)
Dr. Thorsten Wuest [email protected]
Dr. Thorsten Wuest [email protected]
Manufacturing today
hPp://www.3dprin^ngjobs.info/wp-content/uploads/2014/12/Automo^ve1.gif
hPp://3.bp.blogspot.com/-YGLBPWZFOxY/VC10ThjQAoI/AAAAAAAAAbI/VZT7ELIwCiE/s1600/ep.pnghPp://www.thebigdatainsightgroup.com/site/sites/default/files/geindustrialinsight_0.gif
• Newtechnologies• Newglobalrules• Newopportuni^es• Newchallenges…
Dr. Thorsten Wuest [email protected]
You may have heard of
Allthesetermsdescribeasimilardevelopment!
SmartManufacturingIndustrialInternet
Industrie4.0Cyper-Physical(ProducCon)Systems
FactoryoftheFuture
…andmanymore!ManufacturingIntelligence
IMS
IntelligentManufacturing
CloudManufacturing
Industry4.0SmartFactory
Dr. Thorsten Wuest [email protected]
Heading towards the 4th industrial revolution
Source:hPps://www.i-scoop.eu/industry-4-0/
Valuefrom… People Process Technology InformaCon
Dr. Thorsten Wuest [email protected]
Industry 4.0 and employment
DominionPostDec.29,2017
hHp://www.cbc.ca/radio/quirks/september-9-2017-1.4280509/will-you-have-to-become-a-cyborg-for-your-job-1.4280516
DominionPostDec.30,2017
Dr. Thorsten Wuest [email protected]
It is a global development
High-TechStrategyProjectsforthefuture• Industry4.0initiative• SmartServicesProgram• SmartDataProgramforSME
ManufacturingRenaissance• IndustrialInternetConsortium• SmartManufacturingLeadership
Coali^on(SMLC)• ManufacturingUSA
IndustryRevitalizationPlanRestructuringofindustryWorld’sleadingITsocietyConnectedfactory
ChinaManufacturing2025ITintegrationinindustrialprocessesHigh-endautomatization&robotics
Source:SiemensLtd.Seoul2014
SmartManufacturing
Useofdatathroughouttheproductlifecycle
SmartManufacturingFocusondataandanaly^cs
Two different ways of differentiation
AdvancedManufacturingNewtechnologies,products,materialsandprocesses
AdvancedManufacturingFocusonphysicalmanufacturing-technology
Source:MiPal,Khan&Wuest2017Source:Shippetal.2012Schmid&Wuest,2017
Dr. Thorsten Wuest [email protected]
Advanced vs. Smart Manufacturing
Dr. Thorsten Wuest [email protected]
Smart Manufacturing
“SmartManufacturingisadataintensiveapplicaConofinformaContechnologyattheshopfloorlevelandabovetoenableintelligent,efficientandresponsiveoperaCons.”
Wallace&Riddick,2013
Dr. Thorsten Wuest [email protected]
Smart Manufacturing Smartmanufacturingmarriesinforma?on,technologyandhumaningenuitytobringaboutarapidrevoluConinthedevelopmentandapplicaConofmanufacturingintelligencetoeveryaspectofbusiness.
Itwillfundamentallychangehowproductsareinvented,manufactured,shippedandsold.
Itwillimproveworkersafetyandprotecttheenvironmentbymakingzero-emissions,zero-incidentmanufacturingpossible.
Itwillhelpkeepjobsinthiscountry[USA]bykeepingmanufacturerscompeCCveintheglobalmarketplacedespitethesubstanCallyhighercostofdoingbusinessintheUnitedStates.
Chand&Davis,2010
SMART MANUFACTURING PRINCIPLES / CONNECTIVITY / VIRTUALIZATION / DATA UTILIZATION
Schmid&Wuest,2017
Dr. Thorsten Wuest [email protected]
Smart Manufacturing Opportunities The Industrial IoT creates various improvement opportunities
+49%productquality +80%
efficiency
-30%productiontime
+40%customersa^sfac^on
+25%productivityincrease
-25%safetyincidents
+25%energyefficiencyimprovement
+1%GDP
Source:hPps://www.slideshare.net/solaircorporate/
Schmid&Wuest,2017
Dr. Thorsten Wuest [email protected]
Smart Manufacturing Vision Fully Connected Smart Factory
Ineedmorematerials
Alertsmonitor:Problemwithmachine#2.Pleasecheck
I’mcustomerorder#312andwanttoberedcolored.
Endoflinetest:Machine#1,Pleaseadjustmachineparameters
Source:hPp://smartamerica.org/teams/smart-manufacturing/
Controlcenter:Aggregateddatarevealimprovementareas
Packingmaterialislow.Pleasereleaseorder.
Cogwheelwillbreakinfivedays.Ihaveorderedsparepartsandscheduledexternalserviceprovider.
