how does alabama and the greater southern automotive ... · net-centric model based enterprise •...

How Does Alabama and the Greater Southern Automotive Region Establish Itself as a Center

of Innovation in Automotive Manufacturing?

The Digitalization of Manufacturing

Dr. Gregory Harris, P.E.Auburn University

Automotive Advanced Technology SummitBirmingham, Alabama

May 8, 2019

Automotive Manufacturing

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• Not the product of any single person or group.

• The culmination of a worldwide series of experiments and developments.

• Today’s automobile represents over 100,000 patents.

• The origin of the automobile can be traced to prehistoric times It depends on the use of the wheel, fire, and manufactured materials.

Dr. Gregory A. Harris, P.E. Automotive Advanced Technology Summit, Birmingham, AL

Manufacturing Systems

3Dr. Gregory A. Harris, P.E. Automotive Advanced Technology Summit, Birmingham, AL

Products & Processes are changing

• A KPMG study released Monday said that “ride services using self-driving vehicles could slash by more than half demand for owner-driven sedans in the United States by 2030.”

• “Toyota Motor Corp., which has made a big bet on hydrogen-powered cars, is looking more isolated as industry rivals double down on plug-in electric vehicles as the dominant technology in the emerging post-fossil fuel era.”

• Shell is partnering with IONITY, a joint venture between BMW, Daimler, Ford, and Volkswagen, to deploy electric car chargers on Europe’s highways.

• Fuel cells are gaining momentum as range extenders for electric trucks.

• “The city of Lincoln has signed a nearly $100,000 contract with an engineering consultant to study how the city could one day implement driverless vehicles.”


The Industrial Revolutions


Advanced Manufacturing

• Use of innovative technologies to create existing products and the creation of new products.

• Advanced manufacturing can include production activities that depend on information, automation, computation, software, sensing, and networking. (Advanced Manufacturing National Program Office. Manufacturing.gov http://manufacturing.gov/welcome.html)

• Advanced Manufacturing employs innovative, ground breaking technologies to achieve agile and responsive results in product and system realization.


http://manufacturing.gov/welcome.html

The Future of Manufacturing

• Manufacturing and design is a networked and interoperable system with agile and robust manufacturing strategies & integrated capabilities that dramatically reduce the cost and time of producing complex systems and parts.

• Machine to machine communications, data collection capability from new and legacy equipment, data analytic tools made available through high performance computing capability, model based enterprise, and standards development.

• Plug and play functionality allows equipment to utilize manufacturing knowledge and enables better decision-making while planning and processing components.

• The development and integration of smart sensors, controls, metrology, analysis, decision and communication software tools for self-aware manufacturing provides data to enhance continuous improvement and sustainability.

• Distributed manufacturing as a strategy and system is coming quickly as a result of capabilities that technology is providing.

• Manufacturing modeling and simulation tools allow faster time to market and efficient production of desired systems.

• Worker and environmentally friendly, with products that are developed and manufactured with efficiency and effectiveness of the realization process in mind.


One response: Industry 4.0

Industry 4.0

Autonomous Robots

Simulation

Horizontal and vertical

system integration

Industrial Internet of

Things

Cyber Security

Additive Mfg

Augmented reality

Big data analytics

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In October 2012 the Working Group on Industry 4.0 presented a set of implementation recommendations to the German government.

• Automation and data exchange in manufacturing technologies (digitalization). • The "smart factory“ concept.

o Cyber-physical systems monitor physical processes, create a virtual copy of the physical world and make decentralized decisions.

o The Internet of Things, cyber-physical systems that communicate and cooperate with each other and with humans in real time

Industry 4.0 factory or system includes:• Interoperability • Information• Technical assistance• Decentralized decision-making

The characteristics of the German government's Industry 4.0 strategy:• Strong customization of products under the conditions of highly flexible (mass-) production. • Automation technology: self-optimization, self-configuration, self-diagnosis, cognition and

intelligent support of workers in their increasingly complex work.https://www.forbes.com/sites/bernardmarr/2016/06/20/what-everyone-must-know-about-industry-4-0/#71100d5795f7


Manufacturing Data History

Antebellum Era of Manufacturing Mass Production

“One of the most noteworthy accomplishments in keeping the price of Ford products low is the gradual shortening of the production cycle. The longer an article is in the

process of manufacture and the more it is moved about, the greater is its ultimate cost.”Henry Ford, 1926

• Most engineering and manufacturing activities relied on 2 Dimensional (2D) drawings in hardcopy or digital form

• Today, it is possible to perform most engineering functions using data models9Dr. Gregory A. Harris, P.E. Automotive Advanced Technology Summit,

Birmingham, AL

Minimum Turn Radius: 24 ft.Dry Pavement Braking Distance at 60 MPH : 110 ft.

