6/11/2020 1 WE DELIVER RESULTS THROUGH DIGITAL TRANSFORMATION An Automotive Digital Transformation Journey powered by the Industrial IoT and Predictive Analytics Isaac Bennett Mo Abuali Director of IT CEO | PhD Industrial Engineer Detroit Manufacturing Systems IoTco 12701 Southfield Rd 250 E. 5TH ST, Suite 1500 Detroit, MI 48223 Riz Pirani Chief Sales Officer Cincinnati, OH 45202 www.dmsna.com/ Mo Abuali Managing Partner www.IoTco.com Isaac.Bennett@dmsna.com Vijay Rangarajan CTO & Senior Advisor Abuali@IoTco.com 2 1
6/11/2020 Our Expertise Clients Domains Practices Industrial IoT IoT Academy Predictive Analytics MES | OEE Software PDX Software Digital Transformation Connectivity and Automation Analytics as a Service Consulting and Training 3 3 Industrial IoT and Predictive Analytics Technology and Use Cases The Journey – Detroit Manufacturing Systems CALL TO ACTION 4 4 2
6/11/2020 IoT | Industrial IoT | Industry 4.0 Digital and Analytics Strategy 5 5 5 5 Industry 4.0 is about combining traditional manufacturing practices with the technological world 6 6 3
6/11/2020 Industry 4.0 Transition Plan Elements Operator Controlled Intervention No Operator Required People Manual (Analog) Reactive (short term) Automation (Digital) Proactive (long term) AI-driven across Technology Process Self Optimizing the value stream People, Process, Technology Profitability 7 7 The Business Case – SMART FACTORY Real Time Data Collection and Visibility • Improve OEE and Uptime • 5 – 20% OEE increase (Overall Equipment Effectiveness) Predictive Maintenance • 5 – 10% Utilization (Uptime) increase Reduce Unplanned Downtime • 10 – 25% Spare Part Reduction Optimize Spare Part Inventory • 5 – 25% P.M. Labor Time Reduction and • Enhance Maintenance Scheduling Eliminating Overhead Maintenance 8 8 8 4
6/11/2020 Industrial IoT and Predictive Analytics Technology and Use Cases The Journey – Detroit Manufacturing Systems CALL TO ACTION 9 9 What’s Your Digital Maturity? EXTERNAL INDUSTRIAL Internet Industry of 4.0 Things Your transformation across the 4 pillars should be a stepped approach beginning with a Proof of Value before embarking on a wider rollout 10 10 5
6/11/2020 Connectivity to the Plant Floor 1 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? Plant Connectivity Audit Machine Connectivity Process 11 11 Metrics in Real Time 2 • 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 12 12 6
6/11/2020 OEE – Overall Equipment Effectiveness 3 • Real-Time • Integrated from Shop Floor (CNC/PLC) to Top Floor (ERP) • Web-based, Mobile-capable • Standardized and Enterprise-wide 13 13 13 Manufacturing Execution 4 • Modular • Advanced Quality, SPC, and Traceability • Out-of-the-box Functionality • Quick Deployment with Templates 14 14 14 7
6/11/2020 Predictive Analytics 5 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 Industrial A.I. Use Cases The Data Lake Solution Templates 15 15 Solution Templates Industrial Machine Casting and Stamping Ancillary Robots Tools Molding Machines Equipment Non-intrusive High-Pressure and Servo-Motor Vibration-based Compressor Performance Low-Pressure Axis Monitoring Fault Detection Monitoring Die Casting Chiller Tool Condition Fleet-based Acoustic-based Peer-to-Peer Monitoring Injection Molding Pump Analytics Analytics Spindle Bearing Performance Motor Monitoring Feed-Axis Gearbox (Ball Screw) Health and Life Prediction Valve Coolant Analysis and Diagnosis Why Solution Templates? Alarm and Fault • “Out of the box” Connectivity and Analytics Mining • Quick Deployment in Weeks • ROI-based Analytics as a Service 16 16 8
6/11/2020 Smart Machine Solution Template Concept Tool Coolant Unbalance Feed Axes System Spindle Gib Bearings 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 ” 17 17 Smart Machine Solution Template Connectivity & Realization 18 18 9
6/11/2020 Industrial IoT and Predictive Analytics Technology and Use Cases The Journey – Detroit Manufacturing Systems CALL TO ACTION 19 19 My Journey Robots Interface Head of IT Smart Factory Automate Detroit Manufacturing Systems Action Sensor • 18 Years IT Experience Data • 9 years in Automotive Analyze Monitoring Tool 20 20 10
6/11/2020 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 21 21 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 22 22 11
6/11/2020 Industry 4.0 Framework The goal is to generate knowledge from data in order to transform the company into a learning, agile organization 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. 23 23 Industry 4.0 – Where Do We Start? • Creating a Compelling Case for Innovation • Creating a Fully Aligned Strategic Innovation Agenda 24 24 12
6/11/2020 Industry 4.0 Maturity Levels 1. Reac�ve Automa�on → Stand-Alone Manufacturing a. Requirements not aligned between plants. b. Individual production steps are automated. 2. Smart Factory → Site Excellence → An�cipa�ng 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 → Collabora�ng 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 → Orchestra�ng a. Large amounts of external data sources i. Product Excellence ii. Foster Innovation iii. Development of new business models iv. Create market differentiation 25 25 IT and OT Convergence 26 26 13
6/11/2020 Breaking Down Silos 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 27 27 PERFORMANCE Analytics 28 28 14
6/11/2020 PREDICTIVE Analytics • Generating Machine “Health” • Predicting “Remaining Useful Life” • Using AI and Machine Learning 29 29 Finding Proof of Value Projects Think Big → Start Small → Prove Value→ Scale Fast Proposal: GAP Analysis Connectivity Options Hardware Sensors Conduct Data Software Findings Pre-Work Workshop Review (Site Visit) Process Services • Reconfirm process documentation • Assemble Team • Assemble proposal, • Review findings with business • Identify the ideal end with current shop floor activities. highlighting required leaders, project sponsor etc. and state, but focus on • Identify plant and secure components, such as determine path forward. • Detailed infrastructure review those areas which will reference material, regarding infrastructure, sensors, achieve a ROI. infrastructure, data and software and services .. • Confirm critical work centers and processes data collection points. • Discuss reporting requirements . Preparation Workshop Execution 30 30 15
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