Schmid&Wuest,2017
Dr. Thorsten Wuest [email protected]
IT/OT Integration enabling Smart Manufacturing Convergence of the virtual and real world
Virtualworld
OperaConalTechnology(OT)
InternetofThings(IoT)Manual
DataInputBarcode
EmbeddedWirelessSensorRFID
InformaConTechnology(IT)Mainframe
ERPInternet
MES
CNC
Robo^cs
Fieldbus TCP/IPPLC
Sensors
PC
Cloud
SmartManufacturing
Realworld
Dr. Thorsten Wuest [email protected]
Smart Manufacturing and (I)IoT (I)IoT as an enabler of Smart Manufacturing
SmartGrids
ConnectedCarsSmartCiCes
Smart…
SmartManufacturing
• Manufacturingindustries• Systems,things,devices,
ontheshopfloor• Productsthroughout
theirlifecycle
InternetofThings
• Allindustries
• Allthingsanddevices
SmartProcesses
SmartProducts
SmartPlants
Source:hPps://www.youtube.com/watch?v=1Q5Iyw8vll8
Schmid&Wuest,2017
Schmid&Wuest,2017
SMART MANUFACTURING MARRIES TECHNOLOGY, DATA AND HUMAN INGENUITY
Dr. Thorsten Wuest [email protected]
Smart Manufacturing Technologies
• Technologyisalwaysakeyenablingfactor
• ButwhatareSmartManufacturingassociatedtechnologies?
• WecreatedacomprehensiveoverviewasabasisfordiscussionandafirststeptowardsaSmartManufacturingOntology
• OpenAccessPaper:MiPal,S.,Kahn,M.Romero,D.&Wuest,T.(2017).SmartManufacturing:CharacterisCcs,TechnologiesandEnablingFactors.PartB:JournalofEngineeringManufacture,Onlinefirst,1-20.DOI10.1177/0954405417736547
Dr. Thorsten Wuest [email protected]
38technologies(27char./7enabl.factors)Wedecidedtocluster,resul^ngin:1. 3-DPrin^ng/Addi^veManufacturing2. CloudManufacturing3. CPS(CyberPhysicalSystems)/CPPS
(CyberPhysicalProduc^onSystems)4. CyberSecurity5. DataAnaly^cs6. EnergySaving/EnergyEfficiency
7. IntelligentControl8. IoT/IoS/IIoT9. ITbasedProduc^onSystem10. SmartProduct/Part/Material11. VisualTechnology
Smart Manufacturing Technology Clusters
Mittal et al., 2017
Mittal et al., 2017
Dr. Thorsten Wuest [email protected]
• ExampleCluster:VisualTechnology
• Comprisedofthreetechnologies:
• Hologram/DigitalTwin• AugmentedReality• VirtualReality
Source:hPps://compass-ssl.surface.com/assets/d4/8d/d48dbc28-aec3-4417-b319-bed3aac91c81.jpg?n=Overview_Hero_1920_img_new.jpg
Example: Visual Technologies
Dr. Thorsten Wuest [email protected]
… But what does all that mean for manufacturing companies?
• Con?nuousinnova?on• QuesConcurrentprocesses&pracCces!
• Adap?onofnewtechnologies,toolsandframeworks
• Data&InformaCondriven!• Skilledworkforce
• Lifelonglearning!
Smart Manufacturing in Small- and Medium-sized Enterprises (SMEs)
Dr. Thorsten Wuest [email protected]
Dr. Thorsten Wuest [email protected]
Siemens Digital factory
• Siemens’plantinAmberg,Germany
• Productscommunicatewithmanufacturingmachines
• ITsystemscontrolandop^mizeallprocesses
• Produc^onqualityisat99.99885%
Dr. Thorsten Wuest [email protected]
Upgrade existing systems • BoschupgradedLathefrom1887tobeSmartManufacturingready
• Newcapabili?es:• processmonitoringforconstantqualityassurance
• anotheriscondi^onmonitoringinordertopreventunplanneddown^mes
• Extremeexamplebutshowcasesthepoten?al
hPp://www.bosch-presse.de/pressportal/en/69632.html
hPp://www.bosch-presse.de/pressportal/en/69632.html
Dr. Thorsten Wuest [email protected]
Background § InternetofThingsischangingtheindustriallandscape§ ManufacturingisundergoingamajortransiCon§ Largecorpora^onsaredealingwiththistopicintensively
⇒ ButhowtoapplySmartManufacturinginsmallcompanies?⇒ Howcansmallmanufacturerstakeadvantageofit?
Objectives § Examinethecurrentstateofmanufacturingwithasurvey§ Understandthemanufacturinglandscapeanditsspecific
challengesandconcernsbyconduc^nginterviewsandplantvisits§ Supportsmallmanufacturersinadop^ngSmartManufacturing
technologiesbyseengupatrainingworkshop
Work Packages 1. Onlinesurvey2. Interviews&plantvisits3. Analysisofresults&report4. Trainingworkshop
Schmid&Wuest,2017
Project Scope
Dr. Thorsten Wuest [email protected] Schmid&Wuest,2017
Survey Method
0
2
4
6
8
10
12
Total#ofrespondentsfrommanufacturing53
Companysizeby#employees
lessthat20
100-499
20-99
500andmore
Who participated in the survey?
Dr. Thorsten Wuest [email protected] Schmid&Wuest,2017
Survey Results How aware are companies of the transition towards Smart Manufacturing?
