watson iot - ibm · watson iot comes to you 6th october 2017 iot for manufacturing 1 1 watson /...

WatsonIoTComesToYou 6thOctober2017

IoTforManufacturing 1

Watson / IoT for Manufacturing / October 6th 20171

IoT for Manufacturing

Ton van Velzen, IBM (solution architect)

WatsonIoT


IoT driven digital disruption of the manufacturing value chain is what brings us to transformation initiatives such as Industry 4.0

Digital transformation of production processes and systems that create new opportunities to achieve levels of productivity and specialization not previously possible

Industry 4.0 benefits:

• Versatile production process

• Higher specialization towards specific client needs

• Increased competitiveness across the value chain

• Ability to create new markets by establishing new services and business models




Cognitive Manufacturing applies cognitive capabilities to digitize and optimize previously inaccessible areas of manufacturing processes

collected manufacturing and enterprise data

Smarter Factory

Operations

Smarter EnergySmarter

AssetOperations

SmarterProductDesign

Smarter Employee

Safety

Smarter Quality

made into a transparent, comprehensive,

interactive, minable corpus of information

that makes visible new patterns in the data

to continuously monitor, predict, respond and

interact with humans and machines

To deliver

SmarterEquipment

Maintenance


Gather the dataVisualize the patterns

Advance to analytics

Infuse with cognitive

Embracing Industrial transformation with cognitive through logical steps of value

• Instrument your equipment/assets to collect data

• Gather already existing data

• Visualize your data in meaningful dashboards

• Start to see patterns• Build with Bluemix

• Gain insights from the data

• Produce models, prediction recommendations

• Refine models with cognitive machine learning

• Utilize other cognitive functions to improve engagement

Asset needs to be connected, outfitted with sensor or data gathered

Use analytical models to predict equipment failures and provide recommendations

Use the platform to quickly build dashboards for data visualization

Use speech, video, image to diagnose complex problems




IBM$Watson$IoT$Platform

Intelligent assets and equipment

Cognitive processesand operations

Smarter resource and optimization

Primary Use Case Asset Performance Management

Primary Use CaseManufacturing Performance & Quality

Primary Use CaseResource Optimization

Business MetricReliability, Downtime

Business MetricYield, Productivity

Business MetricSafety, Cost

34%Decrease in equipment downtime at

major global auto manufacturer

25%Increase in overall productivity at major

European automaker

8%Annual saving in energy cost at IBM

facilities

Intelligent assets and equipment utilizes IoT and cognitive capabilities to sense, communicate and self-diagnose issues so they can optimize their performance and reduce unnecessary downtime

Cognitive operations and processes bring more certainty to business by analyzing a variety of information from workflows, context and environment to drive quality, enhance operations and decision-making.

Utilize IoT and cognitive insight to optimize resources (worker, energy, expertise) using geolocation data, individual data, usage data and environmental conditions along with analytics.

Prebuilt Predictive and Prescriptive Industry Models

Cognitive Processing of Structured and Unstructured Data

Personalized Learning based on User Engagement

IBM Watson IoT for Manufacturing focuses on driving improved performance and value to three fundamental pillars of manufacturing operations


Intelligentassetsandequipment

Cognitiveprocessesandoperations

Smarterresourceandoptimization

IBM Watson IoT for Manufacturing focuses on driving improved performance and value to three fundamental pillars of manufacturing operations

Prescriptive Maintenance

Plant Performance Analytics

IoT Equipment Advisor

Prescriptive Quality

Prescriptive Warranty

Visual Inspection for Quality

Safety Analytics (coming soon)

Edge IntegratedTap into our ecosystem to find the

right edge or fog gateways for simple rules and filtering

Utilize manufacturing bus and MQTT messaging for advanced

rules and better integration MessageSight Integration Bus

AssetTap into our first mile shop floor integrators to connect to PLCs

and shop floor specific protocols

IBM Watson IoT Platform

IntelligentassetsandequipmentutilizesIoT andcognitivecapabilitiestosense,communicateandself-diagnoseissuessotheycanoptimizetheirperformanceandreduceunnecessarydowntime

Cognitiveoperationsandprocessesbringmorecertaintytobusinessbyanalyzingavarietyofinformationfromworkflows,contextandenvironmenttodrivequality,enhanceoperationsanddecision-making.

