fundamentals of an industry 4.0 solution
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Fundamentals of an Industry 4.0 SolutionAndy Simoneau
Advanced Manufacturing and Industry 4.0AMI4
Industry 4.0 and Cyber Physical Systems
Industry 4.0 and Cyber Physical Systems
My Industry 4.0 Story – Day 1
One day a Tier 1 supplier had a QA problem so they called the biggest cloud computing company to solve it.
Production (OT)• Inspection for part defect• False rejects and missed defects• Defect – microcracking and pitting• Inspection technique – image
analysis and ultrasonic testing• Cycle time 6s - reduce to 2s
Compute side (IT)• Collect images• Store data• Use machine learning• Automate part accept/reject
3HOURS
Industry 4.0 and Cyber Physical Systems
My Industry 4.0 Story – Day 2
Production (OT)• Differentiate images between
microcracks, fingerprints, shadows, grease, etc.
• We need 20 photos of all surfaces stitched together.
• Analyse for defects – Pass/FAIL
Compute side (IT)• We can store the data – no problem• Can’t handle the Volume, Velocity, Variety• We can’t make decisions on the part PASS/FAIL in
time
QA Inspectors (talked to them after the meeting)• No faith in the system• Manipulating parts before and after inspection – “they knew a defect when they saw one”• They were correcting the machines, pre-cleaning parts• Carrying out full inspection of failed and passed components
Outcome:Project postponed till we get more information and can identify the appropriate solution
Industry 4.0 and Cyber Physical Systems
My Industry 4.0 Story – What went wrong?
3 MAJOR MISTAKES
#1. Lack of understanding of how the other side functions, and a language barrier between OT and IT, they were identifying similar goals – but they could not see it because they did not understand the other sides language.
#2. A honed focus on the solution – not the problem.
#3. No understanding of how the people doing the job interact with processes and technology. Assumptions are made about the people and processes that we are developing IoT solutions for. Missed people – missed verticals.
History
Industry 4.0 and Cyber Physical Systems
History
1780 - Mechanisation
1870 - Electrification
1970 - Automation
Present - Digitisation
Future - Personalisation
Industrial production based on machines powered by water and steam
Mass production initiated, assembly lines are trending
Automation using electronics and computers
Introduction of connected devices, data analytics and AI to automate processes further
The 5th industrial revolution will focus on person-machine collaboration, humans working with cognitive computing. People will be added back into the equation, being upskilled to perform value-added tasks leading to mass customisation.
The Pillars of Industry 4.0
Industry 4.0 and Cyber Physical Systems
9 Pillars of Industry 4.0
Advanced Manufacturing Solutions
Additive Manufacturing
Augmented Reality – AR/VR
Simulation
Cloud Storage
Cyber-Security
Big Data and Analytics
Industrial Internet
Horizontal/Vertical Integration
Autonomous systems, robots, numerous integrated systems, sensors and standard interfaces
3D printing for spare parts, rapid prototyping, complex geometries
Cross company data integration based on data transfer standards. Preconditioned for fully automated value chain (supplier to customer, management to the shop floor
Augmented reality for heads up display, SOP’s, safety, maintenance and training.
Full evaluation of available data (e.g. ERP, MES, CRM, machine data). Realtime decision making support and optimization
Simulation of value networks – process, operations, systems, etc.
Management of huge data volumes in open systems and real-time communication of production systemsOperation in networks and open systems to protect data, and machines. High level networking between intelligent machines, products and systems)
Network of machines and products
Industry 4.0 and Cyber Physical Systems
Building Blocks and Fundamental Pieces
Artificial Intelligence (AI)
Digital Twin
Edge Analytics
Additive – 3D printing
Sensors
Robotics
AR, VR, and MR
Platforms & Connectivity
Blockchain
Cybersecurity
Industry 4.0 and Cyber Physical Systems
The Initial Driver of Industry 4.0
Sensors
Digital Twin
Edge Analytics
Additive – 3D printing
Platforms & Connectivity
IND4 + CPS
Industry 4.0 and Cyber Physical Systems
Platforms and Connectivity
Start-Ups and SME’s are critical part of success
Start-ups and SME’s have expertise in niche technologies such as machine learning, predictive analytics, cyber-security.
Independent software vendors (ISV’s) build the underlying platform with the capabilities to host IoT applications and leverage applications using cloud technology
Automation vendors are in the OT domain, expertise in installation and integration -they remain key to data collection and meeting the base requirements of IoT.
AutomationVendors
ISV’s
Start-ups & SME’s
Industry 4.0 and Cyber Physical Systems
Digital Twinning
Converting a physical machine into data that can be interpreted by people.
Can be done for a single process, operation, machine, production line, . . .
➢ Allows for analytical decision making
➢ Allows for process and product visualization
➢ Improved system and process control
➢ Commissioning machines from remote centres
➢ Can be scaledAllows us to accurately predict the current and future states of physical assets by analysing their digital counterparts – READING/ANALYSING SENSOR DATA.
Industry 4.0 and Cyber Physical Systems
Edge Analytics
Decentralized at-source computing is expected to see a significant uptake across all industries.
Popular use cases:➢ Quality assurance➢ Process performance➢ Realtime monitoring of
worksite safety➢ Package tracking and
logistics➢ Traffic monitoring➢ Condition based
maintenance➢ Agri-health monitoring
Industry 4.0 and Cyber Physical Systems
Additive Manufacturing + Hybrid Engineering
Microwave guide array – 316 Stainless steel
Cons:➢ Expensive➢ Low volume➢ Time consuming➢ Material issues➢ Still requires processing – hybrid
machining➢ Removal of design constraints
poses major challenges for manufacturing
Pros:➢ Material
options/combinations are unique
➢ No design constraints➢ Complex, novel structures➢ High degree of
customization➢ Near net shape
Hybrid Systems
Hybrid manufacturing machines combine one of the 7 types of Additive Manufacturing (AM) technologies and CNC milling capabilities into one single machine bed.
Allows both technologies to work on the part one after another or alternatingly to create geometry and desired features.
For example, AM technology with its freedom creates a complex shape while the CNC milling head carries out the precision machining.
Industry 4.0 and Cyber Physical Systems
Hybrid Systems
Industry 4.0 and Cyber Physical Systems
Industry 4.0 and Cyber Physical Systems
Sensors
Sensors are a key growth opportunity and primary facilitator for adoption of Industry 4.0 across industry.
Requirements of Industry 4.0:• Connected multi-interaction between
machines, and human operators through a network
• Digital data – analytics, virtual models, simulation
• Physical and Virtual Technical Assistance – minimizing machine down time, improving decision making through a comprehensive visualization of the process
• Autonomous decision making – complex decision making allowing for mass production and mass customization.
Industry 4.0 and Cyber Physical Systems
Sensors (cont’d)
1. Accelerometer2. Gyroscope3. Magnetometer4. GPS5. Proximity Sensor6. Ambient Light7. Microphone8. Touchscreen9. Fingerprint10. Pedometer11. Barometer12. Bar Code/QR Scanner13. Heartrate Sensor14. Thermometer15. Humidity/Moisture
Industry 4.0 and Cyber Physical Systems
Sensors (cont’d)
Thank you
Advanced Manufacturing and Industry 4.0AMI4
Industry 4.0 and Cyber Physical Systems