Automatic Cruise Control <FAULT>

Thermal/Heat Dissipation: 780°

Ergonomic/Pedal Feedback: 34 ERGS

Hydraulic Pressure: 350 PSI

Sensor MTBF:3000 hrs

Power Rating:18 Amps

Hydraulic Fluid:SAE 1340 not-compliant

Minimum Turn Radius: 24 ft.Dry Pavement Braking Distance at 60 MPH : 110 ft. 90 ft

Manufacturing Created Data

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Source: INCOSE MBSE Initiative-Mark Sampson

Automotive Advanced Technology Summit, Birmingham, AL

Digital Manufacturing and Design

1100101011

PRODUCT LIFECYCLE

11010010010001111011010101111011111

1010110110100001010010010001111011111010101111011111010111110

FABRICATE

FABRICATE

0101010011010101011011010101001001001010010010001111010101011110111110101111101111101

101101101010101010000011010101011011010101001010010010111101010010001111010101111011111010111110111110101111101

000100101010111101010100100100011110110100010010001101010101101101010100010101011011010110100111101111101011111011111010111110111110101

10111101101001111011101101010101011001011010010001101010101101101010100100100011110101001010010010001111010111111110111110101111101111101011111011111010111110111

ASSEMBLE

Operations, Maintenance & Sustainment

QUALIFY

SELL &DELIVER

END OF LIFE

REUSERECYCLE

FABRICATE

DESIGN

FABRICATE

DATA

INFORMATION

DECISIONS

VALUE

Digital manufacturing and design is the aggregation and application of digital

data across the lifecycle of a manufactured product.

Digital Manufacturing enables faster and better decision making based on real-time information11Dr. Gregory A. Harris, P.E. Automotive Advanced Technology Summit,

Birmingham, AL

Change the Design–Build Cycle

Design Knowledge,Simulationand Know-How

ControlPoint

Future State- Integrated Knowledge- Unified & Searchable- Automated Workflow & Data

Movement- Project/Process Centric

Current State- Isolated Expertise- Separate Tool & Data Repositories- Manual Workflow & Data Movement- Task Centric

Enable Rapid Multi-Disciplinary Optimization & Risk Assessment

integrate

Source: General Electric, Dr. Joe Salvo


Why is Industry 4.0 creating such interest?

• Time to market and customer responsiveness are today’s key factors of competitiveness Companies are investing in automation and robotics technologies that have the

potential to meet LCC labor cost levels in any location. • Outsourcing and offshoring allowed greater profitability in the 1990s by

moving low-skill manufacturing to low-cost countries. In the 2000s, the advantages of offshoring began to shrink as LCC wages rose and

freight costs increased. • Traditional productivity levers have been widely exhausted. The pressure on

companies to find new opportunities to boost productivity. In the 1970s and 1980s, lean adoption was the enabler, with Toyota’s system

widely adopted in Western regions (mostly high-cost countries).• The disruptive technologies of Industry 4.0 hold the promise of smart

factories that are highly efficient and data integrated. • Data is the driver A big data/advanced analytics approach can result in a 20 to 25 percent increase in

production volume and up to a 45 percent reduction in downtime.


US manufacturers are beginning to implement IIoT solutions

• Digitally enabled disruptive technologies will have a significant impact on manufacturing in the next 10 years.

