digital manufacturing - petrochem 2017...

Digital Manufacturing

POV Dr. Subhasish Mitra 12 Feb 2015

© Copyright 2014 Hewlett-Packard Development Company, L.P. The information contained herein is subject to change without notice.

Manufacturing in India…… Key trends in the India Manufacturing market

• Indian manufacturing industry is expected

to touch US$ 1 trillion by 2025

• India ranks second in the world as

per Global Manufacturing

Competitiveness index ( GMCI). It is

expected to continue to maintain

this position for the next 5 years

• Around 90 million domestic jobs are

waiting to be created by that

timeframe with the manufacturing

segment contributing about 25-30%

of India’s gross domestic product

compared to current share of 16%

• The national manufacturing policy

suggests raising the share of

manufacturing in GDP to 25% in order to

create 100 million jobs in the coming

decades

• As per a study by Assocham, India's

manufacturing sector is all set to create

3.2 million manufacturing jobs during the period of 2012-17

• The Government of India has taken

several initiatives to promote a

healthy environment for the growth of

manufacturing sector in the country

• India has become one of the most

attractive destinations for investments in

the manufacturing sector

• The manufacturing sector in India is an

attractive hub for foreign investments.

Several mobile phone, luxury and

automobile brands, among others, have

set up or are looking to establish their

manufacturing bases in the country

Manufacturing in India……

Five manufacturing trends that will impact the industry in 2015

SMAC Stack

A manufacturing

comeback is being

driven by SMAC —

social, mobile,

analytics and cloud.

The SMAC Stack is

becoming an

essential technology

tool kit for

enterprises and

represents the next

wave for driving

higher customer

engagement and

growth opportunities

Social media to further

impact business model

innovation

According to an IDC

white paper, "The Future

of Manufacturing,"

sponsored by Infor,

social media is forcing

manufacturers to

become more customer-

centric. The traditional

business-to-business

model is becoming

outdated because

today's connected

consumers are better

informed and expect

products on-demand

Internet of Things (IoT)

will increase

automation and job

opportunities

A renewed focus on

science and engineering

education is cultivating a

manufacturing workforce

that can manage highly

technical systems and

allow for greater

automation

Greater capital

investment

Though the slow

economic recovery

continues to hinder

expansion and

growth

opportunities,

recent government

and industry

reports show an

uptick in capital

investment funding

The emergence of "Next-

Shoring."

The rise of a more technical labor

force to manage supply chain

operations — combined with rising

wages in Asia, higher shipping

costs and the need to accelerate

time to market to meet retailer and

consumer demands — has led to

more companies shifting their

manufacturing strategies from

outsourcing overseas to

developing products closer to

where they will be sold. "Next-

shoring," as this tactic has been

dubbed, allows manufacturers to

increase the speed at which

product is replenished on store

shelves. The faster inventory can

be moved to the consumer, the

sooner the costs to warehouse,

ship and dock goods can be freed

up

http://www.industryweek.com/idc-s-future-manufacturing-report

http://www.industryweek.com/idc-s-future-manufacturing-report

Manufacturing Industry: Five Critical Capabilities Adapt to

changing circumstances

Resiliency Engagement

Successful Innovation Speed product

portfolios

Reliability

Quality remains a priority

• Suppliers • Partners • Employees

Ability to be

more

responsive

3 ©Copyright 2014 Hewlett-Packard Development Company, L.P. The information contained herein is subject to change without notice.

Manufacturing 2015 Top 10 Predictions •

Manufactures Will Begin to Build 3D Value Chains (Demand oriented, Data driven, Digitally executed) •

Operational Resiliency Will Be the Focus of Supply Chain Strategies in 2014 and Beyond •

Supply Chain Technology Investment Will Involve Modernizing Existing Systems While also Trying New Approaches •

The Modernization of the Underlying B2B Commerce Backbone Will Become an Investment Priority for IT

•

Product Life-Cycle Management Strategies Will Become Increasingly Global, Multidisciplinary, Innovation Based, and Customer Focused •

PLM Initiatives Will Focus on Value Realization •

On Its Way Toward the Factory of the Future, 2015 Will Set the Stage for a New Manufacturing Renaissance

•

Plant Floor IT Investments Will Continue to Become a Higher Share of the Overall Technology Investment Portfolio

Source: IDC Manufacturing Insights (December 2013)

4

©Copyright 2014 Hewlett-Packard Development Company, L.P. The information contained herein is subject to change without notice.

