smart, safe and sustainable manufacturing
TRANSCRIPT
Copyright © 2009 Rockwell Automation, Inc. All rights reserved.
Smart, Safe and
Sustainable
Manufacturing
John BernadenEfficient Enterprises: Powering American Industry
September 25, 2009
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Federal R&D and the U.S. Economy
• American science and engineering innovations underpin our economy
• Science and technology investments drove between 50 to 85 percent of
U.S. economic growth over the past half-century
• Two-thirds of productivity gains in recent decades attributable to
scientific and technological advances
• Federal R&D funding is half the 1970’s
rates as a percent of GDP
• Applied research funding declined
40 percent from 1990 to 1998; and
is 30 percent behind basic science
Manufacturing innovation especially needs applied research
Federal R&D Funding
Engineering/Physical Science
0
0.05
0.1
0.15
0.2
0.25
0.3
1970 1980 1990 2000 2009
Perc
en
t o
f G
DP
Source: American Physical Society of Public Affairs
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ContinuousBatch Motion Drive
Discrete
Smart Manufacturing 1.0: Islands of Efficiency
Safety
3
Today, most plants use multiple separate manufacturing technologies
Combined
Heat &
Power
(CHP)
Energy-efficient
MotorsDistributed
Control
Systems
(DCS)
Programmable
Logic
Controllers
(PLC)
Smart
Machines
Copyright © 2009 Rockwell Automation, Inc. All rights reserved. 4Copyright © 2009 Rockwell Automation, Inc. All rights reserved.
ContinuousBatch Motion Drive
Discrete
Smart Manufacturing 2.0: Plant-wide Integration
Safety
4
Essential first step to the connected enterprise
Industrial
Energy
Management
Ethernet/IP
• ACEEE estimates +2x energy savings
• Able to measure and manage carbon
footprints per product line
• More flexible, safer and productive
factories in the future
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Smart Manufacturing 2.0: IT-Connected Plants
Supply Chain Distribution
Center
Customer
Business Systems, ERP
Modern, smart factories will be
interconnected via Ethernet/IP with the
supply chain, distribution, customers, and
business systems
an interconnected world… voice, data,
mobile, etc.
Smart Grid
Smart Factory
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Enterprise Business Systems
Customer Relationship Management
Supply Chain Management
Enterprise Production Management
Supply Chain
Distribution Center
Customer
Major Business Benefits
FLEXIBLE: FASTER TIME TO MARKET
OPTIMIZED WITH BUSINESS RISK MGMT
Machine Factory Enterprise
-Simulation / Advanced Control
-Mechatronics
-Autonomous Control
…..-Prognostics
-Software Integration -Safety / Security
-Wireless
-Track/Trace -Analytics / Reporting -Key Process Indicators –Batch Records
HIGHER PRODUCTIVITY / LOWER TOTAL COST OF OWNERSHIP
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Enterprise Business Systems
Customer Relationship Management
Supply Chain Management
Enterprise Production Management
Sustainable Production Benefits
-Smart Grid Ready
-Regeneration
-Clean Power
-Industrial Energy Management
-Environmental Compliance
-Product Safety
OPTIMIZED WITH BUSINESS RISK MGMT
ENERGY EFFICIENT
HIGH EFFICIENCY
ALTERNATIVE POWER
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Manufacturing the Future
• “Intelligent & Integrated
Manufacturing” recommended as
one of three top federal priorities for
manufacturing R&D by the National
Science & Technology Council
interagency working group in
March, 2008.
• European Union is ahead of the
U.S. with an approved 1.2 billion
Euros for a new “Factories of the
Future” research program to
develop and apply advanced
manufacturing technologies.
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Smart, Safe and Sustainable Manufacturing 2.0 is key to several
federal agencies’ ability to achieve their missions:
• Commerce: Helps enable the U.S. to maintain and grow its
leadership in manufacturing
• Energy: Essential to industrial energy management and
“green” manufacturing
• EPA: Carbon footprints for each product
• FDA: Safer foods and drugs and faster recalls
• Labor: Sustainable, safer, green jobs
All these agencies will play an important role in the evolution of Smart, Safe and Sustainable Manufacturing 2.0
Federal Government Benefits
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Significant Potential for Energy Savings
• By 2020, industrial sector will consume 52% of the energy in the U.S. with estimated reduction potential of 18% yielding potential savings of $47b / year (McKinsey, 2009)
• Of the approximately 4 billion kWh electrical energy used per day in industrial operations in the U.S., a 10% reduction during peak demand translates to savings of $6b/year
• Energy management for industrial operations is more complex than for buildings since stopping/starting processes can increase production costs – domain knowledge is required
• Energy management is manual and fragmented in industrial operations today
– Leverage integrated architecture, sensors, and advanced analytics to automate energy management
Potential Peak Load Reduction (MW)
Residential
Commercial
Industrial
Other
Wholesale
0 2500 5000 7500 10000 12500 15000
(2020)*
* McKinsey Report, 2009
“Greenprint” needed for industrial energy management
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Six steps toward the next generation of energy-efficient manufacturing:
1. Facility Energy Monitoring and Demand Management
• Equipment runtime decisions that lower energy consumption / cost
2. Plant Floor Energy Monitoring
• Energy optimization in a manufacturing process
3. Energy on the Production Bill of Materials
• Understand the cost of energy associated with manufacturing a specific product
4. Production Modeling & Optimizing
• Model energy as a process variable utilizing advanced modeling tools
5. Production Demand Management
• Schedule production with energy as a variable (responds to water or electricity restrictions)
6. Demand Response to Regulation
• Respond to external market signals (like the smart grid) to optimize demand to real-time supply
and provide continuous emissions monitoring
Industrial Energy Management “Green Print”S
ense
&M
easu
re
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Public Support for U.S. Manufacturing
82%
70%
Factory automation important to U.S. economic growth
Use stimulus $$ to increase factory automation
42%
U.S. losing its competitive edge
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Call to Action
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• Establish $2 billion in public-private partnership funding to research and develop a manufacturing “greenprint” for Smart, Safe, Sustainable Manufacturing 2.0
• Establish “applied research “demonstration projects in collaboration with manufacturers to refine and improve the “greenprint” model across the five industries with the highest energy intensity –petroleum, chemical, metals, minerals and food processing, to achieve the following:
• Plantwide optimization of resources, including water, compressed air, natural gas, electricity and steam (WAGES)
• Industrial energy management that enables "real-time" inclusion of energy or emissions as part of a product's cost
• A safer working environment for employees
• Safer products and the ability to more efficiently meet federal regulations, especially for faster recall tracking and tracing
• Establish educational and outreach programs about the “greenprint” model for Smart, Safe and Sustainable Manufacturing 2.0