IOT and Digital Manufacturing The new evolution Alexis Malchair Solutions Sales Manager, Internet of Things June 2016
Digitization Trends Across Major Industries Where is the value Unconnected 50 Billion Connect the Smart Manufacturing Grid Modernization Shopper Insights Smart Connected Devices by 2020 Hyper-connectivity, IT and OT convergence Smart Cities Connected Transit Smart Space Over 60% of the IOT value will be generated in Enterprise deployments IoT Enabling Transformation <1% of data currently used, more can be used for optimization and prediction TRANSFORM BUSINESS ENABLE NEW BUSINESS PROCESSES MODELS Interoperability across silo’ed systems Higher productivity by predictive Create recurring revenue models maintenance and better asset utilization with increased customer intimacy required to capture 40% of IOT value Source - McKinsey: The Internet of Things: Mapping The Value Beyond The Hype
IoT: The Internet of Things Processes & integration ACT CONTROL AUTOMATE Analytics & insights Connectivity Sensors
“The network will play a crucial part in how we develop the car; gathering data, learning from it and adapting will ultimately determine our season.” Christian Horner Team Principal, Infiniti Red Bull Racing
A New Industrial Revolution Digitizing Manufacturing to Capture the Value of the Internet of Everything Technology Smart Progress Devices 70’s 20 th Century Today 18 th Mass Production Digitization Century Robots Steam Digital Manufacturing Priority Investments #1 Analytics | #2 Connectivity | #3 Automation | #4 Mobility Source: SCM World/Cisco “Smart Manufacturing & the Internet of Things 2015” survey of 400 Manufacturing Business Line Executi ves and Plant Managers across 17 vertical industries.
Design principles for Industry 4.0 • There are 6 design principles 1. One open standard for communication 2. Virtualization and simulation models of production 3. Flexible and decentralised control 4. Capability to collect, process and store data in real time 5. Service possibillities over the network 6. Modular and flexible production for fast adoption and small seriespå produkt
Digital Manufacturing Driving Business Outcomes Reduction in Improved New Product Reduced Reduction in OEE Energy Use Inventory Introduction Downtime Defects Improvement 18% 35% 23% 48% 49% 16% Annual energy Inventory New product Unplanned Defect rate Average OEE cost down from turns increased introduction cycle downtime down down from improved $8.4M from time reduced from from 11% 4.9% from to $6.9M 14 to 19 15 to 11 to 5.8% to 2.5% 74% to 86% The Real Economic Value is Immense Source: SCM World/Cisco “Smart Manufacturing & the Internet of Things 2015” survey of 400 Manufacturing Business Line Executives and Plant Managers across 17 vertical industries.
Disruptive Trends in Manufacturing Convergence (industry 4.0, Industrial Internet Consortium) • Network integration between machine and factory • Factory network integrates with the enterprise network • Single network platform Increased focus on Services by OEM’s • Customer demand for high availability and uptime • Take control of after market for parts and tools • Remote connectivity and monitoring to reduce service costs • Zero touch deployment and provisioning Data Driven Manufacturing • TQM: Real time quality control with in-line re-work • Real time operator visibility with OEE alerts from OEM • Flexible cell manufacturing, rapid re-tooling Secure Operations and Machines • Operations needs IT to address security • Security strategy drives new business and partnership models • Framework approach to address organization boundaries Convergence Cloud Services Manufacturing Data Security Smart Industry
IOT Standard topology 9
Cisco Validated Ethernet Architecture Internet Enterprise/IT Integration Collaboration Enterprise Network Levels 4 – 5 Wireless Application Optimization Web Apps DNS FTP Patch Management Terminal Services Application and Data share Application Mirror AV Server Gbps Link for Failover Demilitarized Zone Detection Access Control (DMZ) Firewalls Firewall Cisco (Standby) ASA 5500 Threat Protection Firewall (Active) Site Operations and Control Manufacturing Zone Cisco Catalyst Cisco Multi-Service Networks 6500/4500 Catalyst Level 3 HMI Switch Network and Security Management Scada Distribution and Core Application Servers Routing Network Services Cisco Cat. 3750 Switch Stack Ethernet/IP, Profinet or any standard Ethernet protocol HMI Controller Real – Time Control Cell/Area Zone Layer 2 Access Switch Levels 0 – 2 Drive HMI Fast Convergence Layer 2 Access Controller Traffic Segmentation and Management Drive Drive HMI Distributed I/O Distributed I/O Managed switches Controller Cell/Area #1 Cell/Area #2 Cell/Area #3 (Redundant Star Topology) (Ring Topology) (Linear Topology)
Supply chain
Factory IT in a Box Backup & Backup & Replication Replication Centralized Management Core Data Center Cloud Fog-Edge
Connected Machine service model Machine as a Service Zero Down Time like Services Machine monitoring Condition based Monitoring green light, New OEM services models w/ SLA’s utilization, Connected Machines Machine, Process, & Quality Optimization OEE Rapid Provisioning Advanced Analytics streaming analytics IT/OT Interface, security Manufacturing Plant Cloud or Data Center IoT Platform Plant embedded/cell Systems Plant Distribution Network IT/O /OT, , Security, ity, NAT 1 Persiste sistent Secure Utilizat izatio ion Connect ction OEE Transa sactio ction/S /Str treaming Machine ine Applica cation (ZDT DT, , Advance ced Quality ity Monito itoring, Advance ced Analyt ytics) cs) Plant Level Network Hosted Systems OPC MTConnect IoT SW OEM Plant Data Center Agents MES Perimeter Perimeter Data Store SW/HW 1:1 machine Quality FW FW Applications Machine 1:1 cell OEE DPI DPI Analytics Adapter 1:1 Plant Policy Policy Visualization
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