What is Digital Manufacturing? Digital Manufacturing (CIM) is the approach of using computers to control the

entire production process.

Systems that support definition of the processes used to produce

a product, simulation and analysis of those processes and the

manufacturing environments used to produce the product

including production equipment and lines.

Future Intelligence Factories CAD/CAM/CAPP Interfaces & Collaboration Line Configuration (Mass Production / Dynamic Production Change) Predictive Manufacturing Cyber Physical Models (Software, Sensors, Processors & Communication Technology)

Line Feedback/Data Analytics


What is Digital Manufacturing at the heart?

CAM

CAD

CAPP

MI

M2M


Digital Manufacturing, why? Disrupt and transform manufacturing of the future Goal Statement: Revolutionize the manufacturing value chain to boost competitiveness by leveraging the convergence of digital and physical production

capabilities. Manufacturing value chain includes design, production, processes and

supply chain management.

Novel Design

Paradigms &

Innovations

Cyber-Physical

Systems & Intelligent

Factories

Digital

Manufacturing

Processes

Data Drive Urban

Logistics & SCM

Big Data Analytics for Manufacturing

7

©Copyright 2014 Hewlett-Packard Development Company, L.P. The information contained herein is subject to change without notice.

Industry 4.0 - Siemens

From the computer to the production line, new technologies are shrinking

the time between virtual

planning and

manufacturing.

Self Organizing Factories

Source: DFKI (2011)


Industrial Internet - GE

Key Elements

Source: GE Industrial Internet


Information System mapping to ISA-95

Business Planning & Logistics Plant Production Scheduling,

Shipping, Receiving, Inventory, etc

Level 4

Manufacturing Operations Management Dispatching, Detailed Production Scheduling,

Reliability Assurance, ...

Level 3

Level 2 Batch Continuous Discrete

Control Control Control

Level 1

4. Establishing the basic plant schedule - production,

material use, delivery, and shipping. Determining

inventory levels

Time Frame: months, weeks, days

3. Work flow/recipe control to produce the desired end

products. Maintaining records and optimizing the

production process

Time Frame: days, shifts, hours, minutes, seconds

2. Monitoring, supervisory control and automated

control of the production process

Time Frame: minutes, seconds, milliseconds,

microseconds

1. Sensing the production process, manipulating the

production process

ERP SCM

Ap plication Managemen t

PLM CRM

Ap plication Development

MES Ap plication

Transfo rmatio n

HMI SCADA Secu re

Network / Monitoring

PLC DCS

System Integratio n

Devices / Sensors

Managed Clou d

Hosting

Infrastructure Sup port

Enterprise Service

Managemen t

Wo rkpl ace Services


Business Planning and

Logistics

Plant Production Scheduling,

Shipping, Receiving, Inventory

etc.

4. Establishing the basic plant schedule-

production, material use, delivery and

shipping. Determining inventory levels

Timeframe-months, weeks, days

ER

P

PL

M

SC

M

CR

M

Manufacturing Operations

Management

Dispatching, Detailed Production

Scheduling, Reliability

assurance.

3. Work Flow/recipe control to produce the

desired end products. Maintaining

records

and optimizing the production process

Timeframe-days, shifts, hours, minutes,

seconds

MES

2. Monitoring , supervisory control and

automated control of the production process

Timeframe-minutes, seconds, milliseconds,

microseconds

HMI

SC

AD

A

PLC DC

S Batch

Contr

ol

Continuous

Control

1.Sensing the production process,

manipulating the production process Devices

/Sensors

Discrete

Control

New Style of IT Manufacturing Reference Architecture

Analytics & Data Management

ERP

PLM

Workplace

& Mobility

MES Plant 1

MES Plant 2

Applications

Cloud

Security Services


Devices, Smart Sensors, PLCs, NC (OPC Compliant)

