Smart Manufacturing As A Real -Time Networked Information Enterprise

The infusion of intelligence that transforms the way industries conceptualize, design and operate the manufacturing enterprise. Smart Manufacturing as a Real-Time Networked Information Enterprise Jim Davis UCLA/Institute for Digital Research and Education and Tom Edgar UT Austin SMLC (501c6) https://smartmanufacturingcoalition.org http://smartmanufacturing.com

What is Smart Manufacturing? Smart Manufacturing enables all information about the manufacturing process to be available when it is needed, where it is needed, and in the form that it is needed across entire manufacturing supply chains, complete product lifecycles, multiple industries, and small, medium and large enterprises.

Technology Roadmap Report (2009) 1. Motivating Smart Process Manufacturing 2. The Business Case and the Business Transformation 3. The Technical Transformation 4. The Smart Process Manufacturing Roadmap 5. The Path Forward 3

Implementing 21st Century SM Report (2011) Priority actions in four categories: Industrial Community Modeling and Simulation Platforms for Smart Manufacturing Affordable Industrial Data Collection and Management Systems Enterprise Wide Integration: Business Systems, Manufacturing Plants and Suppliers Education and Training in Smart Manufacturing 4

SMLC Program Agenda for a Smart Manufacturing Platform Lower the cost for applying advanced data analysis, modeling, and simulation in core manufacturing processes Build pre-competitive infrastructure including network and information technology, interoperability, and shared business data Establish an industry-shared, community-source platform and associated software that functions as an “apps” store and clearinghouse Create and provide broad access to next-generation sensors, including lowcost sensing and sensor fusion technologies Establish test beds for smart manufacturing concepts and make them available to companies of all sizes

Industrial Gas Manufacturing Steel Energy Bio/Pharma Electronics Healthcare Energy Supply Production and Delivery Customers Our customers demand capital discipline and high reliability Our goal is to meet their demands and maintain high energy efficiency

Smart Manufacturing Helps Meet Our Goals Low cost sensors and wireless enable real time decisions Hosted computing improves results at a lower cost Design Operations Common infrastructure facilitates supply chain collaboration

Machine Operations & Line Management Trade-Offs General Dynamics Machine Function Benchmarking & Integrated Line and Energy Management Managing Power from the Grid

FORD In-Production Virtual Aluminum Castings Target Strength 220 MPa 230 210 Aging at 250C for 3hrs 220 Aging temperature 240C for 5hrs Initial Heat Treatment Process John Allison AIChE 2010 205 Optimized Heat Treatment Process Faster and Stronger !!

General Mills Customers “pushing” demands Farming Tracking & Traceability Supply Chain Manufacturing Plant Distributor Customer

General Mills Networked-Based Manufacturing Intelligence & Collaborative Manufacturing Recipe Management Mapping formula into operating recipes EDI transaction & quality certifications Business Systems, ERP Mapping SAP information Into operation Customer Supply Chain Smart Factory Smart Grid 11 Distribution Center FDA Tracking & traceability Green Light Analyze - to put into production Make – right ingredients – confirmation on recipe Release – meet requirements to release

GM’s ECO System of “ STUFF” Demand Driven Supply Chain Green Light to Ship Allergen/Micro WorkFlow Line Schedule Production Order Demand Plan WorkFlow Production History Plant Floor Inventory Direct Consumption Overusage Trace/Recall BOM Validation Core Functions Bin Mgmt Line Supply Yard Mgmt Directed Work Finished Product Inventory Supplier Managed Inv eCOA Optimization Engine Business Applications Optimized Inventory Raw Mat’l Inventory Green Light to Convert Lot Tracking Value Creation Master Data (BOM,Specs,Vendor,Ingredients,FP) Core Systems Data Input MQIS MES SAP ERP SAP MRP SAP APO SAP PLM Red Prairie

Test Bed Generated SM Systems Smart Machine Operations In production machine-product management Benchmarking machine-product interactions Integrated dynamic management of machine-electrical power interactions Adaptable machine configurations In Production Use of High Fidelity Modeling and Simulation High fidelity modeling for better management Rapid qualification of components and products In Production Decision Making with Global Integrated Metrics Dynamic Business and Operational Tradeoff Decision-Making Dynamic performance management of global integrated metrics Untapped cross factory degrees of freedom for optimizing efficiency and performance and compressing time Supply Chain Management Supply chain variability reduction and management of risk Tracking and traceability

Industry Test Bed Strategy

Industry-Driven Defined from Test Bed systems

The Technical Basis for Collaborative Manufacturing and the SM Platform Challenge 1 Factory and supply chain demonstrations sites of applied manufacturing intelligence Meta 2 Demand-Dynamic Customer to Source Variability Planning Challenge 4 Meta 1 Integrated Workforce, Cyber, Physical System Performance Variability Reduction Benchmarking Challenge 2 Integration of manufacturing enterprise data, control, automation, management and optimization infrastructures Meta 3 Higher Fidelity Production Real-time Qualification Integrated Computational Materials Engineering Materials & Energy Mgmt. Multi-Dimensional Smart Manufacturing Precompetitive and competitive community source modeling innovation & simulation assimilation platform META 4 Interoperable Supply Chain Network Control, Automation, Optimization Management & Decision Challenge 3 Real-time syncing virtual models and physical operations Enabling New & Dormant Technologies

First Concept of the Smart Manufacturing Platform Infrastructure for Real-Time Data Driven Modeling and Simulation SMEs Small & Medium Enterprises SMLC Industry-Driven Integrated Performance Metrics Variability Management Real-time Plan Passes Micro, Meso, Macro Real-time Data & Community Modeling Workflow To& Source & Metric Toolkit/ Resources App Development UCLA Key Development Resources Universities, SME’s Manufacturers, Labs Pre-competitive & Competitive Hub Manufacturing Consortia Apps Store Cloud Services Benchmarking Rapid Qualification ICME Community Source Market Place Test Bed Manufacturer & Supplier Crosslinking Engagements Standards and Reference Architecture IT Providers Real Time Virtual Manufacturing Demonstration Facility 17 (VMDF)

