An Automotive Digital Transformation Journey powered by the - - PDF document

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An Automotive Digital Transformation Journey

powered by the Industrial IoT and Predictive Analytics

WE DELIVER RESULTS THROUGH DIGITAL TRANSFORMATION

Riz Pirani Chief Sales Officer Mo Abuali Managing Partner Vijay Rangarajan CTO & Senior Advisor Mo Abuali

CEO | PhD Industrial Engineer IoTco 250 E. 5TH ST, Suite 1500 Cincinnati, OH 45202 www.IoTco.com Abuali@IoTco.com

Isaac Bennett

Director of IT Detroit Manufacturing Systems 12701 Southfield Rd Detroit, MI 48223

www.dmsna.com/

Isaac.Bennett@dmsna.com

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Our Expertise

Domains Practices

Predictive Analytics PDX Software

Analytics as a Service

IoT Academy Digital Transformation

Consulting and Training

Industrial IoT MES | OEE Software

Connectivity and Automation

Clients

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Technology and Use Cases Industrial IoT and Predictive Analytics The Journey – Detroit Manufacturing Systems CALL TO ACTION

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IoT | Industrial IoT | Industry 4.0

5 Digital and Analytics Strategy

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Industry 4.0 is about combining traditional manufacturing practices with the technological world

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Industry 4.0 Transition Plan Elements People Process Technology

Manual (Analog)  Automation (Digital)  AI-driven across the value stream Operator Controlled  Intervention  No Operator Required Reactive (short term)  Proactive (long term)  Self Optimizing People, Process, Technology  Profitability

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• Real Time Data Collection and Visibility
• Improve OEE and Uptime

(Overall Equipment Effectiveness)

• Predictive Maintenance
• Reduce Unplanned Downtime
• Optimize Spare Part Inventory
• Enhance Maintenance Scheduling

5 – 20% OEE increase 5 – 10% Utilization (Uptime) increase 10 – 25% Spare Part Reduction 5 – 25% P.M. Labor Time Reduction and Eliminating Overhead Maintenance

The Business Case – SMART FACTORY

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Technology and Use Cases

Industrial IoT and Predictive Analytics The Journey – Detroit Manufacturing Systems CALL TO ACTION

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What’s Your Digital Maturity?

INDUSTRIAL EXTERNAL

Internet

• f

Things

Industry 4.0

Your transformation across the 4 pillars should be a stepped approach beginning with a Proof of Value before embarking on a wider rollout

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Connectivity to the Plant Floor

Manufacturing data is the foundation to achieve ROI from IIoT and continuous improvement programs.

• Is the machine capable of communicating on the plant network?
• What will it cost to add network communication capability?
• How long will it take?
• How much data is available from the machine?

Machine Connectivity Process Plant Connectivity Audit

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• IIoT Technology leverages Plant Floor Connectivity from “Shop Floor to Top Floor”
• Performance Metrics: TRUE OEE Metrics for Plant-Level and Enterprise-Level Benchmark
• Predictive Analytics - Asset Health, Prediction, and Diagnostics

Metrics in Real Time

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OEE – Overall Equipment Effectiveness

• Real-Time
• Integrated from Shop Floor (CNC/PLC) to Top Floor (ERP)
• Web-based, Mobile-capable
• Standardized and Enterprise-wide

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Manufacturing Execution

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• Modular
• Advanced Quality, SPC, and Traceability
• Out-of-the-box Functionality
• Quick Deployment with Templates

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One minute of unplanned downtime can cost tens of thousands of dollars.

Predictronics (PDX) takes the guesswork out of production and maintenance planning, replacing it with accurate predictions that allow for a worry-free process.

Predictive Maintenance

• Asset Health
• Remaining Life
• Diagnostics

Predictive Quality

• Part Health
• Defect Prediction

Predictive Analytics

Industrial A.I. Solution Templates The Data Lake Use Cases

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Industrial Robots

Servo-Motor Axis Monitoring

Machine Tools

Non-intrusive Performance Monitoring Tool Condition Monitoring Spindle Bearing Performance Monitoring Feed-Axis (Ball Screw) Health and Life Prediction Coolant Analysis and Diagnosis

Stamping Machines

Vibration-based Fault Detection

Ancillary Equipment

Alarm and Fault Mining Fleet-based Peer-to-Peer Analytics Acoustic-based Analytics Pump Motor Gearbox Valve

Why Solution Templates?