Big Data

Analytics & Visualization

Signal Processing & Feature Extraction

Health Assessme

nt

Performance Prediction

Fault Diagnosis

Vibration, pressure temperature

MT-Connect, OLE-DB, OPC

National Science Foundation (NSF)

Industry/University Research Cooperative

Center (I/UCRC) for Intelligent

Maintenance Systems (IMS

SAS

Hadoop

SAP

Internet of Things (IOT) for Factory-wide OEE

Product Lifecycle Management (PLM) Innovation and productivity by integrating product information from concept to recycling


3-D Printing in Product Design

Additive Manufacturing

3-D Printing

Prototyping

HP’s framework for manufacturing business & IT

Manufacturing

1.0 Marketing

1.1 Market

Analysis

1.2 Portfolio

Planning

1.3 Create

Product/Service

Demand

1.4 Sell Products/

Services

1.5 Marketing and

Sales Analytics

2.0 Product Development

2.1 Refine Plan

And Define

Product/Service 2.2 Design and

Release

Product/Service 2.3 Validate Product/Service

Design to

Requirements 2.4 Prepare and

Validate Production

Environment

2.5 Prepare and

Validate In-Service

Environment

3.0 Manufacturing Operations

3.1 Plan and

Schedule Production

3.2 Manage

Supply and

Inbound Logistics

3.3 Make or

Assemble Product 3.4 Fulfill

Production Order

4.0 Manage Supply Chain

4.1 Develop

Supply Base

4.2 Manage Production Support

And Materials

4.3 Manage Warehousing and

Distribution

4.4 Conduct Supplier

Aftermarket Support

5.0 6.0 Manage Manage Service Chain Business

5.1 Manage 6.1 Provide

Technical Administrative

Maintenance and Services

Engineering Inform.

5.2 Plan

Maintenance

5.3 Perform

Maintenance/

Repair 6.4 Provide

Financial

5.4 Manage Services Supply Support 5.5 Manage 6.5 Manage Public

Service Contracts Affairs

And Warranty 6.6 Provided Legal

5.6 Analyze and Counsel

Report Service 6.7 Provide

And Quality Data Information

Technology and

Communications

1.0 Marketing and Sales

6.2 Manage

Business

6.3 Provide

Human Resource

Support

2.4 Prepare and 3.4 Fulf Validate Production Produc Environment

2.3 Validate

S Product/Service In

Product/Service A Design to Requirements

Sales Analytics

1.3 Create Product/Service

Planning

1.2 Portfolio

Analysis And Define

1.1 Market 2.1 Refine Plan

HP’s framework for manufacturing business & IT

Integrated Manufacturing Enterprise

Integrated Integrated sales and product service development

2.1 Refine Plan

Integrated Integrated manufacturing supply operations chain

3.2 Manage 4.2 Manage

Integrated sales and service

5.1 Manage Technical Maintenance and Engineering Inform.

5.2 Plan

Integrated business services

6.1 Provide Administrative Services

6.

Maintenance

Bu

Distribution

orm ance/ Repair

5.4 Manage Services Supply

6.

Su

6.4 Provide Financial Support

6.5 Manage Public Affairs

6.6 Provided Legal Counsel

6.7 Provide Information Technology and Communications

Integrated

Sales and

Services

Customer Relationship Management (CRM)

2.5 Prepare and Validate In-Service Environment

Product Lifecycle Management (PLM)

Enterprise Resource Planning (ERP)

Manufacturing Operations Management (MOM)

Supply Chain Management (SCM)

Customer Relationship Management

(CRM)

(CRM)

Enterprise

Hu (ERP)

Resource Planning

Integrated

Product

Development

Integrated

manufacturing

operations

Integrated

Supply

chain

Integrated

Sales and

Services

Integrated

business

services

Integrated Manufacturing Enterprise

Integrated Manufacturing Enterprise (IME) is an industry solution that integrates technologies within the manufacturing client’s enterprise. This comprehensive integration enables the fast, free flow of information throughout the enterprise, making it visible for analytical capabilities that enable quick reactions in the functional domain and for business intelligence needed to drive strategic decisions at the corporate level that are required to achieve and maintain market leadership.

Digital Manufacturing

POV Asit Sinha/Feb 2015

Thank you

digital manufacturing - petrochem 2017...

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