industry 4.0, big industrial transformation (by paul poelmans & joris vanderschrick)
TRANSCRIPT
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CONFIDENTIAL Template Innovation Day 2017 CONFIDENTIAL
INDUSTRY 4.0: BIG INDUSTRIAL TRANSFORMATIONAn opportunity or another hype ?
Joris VanderschrickBusiness Development Manager Industry
[email protected] +32 (0)473 78 37 67
Paul PoelmansSenior Advisor Innovation & Transformation TechXferESA Technology Transfer Network – Prime contractor
[email protected] +32 479 26 06 99
TRACK 4 - SMART INDUSTRIES
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CONTENT
i4.0 a route to Digital Transformation 4 your Industry
Let’s make it concrete
Conclusion and take-away’s
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INDUSTRY 4.0It’s a another hype, the same old wine in new bottles ?!It’s just an extension on what we already do in operational excellence !It’s only for B2C companies, not for us in B2B or at the beginning of the value chain
It’s an opportunity for growth
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Exponential growth and convergence in IT technology
WHAT’s happening !
Moore’s law Ray Kurzweil’s comparison
The emperor and the chess board India 6th century
18.446.462.598.732.800.000
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Some history …
Industry 4.0DigitalTransformation4industry
TRANSFORMING INDUSTRY
40 yrs. evolutioninfrastructurecomputer & network applications
Digital
data algorithmsinternetappscloud
DT4i
interoperabilityinformation transparencytechnical assistancedecentralized decisions
project in German’s high-tech strategy to promote digitalization of manufacturing
2012
GlobalisationDisruption
AdidasUberairbnbKodak
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i4.0 original infograph 2012
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DT4i motivators !?
TREND
MOTIVATORS
COST ↘ REVENUE ↗‘new future’ BUSINESS
TRANSFORMATION
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It will disrupt your business ! How? When? Who?
• How will future processes / plants look like? • New feeds? waste, bacteria's, insects, ….• What unexpected players will enter your market?
• Operator Management industry in gas industry ?!• Waste industry entering chemical industry ?!
• What skills will be needed?• What about stakeholders?• …
Sooner then expected, also our business might be disrupted as UBER disrupted the taxi industry
Head of Corporate Innovation Evoniksept. 2017
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READY TO RE-INVENT THE FUTURE?Impact DT4i
Nancy DuarteTED speaker - WriterThe future is not a place you go,
it’s a place you invent
Existing ! Well known !
NEW SHORT TERM OPPORTUNITIES !!!
NEW LONGER TERM OPPORTUNITIES !!!
Asset Management
R&D Supply Chain
Processing
Digital DrivenInnovative
Operational Excellence
Digital DrivenInnovative
Operational Excellence
CustomerInteraction
SmartProducts
New Innovation
Models
New BusinessModels
LeanOperational Excellence (OE)
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Verhaert’s concrete DT4i transformation opportunities
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LET’s MAKE IT CONCRETEDIGITAL DRIVEN INNOVATIVE OPERATIONAL EXCELLENCESOME INSPIRATION
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SOME RECENT TOPICS IN THE MARKET
We have squeezed out the last ms during SMED exercises, we want to turn totechnology to further optimize (automize) the manufacturing plant.
Automize very specific handling in production lines
Automize manual operations
We want to master a new or complex manufacturing process & related risksWe want to master a new technology & related risks
Before the production line upscaling, build & installation
We want to improve our energy consumption
We want to improve our supply chain
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BOTTOM UP APPROACH TO DIGITALIZATION
Measure # Physical Parameters of the product in process machineryMeasure # process parameters
Data Analytics: Find use for the gathered sensor data
Duplicate & connect
Cyber Security
• Optimize supply chain• Optimize logistics• Optimize production process
(Plant of fleet level)
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IOT PLATFORMS OPTIMIZING THE SUPPLY CHAIN
Control supply chain
TOOL AVAILABILITY ↗ TECHNICIAN TRAINING COSTS AND TIME ↘
• Connecting machines in different phases of the value chain allows to optimize production in function of use , trends and behavior
System data of all beer dispensers of ABInBev distributed worldwide is collected centrally and after processing it including unstructured data (social, geographical, cultural …) it allows to:
• Feed the supply and logistics management system• Rapidly detect operational malfunctions• Feed a dashboard with the consumption of beer in any dispenser,
anywhere in the world, allowing to trace consumption profiles according to social and geographical location.
IN-LINE INFORMATION ↗ MAINTENANCE VARIABILITY ↘
A Telemetry system was developed for Coca-Cola Company which monitors remotely all vending machines of its new prototype, spread all over the world.Verhaert created the entire online infrastructure that allows to access remotely all machines enabling to solve problems anywhere in the world. The online portal also allows to view information graphically and intuitively anytime, anywhere.All data such as temperature, sales and operational problems are displayed in real-time and accessible via any internet enabled device.