• 35% are currently collecting and using data generated by smart sensors to enhance manufacturing/operating processes

• 70% believe it is important that US manufacturers adopt an IIoT strategy in their operations

• 38% currently embed sensors in products that enable end-users/customers to collect sensor-generated data

• The North American market for IIoT will reach to $599B with a CAGR of 13.1% by 2021

Source: http://www.digitaljournal.com/pr/3103499#ixzz4PWksAVFw, https://www.pwc.com/us/en/industrial-products/assets/big-data-next-manufacturing-pwc.pdf


http://www.digitaljournal.com/pr/3103499#ixzz4PWksAVFw

https://www.pwc.com/us/en/industrial-products/assets/big-data-next-manufacturing-pwc.pdf

The Cyber Security Problem

• Defense contractors throughout DoD's supply chain have been targeted by cyber criminals attempting to steal unclassified technical data.

• Protecting the operational systems of a manufacturing enterprise presents a new and different set of challenges. Technical data must be protected from theft, alteration, and impairment or denial of process control These concerns are especially challenging for small and mid-size manufacturers.

• Manufacturing is consistently one of the most targeted sectors for cyber attack. “Attackers tend to go after systems

that can be successfully compromised, and ICS [industrial control systems] have shown themselves to be a target-rich environment.” McAfee 2012

Over 70% of the attacks examined in 2012 were of low or moderate sophistication. As Verizon puts it, “Would you fire a guided missile at an unlocked screen door?” NDIA, Cyber Security for Manufacturing, 2014


Challenges in implementation of Industry 4.0

• Reliability and stability needed for critical machine-to-machine communication (M2M), including very short and stable latency times

• Need to maintain the integrity of production processes• IT issues that cause expensive production outages• Threat of redundancy of corporate IT • General reluctance to change by stakeholders• Loss of jobs to automatic processes and IT-controlled processes• Low top management commitment• Unclear economic benefits/excessive investment• Lack of regulation, standard and forms of certifications• Insufficient qualification of employees, lack of adequate skill-sets


Industry Readiness for Digital Manufacturing May Not Be As We Thought

• Industry interviews revealed a significant gap in the believed readiness or capability of suppliers to adopt digital manufacturing processes and participate fully in a digitally enabled supply chain.

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Little understanding of what is “Digital Manufacturing”

Most interviewees translate or recreate CAD files, even STEP, without validation or notifying the customer

91% use email to exchange tech data, 23% still use fax, with both methods leading to loss of data fidelity

Very little design collaboration

Limited exchange of production data


I4.0/Smart Mfg./Smart Factory

• Digitally enabled manufacturing is discussed using many terms that all mean something specific, but are quite often used interchangeably by manufacturers, government and academics.


Other Research

• Report on Korean and U.S. industries found “… that, for all manufacturing digitalization’s promise, U.S. manufacturers – especially small- to medium-sized enterprises (SMEs) … have been particularly slow to adopt digital manufacturing practices, with most companies remaining just at the initial stages of smart manufacturing technology adoption”

• Wuest et al. found that “Overall, there is little awareness of Smart Manufacturing and related topics among manufacturing SMEs in WV”

• A DoD study in 2016 provided insight into a number of issues with organizations, albeit government, adopting digital manufacturing/model-based enterprise (MBE) capabilities.

• Mittal, et al., found similar issues with European manufacturers with adoption of Industry 4.0 digital capabilities.


Issues Categories and Sources

Sources• Review a library of past articles, presentations, white papers, and reports (40+)• Interviews• DMDII Data Call• Net-Centric Model Based Enterprise

• Overcoming Key AME Inefficiencies Through Improved MBE Tools and Processes• Systems Engineering Research Center • Workshop Report on MBx: Towards Defining the Components of the Model-Based

Enterprise

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Interoperability

Advanced Manufacturing Vulnerabilities

Analysis

Data Reuse, Communication,

and Archiving

Infrastructure


What does this mean for the Southern automotive industry?

• The world of manufacturing and automotive is changing at a rapid pace.

• If you have not started your digital journey you are already behind.

• If you believe that you can buy your way into digitalization you are mistaken.

• Even if you are on your way to digitalization, your supply chain is probably not.

• There are huge benefits, hidden in your overhead costs, waiting to be discovered.


Questions?

Gregory A. Harris, Ph.D., P.E.Industrial & Systems Engineering

Auburn [email protected]


mailto:[email protected]

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