UtilizeIoT andcognitiveinsighttooptimizeresources(worker,energy,expertise)usinggeolocationdata,individualdata,usagedataandenvironmentalconditionsalongwithanalytics.

Plant Advisor

Predictive Maintenance and Optimization




Estimated ranges of benefits of Predictive Maintenance

maintenancecosts

unexpectedfailures

repairandoverhaultime

sparepartsinventory

uptime

costofunplanneddowntime

assetlife

maintenance costs

equipment downtime

capital investments

0%-50% +50%

PlantEngineer’sHandbook- KeithMobleyNucleusResearchROIworkdonewithIBMMcKinsey&Co.TheInternetofThings:MappingtheValueBeyondtheHype


PredictiveMaintenanceandOptimizationexampleapplication




IntegrationBus

End-userReports,Dashboards,Drill-downs

AnalyticDatastore

Predictive&StatisticalAnalytics

DecisionManagement&Optimization

Reporting&Dashboarding

EnterpriseAssetManagementSystemHigh-volumeStreamingData

Telematics,ManufacturingExecutionSystems

LegacyDatabases,DistributedControlSystems

MasterDataManagement

Predictive Maintenance and Optimization architecture


Physical & 3rd

Party Models (Optional)

Ad Hoc DashboardsData Science Tooling &

Authoring

IBMAna

lytics

Platform

Apps

EAM

DataSou

rces

Optimization System

Platform Services

IBMPredictiveMaintenance&Optimization

Math Rules

Optimization

ReportsCustom Applications

Predictive System

SOP Alarm & Alerts

Models Prediction & Forecasting

Text Analytics Feature Extraction

Integration ( Real time and Bulk load)

HortonWorks Data Platform for IBM

DataLakeSpark MapReduceOperationalDataStore

SCADA

SDK

BI SystemReports

Ad-hoc Query

Client Applications

Hosted/ On-premise

Client Systems

Vibration data analytics

Material prognostic analytics

WeatherService

Cloud services

Operation Engineer Engineering Manager Analyst

Stakeh

olde

rs

Users

Reliability Engineer

Historian MES

Watson IotPlatform(Optional)

Cognitive System

Content Insight

Data Insight

Visual Insight

Speech Insight

Partner ServicesIoT

Emotional Insight

Predictive Maintenance and Optimization big picture




Usage in various Industries along with demonstrated benefits

97% ability to predict delays & cancellations within 12 weeks aviation – analysis of terabytes of jet engine performance data

87% accuracy within 48-hour regarding potential equipment failures

oil & gas exploration - identify situations that lead to equipment outages; improve production forecast

45.5% ¯ in unplanned maintenance steel – analyze production data; detect impending machine malfunctions; implement preventive maintenance

$44M+ savings from reduced maintenance

aviation - reduce # of tail rotor gearbox removal maintenance procedures34% accuracy predicting machine failures 2+ hours in advance

automotive – analyze robotic assembly line failure data

30% chiller efficiency

electronics – assess operational parameters that lead to sub-optimal performance


Utilize purpose driven advanced analytics dedicated to industrial use cases or generate custom analytical models with Predictive Maintenance and Optimization

IBM Watson IoT for Manufacturing

Manufacturing Analytics

Plant Performance

AnalyticsPrescriptive Maintenance

Prescriptive Quality

Prescriptive Warranty

• Prebuilt industry models• Role specific user interface

• Proven algorithms• Cognitive extension

• Packaged analytics tools• Custom build and

execute models• BI customizable interface

Predictive Maintenance and Optimization




ImageAnalytics

Enablesmonitoringofunstructureddatafromimagessnapshotstoidentifyqualitydefectsandfailurepatterns