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BIGGER OPPORTUNITIES THROUGH SENSORS & DATA ANALYTICS
Data miningPredictive analyticsMachine learningStatisticsClassificationForecastingPattern recognitionVirtual sensors
Giving added-value to sensor data
New opportunities
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CONDITON-BASED MONITORING & PREDICTIVE MAINTENANCE
Condition monitored maintenance programs envisage to
• Improve downtime• Increased effectiveness• Reduced maintenance cost• Reduced spares inventory
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FLAVOUR OF DATA ANALYTICS
Prognostic Health Management (PHM)
To predict health state by combining :
Sensor dataPhysical modelHistorical information
• It derives the features of the data based on training (no labeling of known faults, nor pre-processing to enhance known fault characteristics)
• Universal and rapidly applicable to any piece of equipment
Anomalies detection• Diagnose a fault as early as possible
• Differentiate unknown faults from known nominaland fault behaviour. Decrease false alarms
• Early, non obvious fault detection
• Prognose remaining lifetime (confident guess)
Neural networks have the ability to learn, from training data
Store information as patternsExtracting features
Used inSignature analysisInvestment analysisProcess control
Where can neural networks be used in?Where no algorithmic solution is availableWhere we can get lots of examples of the behaviour we require
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CONFIDENTIAL APPLIED IN:
Electrical motorDetect robustly anomalies in measurements from a range of sensors detecting electrical current, vibration, etc.No engineering model available
Diamond grinderAs the diamond and the diamond powder based grinding wheel have equal hardness, the system needs to detect which one is wearing fastest. Additionally the system needs to warrant the diamond due to stress is not going to shatter into small pieces
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CONFIDENTIAL APPLIED IN:
Small oil cooler fan mounted on military equipment
Early and robust detection of a trend to failureSingle mounted accelerometer sampled over 20secUsed as trend detector and alarm signalVery sensitiveVery low false alarm rate
Single accelerometer identifying anomalies in gearbox used as trend detector
Gearbox behaves differently in almost eachhelicopterEliminates subjective interpretation of experts
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RTRT (Real-Rime Release Testing) IN PHARMA
• Integrated advanced process control and PAT tools enable monitoring during production
• Approve by FDA that you can clear It based on sensor data & analytics
• Real-time release
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CO-MODELLING AUTOMIZING OPERATIONS
• Connecting the physical with the embedded world
• Machine learning: Train algorithm to make It reliable
• Own co-modelling platform: DESTECS
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EXCAVATOR FOR DREDGING
Performance highly dependent on operator skillsGoal:
• Increase performance and decrease down time
• Develop ‘smart’ controller:
o Prevent overloads
o Semi-automate digging task
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ANALYTICS & ROBOTICS FACILITATING AUTOMATED HANDLING
UNLOADINGNEW PROCESS
LINESTACKING
STACKING
• Container with materials in # different options of positioning & # shapes
• Difficult handling (surfaces) • Place on trolley • Transport to process line
AUTOMATED PROCESS LINE
• Chemical process notproven to work yet
UNLOADING
• QA check• Load on trolley
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AUTOMATED HANDLINGSTRATEGY
STACKING
Recognizecomplex shapes &
positioning &
Separate
NEW PROCESS LINE
UNLOADING
= + -
=
=Robotics
+
Machine building
+ =
+Robotics
=
-=
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SOME INSPIRATIONDIGITAL DRIVEN NEW GROWTH PLATFORMS
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INTEGRATION
SOME CASES
Converging and connected technological solutions
NEW GROWTHPLATFORM
Pushes corporates to go and explore challenging but unknown business opportunities and treats
Connected Products
Connected Operations
& Machines
Connected Services
Connected Demand
Connected Value Chains
Connected Logistics
Connected Factories
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Conclusion
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Impact DT4i
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Nancy DuarteTED speaker - WriterThe future is not a place you go,
it’s a place you invent
BE PREPARED AND
Existing ! Well known !
NEW SHORT TERM OPPORTUNITIES !!!
NEW LONGER TERM OPPORTUNITIES !!!
Asset Management
R&D Supply Chain
Processing
Digital DrivenInnovative
Operational Excellence
Digital DrivenInnovative
Operational Excellence
CustomerInteraction
SmartProducts
New Innovation
Models
New BusinessModels
LeanOperational Excellence (OE)
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Strategy
Business
Technology
User centricity
TRANSFORMATION FRAMEWORK
Designthinking
Digital & datasciences
Business modelinnovation / servitization
3D printingAdvancedmaterials
IoT &sensors
Robotics &autonomous
platforms
Early uservalidation
(User)co-creation
Behavioralchange
Roadmap
Accelerated by open innovation and technology transfer
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Other external Challenges
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SECURITY
Ready to open your production capability ? Hackers, Privacy, IP of customers
RELIABILITY and STABILITY
For critical machine-to-machine communication Protect INDUSTRIAL KNOWHOW
Maintain INTEGRITY of PRODUCTION PROCESSES
Avoid any IT snags, as those would cause expensive production outages
Unknown future (black swan’s)
Lack of ADEQUATE SKILL-SETS
Threat of redundancy of the corporate IT department
General reluctance to change by stakeholders
CULTURAL CHANGE
Connection & Agility
Social IMPACT
Loss of many jobs due to automatic IT-controlled processes, especially for lower educated employees Union’s
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Questions / Remarks
thank you !
Paul Poelmans
JorisVanderschrick
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Innovation Day is an initiative of Masters in Innovation, the umbrella brand of the Verhaert Group which aims to connect, train and accelerate professional innovators.
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