Future of Nondestructive Testing

Industry 4.0/Smart Manufacturing Disrupting Established Products,

Technologies and Business Models

Mariano Kimbara

Measurement and Instrumentation

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2

Focus Points—Agenda

• Understanding Industry 4.0

• The next Industrial Revolution is Around

the Corner

• The Vision

• Industry 4.0 and the NDT Industry

• Industry 4.0 Disrupting NDT

• Transformational Implications

• Smart Inspection

• Permanent Monitoring

• NDT Services 2.0

• Conclusion

Understanding Industry 4.0

4

Understanding Industry 4.0—The next Industrial

Revolution is Around the Corner

Industrial Market Evolution, 1800-2020

Year

Deg

ree

of

Co

mp

lex

ity a

nd

Ris

k

1800 2020 1900

High

Low

2000

1760s—1900

Use of steam and mechanically

driven production facilities

Industry 1.0

The steam

engine

1990—1970s

Electric Power driven mass

production based on division

of labor

Industry 2.0

Henry Ford’s

T-Model 1970s—Now

Extensive use of Controls, IT and

Electronics for an automated and

high productivity environment

Industry 3.0

IT-OT

Convergence

Future

Smart: based on integration

of virtual and physical

production systems

Industry 4.0

/IoT/IIoT

Cyber-physical

Production

Systems

5

Understanding Industry 4.0—The Vision

Industry 4.0

Technology

Processes

Collaboration

Wireless Intelligence

Big Data

Cloud Computing

Industrial Internet of Things

Integrated Industries

Social Innovation

IP Centralisation

Internet of Services

Sustainable Manufacturing

Lifecycle Assessment

• Mechanized Process

• Mass Production

• Production Automation

Industrial Revolution

1.0 – 3.0

• Production Innovation

• Increased Collaboration

• Operational Process Enhancement

• Cyber-Physical Production

Industrial Revolution 4.0 Pursuits

• Convergence of applications resulting in transformational advancements

• Energy efficiency and sustainability to gain greater business focus

• Greater presence of mobility and web-based information systems

Strategic Trends

The Industry 4.0 Business Ecosystem Industry 4.0 and NDT Industry

Industrial

Automation

ICT Vendors

Sensors, RFIDs

NDT Industry

Digital

Manufacturing

Virtual Reality

Advanced Analytics

The Industry 4.0

Ecosystem

Telecom Providers

Control

Systems

Motors &

Drives

PLM

Machine Tools

Key Attributes of the Industry 4.0

Ecosystem

Combined synergies of core NDT industry,

ICT, industrial automation technologies

supported by sensing for better tracking

Enterprise level quality process management

level software fostering high degree of

innovation across the value chain

Strategic shift in business approach towards

automation and monitoring driven by end-user

need for asset management

Ubiquitous

wireless

sensors

Production

tracking

The age of Industry 4.0 will reinvent

competitive dynamics across multiple

industrial verticals. The result will be a

grand new ecosystem where a mix of

companies from different background, co-

operate, co-opt and compete with each

other

Source: Frost & Sullivan

Robotic inspection

Robotic inspection

In Line NDT

7

Industry 4.0 Disrupting NDT

Cloud Computing Robotics Big Data Analytics

Smart Inspection NDT Services 2.0 Permanent Monitoring

Key Technological Pillars of Industry 4.0

Industrial Internet of

Things

Transformational Implications

Transformational Implications

9

Smart Inspection Real-time convergence of digital technology platforms with existing NDT techniques to give

rise to the smart inspection ecosystem where end user productivity is the central theme

Smart

Integrated

Testing

MiRA

Onsight

Connect

Smart

X-ray

Digital Technology

Platforms

Nondestructive Testing

Techniques

Visual

Inspection Augmented

Reality

Wearable

Computing

Ultrasonic and

Eddy Current

Testing

Robotics

Virtualization

Analytics

Radiography

Testing

Cloud

Computing

Cyber-physical

Systems

M2M

Real-time

streaming Remote

Collaboration

The vision of Smart Factories or Smart Manufacturing

will form the basis for an advanced Smart Inspection

ecosystem with new innovations enabled by

emerging disruptive digital technology platforms.

Despite evolving end-user needs, ROI or

productivity gains will push the adoption of

this advanced Smart Inspection ecosystem

where industry convergence and

collaboration will be central to success.

Potential New Product Innovation Existing Product

Key

10

Permanent Monitoring Convergence of condition monitoring and industrial automation with NDT technologies gives

rise to permanent monitoring because of inherent challenges in the NDT industry

Pre 2000s Early 2000s Post 2010

Periodic tests using PIGs,

ultrasonic scanners and

thickness gauges

Utilizing advanced sensor

technology through to monitor

assets

Periodic Testing Periodic Monitoring Continuous Corrosion Monitoring

Utilizing ubiquitous permanently installed

wireless sensor to not only monitor assets but

also detect small changes in pipeline wall

thickness, operate remotely, and send data

wirelessly to analysis stations.

Condition

Monitoring NDT

Industrial

Automation

Challenges:

•Lack of skilled technicians

•Aging workforce

•Increasing complexity of testing

•End-user demand for predictive

maintenance and preventive

maintenance

Permanent

Monitoring

11

NDT Services 2.0 The next generation of NDT services to transition from just inspection to engineering

decisions delivered from a remotely located office which houses NDT engineers (experts)

NDT Services 2.0: Vector of Business Transitions in the Service Landscape

NDT Services 2.0: Service Evolution for

the Future of NDT

Evolution from only

inspection services to

NDT inspection and

engineering services

1. Functional Core Strategic Partnerships

Forging relationships for

advanced service

capabilities with ICT

networking, communication

and analytics companies

Evolution from

field services to

remote services

2. Delivery Innovation

Time frame for Impact

(Years)

0

2

4 6

8

10

“If we can link simulation, rendering of assets in 3D with the data analysis and

report that–that’s a very powerful tool to work with. It will take time but we are

moving in that direction already”

- A pioneering company in the test and inspection business

Time frame for Impact

(Years)

0

2

4 6

8

10

Inspection and

Engineering Services Remote Services

Conclusion—The Last Word

13

What does this mean for NDT?—3 Big Predictions

2 While historically innovation has been incremental in the NDT

industry, going forward the model will be disruptive innovation

3 Organizations need to adapt and embrace the disruptive

business ecosystem to be relevant in the next 10 years

1

The current business model for NDT inspection services is

increasingly coming under threat and will change over the next

years.