MachineLearning

Automatesdataprocessing,identifies thebestmodelforthedata andcontinuouslymonitorsnewdatatolearnandimproveresults

Textual Analytics

Enablesminingoftextualsourcestofindcorrelationsandpatternsin structuredandunstructuredtextsuchaslogsandnotes

AcousticsAnalytics

Utilizesaudioasanadditionalsourceofunstructureddatatoenableanomalydetectionandpatternrecognition

EquipmentAdvisor

VisualInspectionforQuality

AudioInsights

PlantAdvisor

Begin the journey to cognitive manufacturing with use case driven application for value


IBM Visual Inspection for Quality utilizes deep learning to improve quality processes• New offering in the IBM IoT for Manufacturing solution suite• Cognitive capabilities classifies product image against defect

patterns • Quickly identify and classify defects in manufacturing process• Works in conjunction with IBM Prescriptive Quality • Optional integration with the IBM Watson IoT Platform• Available NOW

passfail




IBM IoT Equipment Advisor delivers Cognitive Prescriptive Insights

Equipment Advisor consumes varied sources of data and provides insights & visualization for problem diagnosis and resolution to help technicians identify the right repair

Watson, through interaction with Field Technicians, learns over time to become an expert on the specific equipment

Aggregated Data Views

Cognitive Learning Point of Impact Insights

Watson Explorer (WEX)PMO

Equipment Advisor Solution Components


IBM Plant Advisor optimizes throughput, energy cost and quality in Process Manufacturing Plants

Physical ManufacturingOperations

Process Automationand Control

Ø On-line Operator Actions

Ø Real time Process Inputs

Ø Real time Process Outputs

Ø Maintenance History

Ø Historical Operators Actions

Ø Historical Process Inputs

Ø Historical Process Outputs

Historian Systems

Continuously learn from all dataAugments operator performance

Captures and retains company expertiseEnables manufacturers to achieve high performance

IBM Plant Advisor

Optimize KPIsOffers the flexibility to optimize costs, quality, throughput, or any identified variable at any given point in time

Recommend ActionsProvides meaningful recommendations at appropriate intervals which the operator can implement or reject

Optimize ProcessesCan be trained and applied in multiple plant processes

Link Actions to PerformanceOffers a closed-loop mechanism to link specific actions with actual performance and predict outcomes




IBM Plant Performance Analytics

TransactionsEAMCMMProduction Plan

Cycle timePositionalParametricEvents

ISA 95 Info Model

Industry Analytical Models

Pred

ictio

ns Probability of Occurrence

Time to Occurrence

Root Cause

Probable Time to Recover

Issue prediction

Recommended Repair PlanRecommended Action

Pres

crip

tions

Plant Operational Effectiveness (OE)

OvertimeMaintenanceMaterial

Integration


Overall Equipment Effectiveness (OEE) of Manufacturing Plants is Impacted by 3 Big Losses

IBM Plant Performance Analytics predicts potential OEE losses, prescribes remedies, and maximizes OEE

bottleneck – machine # 1 is delaying production

Downtime loss

Quality loss

Performance loss




Differentiating elements of Watson IoT technology and ecosystem

Partnered InnovationOpen ecosystemDevice partnershipsEmbedded securityEdge Analytics

Data IntegrationWeather dataSocial dataApplication dataPlatform of platforms

Advanced AnalyticsPredictive AnalyticsReal-time AnalyticsData MiningOptimization

Cognitive TechnologyNatural Language ProcessingMachine LearningTextual AnalyticsVideo/Image Analytics

Critical differentiators• Partnered Innovation – Edge Analytics and IoT Connectivity Integration

• Cognitive Technology – Unstructured data analysis and insights

• Advanced Analytics – Purpose driven and Industry specific models


Thank you

watson iot - ibm · watson iot comes to you 6th october 2017 iot for manufacturing 1 1 watson /...

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