• “Out of the box” Connectivity and Analytics
• Quick Deployment in Weeks
• ROI-based Analytics as a Service

Chiller Compressor

Casting and Molding

High-Pressure and Low-Pressure Die Casting Injection Molding

Solution Templates

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17 Tool Unbalance Spindle Bearings Feed Axes Gib Coolant System

• PREDICTIVE MAINTENANCE - Prognostic templates for each critical component is

available to generate an overall Machine Tool Health Index (MTHI)

• PREDICTIVE QUALITY – Critical components to be monitored were selected to

ensure Near-Zero Defects and “First Part Correct”

Smart Machine Solution Template Concept

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Smart Machine Solution Template Connectivity & Realization

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Technology and Use Cases Industrial IoT and Predictive Analytics

The Journey – Detroit Manufacturing Systems

CALL TO ACTION

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My Journey

Robots Interface Automate Action Analyze Monitoring Tool Sensor

Data

Smart Factory

Head of IT Detroit Manufacturing Systems

• 18 Years IT Experience
• 9 years in Automotive

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DETROIT MANUFACTURING SYSTEMS At A Glance

– Founded in 2012 – Joint Venture with Faurecia – Plants in Detroit and Toledo – World-Class Tier 1 Component Manufacturer

• Value-add Assembly JIS / JIT
• Injection Molding – 30 Machines

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The Digital Transformation Journey

• Plants are at different maturity levels
• Some plants have MES systems some don’t
• Departments don’t collaborate
• Data is either not gathered or not used
• No standard solution for data collection

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Industry 4.0 Framework

The goal is to generate knowledge from data in order to transform the company into a learning, agile

• rganization and enable rapid

decision-making and adaptation processes throughout every part of the business and across all business process areas. The acquisition of this agility provides companies with a significant competitive advantage in a disruptive environment.

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Industry 4.0 – Where Do We Start?

• Creating a Compelling Case for Innovation
• Creating a Fully Aligned Strategic Innovation Agenda

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Industry 4.0 Maturity Levels

• 1. Reacve Automaon → Stand-Alone Manufacturing

a. Requirements not aligned between plants. b. Individual production steps are automated. 2. Smart Factory → Site Excellence → Ancipang a. Intelligent Production Automation b. Asset Performance c. Preventative Maintenance d. Product Quality Improvement e. Energy Management 3. Connected Plants → Integrated Manufacturing Network a. Scaling smart factory to multiple plants. b. Improve resource allocation. c. Improve agility towards customer and market needs. 4. Connect Global Value Chain → Collaborang a. Integrate manufacturing with end-to-end supply chain processes. b. Use additional external data sources for prediction and decision making. c. Identify potential new business functions. 5. Connected Global Ecosystems → Orchestrang a. Large amounts of external data sources i. Product Excellence ii. Foster Innovation iii. Development of new business models iv. Create market differentiation 26

IT and OT Convergence

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Think Big → Start Small (Fail small) → Prove Value→ Scale Fast

Data Collection, Connectivity and Reporting is the Foundation

• MES Replacement and Implementation (JIT, JIS)
• Connecting data across the manufacturing operations
• Production, Quality, Maintenance, Inventory
• Data Collection from Injection Molding
• Reporting and data visibility, Alerting
• Predictive Maintenance
• Predictive Quality

Breaking Down Silos

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PERFORMANCE Analytics

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PREDICTIVE Analytics

• Generating Machine “Health”
• Predicting “Remaining Useful Life”
• Using AI and Machine Learning

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• Assemble Team
• Identify plant and secure

reference material, regarding infrastructure, data and processes Sensors Data

Pre-Work Findings Review Conduct Workshop (Site Visit)

Process

• Review findings with business

leaders, project sponsor etc. and determine path forward. Preparation Workshop Execution

• Reconfirm process documentation

with current shop floor activities.

• Detailed infrastructure review
• Confirm critical work centers and

data collection points.

• Discuss reporting requirements.
• Identify the ideal end

state, but focus on those areas which will achieve a ROI. GAP Analysis Proposal: Connectivity Options

• Assemble proposal,

highlighting required components, such as infrastructure, sensors, software and services.. Hardware Software Services

Think Big → Start Small → Prove Value→ Scale Fast

Finding Proof of Value Projects

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Technology and Use Cases Industrial IoT and Predictive Analytics The Journey – Detroit Manufacturing Systems

CALL TO ACTION

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Call to Action

 Start your Digital Transformation Journey Today - Think Big, Start Small  Make it Operational with a Proof of Value  Achieve a Smart Connected Factory with Zero-Downtime and Zero-Defect Vision  Leverage Smart Connected Products with Analytics  Find your Weak Link: People, Process or Technology Benefits only accrue as far as the weakest link  CALL TO ACTION:

IoTco would like to offer select PMA Members a complimentary Digital Transformation Assessment. Schedule your 30-min call discovery call today.

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Mo Abuali, PhD

Managing Partner – IoTco Email: abuali@IoTco.com Phone: +1 (513) 813-8777 Office: 250 E. Fifth Street Cincinnati, OH Twitter: @IoT_co LinkedIn: https://www.linkedin.com/company/iot-co/

Thank You for Your Attention. Q&A.

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