0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
Industry4.0
SmartManufacturing
IndustrialInternet
InternetofThings(IoT)
SmartFactory
Cyber-physicalsystem
Ihavealreadyheardabout...0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
Mycompanyisdealingwith...
Dr. Thorsten Wuest [email protected] Schmid&Wuest,2017
Survey Results How prepared are companies for Smart Manufacturing?
0% 10% 20% 30% 40% 50% 60% 70%
Slightlyprepared
Moderatelyprepared
Veryprepared
Towhatextentisyourcompanyandyouremployeesprepared?
0% 10% 20% 30% 40% 50% 60% 70%
Notrelevantatall
Moderatelyrelevant
Veryrelevant
HowrelevantisSmartManufacturingforyourcompany?
Dr. Thorsten Wuest [email protected] Schmid&Wuest,2017
Survey Results What are the needs of manufacturers when it comes to Smart Manufacturing?
Dr. Thorsten Wuest [email protected] Schmid&Wuest,2017
Interview Method Who participated in the interview sessions?
Manufacturing Experts
Intervieweesinmanufacturingcompanies
9Expertsinacademia,associa^ons&state
agencies
Manufacturers
5
Selected insights from interviews
Dr. Thorsten Wuest [email protected]
Lack of economic opportunities - Declineofcoalindustry- Declineinlocalmarkets- Oversupplyinglobalmarkets- Globalcompe^^on
Infrastructure challenges - Telecommunica^oninfrastructure- Lackofinvestmentsinfacili^es/tech.- Infrastructureofsupportsystems
Increasing cost - Increasingu^lityrates- Rapidlyrisinghealthcarecost- Lackofcapitalto‘keepup’w/tech.
Manufacturing reputation problem - Mindsetof‘second-class’jobs&lowwages- Misconcep^onofdirtyanddangerouswork
Perception of Smart Manufacturing value - Lackofawarenessofexis^ngtech.&poten^alimpact- Hardtoimaginevalue-addfordiscretemanufacturing- Difficulttoimagineinasmallscale- Lackofshowcases&successstories/rolemodels
“It’s a different deal in small companies in many ways” - Smallcompaniescouldmovefaster- Lessresourcesreg.humansresources,money&^me
Key challenges of Smart Manufacturing adoption for SMEs
Lack of opportunity
Resources & cost
Knowledge & awareness
Skilled workforce
Missing ‘success stories’
Dr. Thorsten Wuest [email protected]
‘Capability creates Opportunity’
Dr. Thorsten Wuest [email protected]
Craig Hartzell, Azimuth Inc., 2017
SMART MANUFACTURING IS NOT ONLY FOR THE BIG GUYS.
Schmid&Wuest,2017
Opportunities for collaboration & entrepreneurs
Brave new world
‘Low’ initial investment
Dedicated ‘Apps’ (Platform solution)
Scalable solutions (interoperable & extensible)
Fast deployment
Dr. Thorsten Wuest [email protected]
• ProvideeducaConalresourcesonSmartManufacturingandIndustry4.0(‘spreadtheword’inanaccessibleway)forindustrialpartners.
• Jointlydevelopcurriculumfor1)professionalstoequipthemwithrequiredknowledgetoinnovateandoperatewithinaSmartManufacturingenvironment,and2)includeSmartManufacturinginexisCngengineeringcurriculaacrossins^tu^ons(‘highschooltomasters/Ph.D.’),departmentsandmajors.
• Communicatesuccessesbroadlyandencouragepeer-to-peerexchange(acrossindustries)ofbestprac^cesandlessonslearned.
Recommendations (1/2) for Smart Manufacturing in SMEs
Dr. Thorsten Wuest [email protected]
• Buildstrongandsustainablepartnershipsbetweencompanies,academiaandindustryassocia^ons.Forexample,leverage(local)technologystart-upstoteam-upwithestablishedmanufacturersandacademia.
• Startwithsmall‘lighthouse’projectstarge^ngspecificpainpointstolearnandachievequickwins.
• LeveragestateandfederalfundingtocomplementthelimitedrecoursesavailabletomanufacturingSMEs.
Recommendations (2/2) for Smart Manufacturing in SMEs
Dr. Thorsten Wuest [email protected]
SMART MANUFACTURING CANNOT BE BOUGHT. THE SUCCESS HAS TO BE EARNED.
Schmid&Wuest,2017
Dr. Thorsten Wuest [email protected]
My take on this issue: • Solu^onsmustbetailoredtoSMEs’(real!)needs&requirements!
• Createrealvalue(shortANDlongterm)!
• Fitthestrategy/vision!
TodosoSMEsneedto:• Assesstheircurrentprocessescri^cally
• Iden?fytheircorecompetencies• Buildonthoseand• Developaroadmapwithspecificmilestones/objec^ves
• (keep80/20ruleinmind!)
Contact:ThorstenWuest,Ph.D.AssistantProfessorSmartManufacturingWayneandKathyRichardsFacultyFellowWestVirginiaUniversityIndustrialandManagementSystemsEngineering347EngineeringSciencesBuildingMorgantown,WV26506-6070,USA+1(304)[email protected]
Thank You!
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