SMLC Partners & Collaboration Roles Test Beds - General Dynamics, General Mills, General Motors, Praxair, Corning, Pfizer, Alcoa, Exxon Mobil, Shell, Air Liquide, RPI/Center for Advanced Technology Systems Design/manufacturing Platform Providers – JPL/NASA, UCLA, Rockwell, Honeywell, Emerson, Nimbis Modeling & Simulation Materials, Design, Manufacturing – Caltech/JPL, NETL, Argonne, UCLA, UT Austin, Tulane, NCSU, CMU, Penn, Purdue Smart Manufacturing/Smart Grid – EPRI Global Performance Metrics – AIChE, ACEEE, Sustainable Solutions Agency partners – NIST, NSF Regional partners - Center for Smart Manufacturing (CA), Wisconsin Manufacturing Institute

Multi-Layer Smart Manufacturing (MLSM) Workflow Foundation Design Data Prototype Materials & Process Tech Macro Layer Product Volume Scheduling Supply Chain APP Store Reference Flows Process Models Control Metrics Conditional decisions Model building &updates Model insertion Product Manufacturing Meso Layer Management Machine Flow Optimization Micro Layer Sensors/Actuators Control/Optimization Automation Qualification In Service People Involved Integrated Metrics & Decision Making Virtual MDSM Host Dash Board Collaboration MDSM Program “Host” Manufacturing Initiatives

Workflow Distinguished from Control & Automation

Process & Line Data Machine Benchmark Data Factory Data Control Automation Factory Workflow General Dynamics Benchmarking Model Workflow Service Framework Process & Line Set Point Conditions Check Table Optimal Machine Usage Calculate Machine, Energy, Product Metric Dashboard Recommend Tradeoff Points Computational Resources Batch Scheduler New Machine Maintenance Process Data Run Machine Usage PatternBased Analyzer Update Machine Usage Model Build Table Optimal Machine Usage Windows Table Model Accepted

Multi-Layered Smart Manufacturing Management (MLSMM) Time Managed as Workflow Not Control Transformational Machines – People - Materials Dynamic Manufacturing Ecosystem Design Data Prototype Materials & Process Tech Product Manufacturing Macro Layer 10s of control loops Control Points - ? Manpower - X Time – days Meso Layer 100s of control loops Control Points - ? Manpower – 10X Time -hours 1000s of control loops Control points Manpower – 100X Time - minutes Micro Layer Qualification In Service Current Practice – One Pass per Day per Event; Too Late, Stale Data, Slow Responsive Manufacturing Goals: 100x Event Variability Adjustment Capability & Dynamic Certification Improvement Focus: Integrated metrics, Qualification, Computational Materials Engineering, High Fidelity Dynamic Operations

The Concept of Data-to-Applications Performance Management Data & Modeling Workflow Process sensor data Ref Arch Data Collection Manufacturer Ref Arch Data Collection Supplier Data and Computation Manufacturer Real-time Management Dashboard Manufacturer Data Warehouse Local/Global Integrated Productivity Metric Dash Board Encrypted links Data Validation App SM Platform Workflow, Data and Computation Services EPM App from Toolkit Linked Apps to Form Function Risk Scenarios App Real-time Action & Risk Support App Reduced Order Model Scenarios App

Major Platform Concepts Multi-Layer Workflows interface with control and automation and factory optimized workflows Real-time is defined by the workflow & actionable objective Data-to-Application instead of Application-toData Workflow as a Service (Wfaas)

Implementation ENGINEERING THE PLATFORM FOR THE USE CASES

Local Web Server Praxair SMR Example Process Data Data Control Automation Proprietary Workflow Process Data Transfer New ROM Transfer Workflow Control Server Data Validation and filtering Local Storage Workflow Service Framework Validated Data CFD Preprocessing CFD Runs ROM Accepted Update ROM using CFD Output Offline Simulation with ROM ROM Validation Rerun ROM Batch Scheduler Computational Resources

SMLC Concept Workflow as a Service (WfaaS) Factory Data Control & Automation Workflow Proprietary Workflow Workflow (WFaaS) Provisioning Orchestration Tasking State Security Provenance Application Instances

WfaaS Integrated with SaaS, PaaS, IaaS Workflow (WfaaS) Factory Data Control & Automation Workflow Proprietary Workflow Provisioning Orchestration Tasking State Security Provenance /UCLA Services Technical Computing Marketplace Buyer/User (SaaS) Buyer Dashboard Buyer Catalog Portal Apps Seller/Provider (PaaS) Seller Dashboard Dev Tools Software Images Application Instances Compute Platform (IaaS) Cycles Software / Licenses Storage

Nimbis Secure Cloud Portal Architecture Data and Application Management Foundation Web Browser / Desktop Application Nimbis Ecommerce Subsystem (NES) URL Dispatcher Template Caching View Model Asynchronous Task Queue Tasks HTTP / REST / SOAP Compute Platform HTTPS / SSH VPN / VNC Database Message Queue Nimbis Broker Subsystem (NBS) Browse, Configure, Price, Purchase OAuth-OpenID Compute Provider Interface (CPI) License Manager Job/Session Management Resource/License Metering Remote Access Node PBS Application Images Shared Storage Nimbis Services Inc. Proprietary

Open Architecture Workflow Construction & Management

SM Platform Apps Store, Shared Market Place & Distribution Hub Multiple Service Environments