Smart Factory 실현을 위한 접근전략
이창호 박사IBM GBS
Understanding the 4th Industrial Revolution
IBM Capabilities & Offerings
Strategy for Smart Factory Implementation
Selected Client Cases
Understanding the 4th Industrial Revolution
IBM Capabilities & Offerings
Strategy for Smart Factory Implementation
Selected Client Cases
Several initiatives around the global are aiming to bring innovation
and revolutionize manufacturing, creating what is been called the 4th industrial revolution
How Germany is dealing with the fusion of the online world and the world of industrial production. "Those who are the leaders in the digital domain will take the lead in industrial production."
Leading the USA industrial sector transformation into a networked, information-driven environment Providing an open Smart Manufacturing Platform to support real-time, high value applications.
Bringing innovation to the manufacturing process in Korea, expanding the use of smart factories Developing core technologies related to the Internet of Things, 3-D printing and big data
Innovation in Manufacturing 3.0
Transform China from a manufacturing giant into a world manufacturing power. Priorities include improving manufacturing innovation, integrating IT and OT and promoting
service-oriented manufacturing.
France industrial plan to enable the industrial sector for the next industrial revolution. Assist companies in their transformations towards a world where digital is closing the gap between
industry and services.
UK strategic initiative that aims to revitalize the manufacturing industry. Consists of technology and innovation centers that work as gateways to access the best
manufacturing talent and facilities in the country.
New business processes / new business models
Innovative products, applications and services we cannot dream of today
Servicization – from products to service transformation
Major increase in competitiveness for the companies getting it right
IT will be consumed and adopted as a service
Security the enterprise even more complex
Calls for new Privacy laws
Implications
Increase competitiveness of the country
Digitally enabled industrial economy & mass
customization
Vertical and horizontal integration across the
value chain
Convergence and alignment between IT and OT
Cyber-physical systems
Information security, ownership of the data
Mixed human/robotic workforce &
cognitive capabilities
Shorter product lifecycle
Circular economy
Common Themes
Industry
4.0
Autonomous Systems
Internet of Services
Analytics & Cognitive
Flexible Manufacturing
Internet of Things
Ability to connect and manage
devices
Near real-time data collection
Insights of what is happening
New business models
Internet of Things
Flexible machines
3D printing
Machine to machine
Mixed human / robotics
New standards and protocols
Vertical and horizontal integration
Flexible Manufacturing
New delivery channels and business
models
Integrations across value chains
The API economy
Internet of Services
Embedded in equipments, products and
services
Predict what may happen
Prescribe actions for best outcomes
Self learning
Communicate in natural language
Analytics& Cognitive
Smart and networked products
Ability to communicate thru the Internet
Self diagnose / self awareness
Autonomous Systems
Internet of Things is a key enabler, but Industry 4.0 requires other capabilities
Sources: Acatech: Recommendations for implementing the strategic initiative Industrie 4.0,
April 2013;Gartner: Industrie 4.0- The Ten Things the CIO Needs to Know; Deutsche Bank
Research: “Upgrading of Germany’s industrial capabilities on the horizon “, April 2014
Understanding the 4th Industrial Revolution
IBM Capabilities & Offerings
Strategy for Smart Factory Implementation
Selected Client Cases
Device & Network Ecosystem
Programming Platform
Analytics
Security
Connectivity
Engineering Platform
Integration
Variation
Compliance
Applications & Solutions
Industry Transformation
Service & Warranty
Industry Insights New revenue opportunities Increase competitiveness
across the value chain Higher profitability
New Business ModelYour Business
Connect to the IoT device
anywhere to IBM cloud,
ingest, organize and store
information securely.
Make use of information to
start getting real time insights
Handle the complexity of
IoT-enabled devices
Keep devices active and
operational in the field
Extensive library:
Asset Health, Energy Analytics,
Project Analytics, Maintenance
Scheduling, Production
Optimization, Inventory
Optimization, Cognitive
Analytics, etc.
Since 2008, when IBM launched the Smarter Planet Strategy, we have been working with thousands of clients around the globe and have created a very comprehensive set of capabilities to drive the industry transformation
Transformation of the Manufacturing Industry
Example: CPS Asset Health (1 of 3)
CPS Asset Health
Real-time Data Exchange
Equipment (sensor) time-series
Vibrations, temperature, pressure, "speed"
variables (rotational, translational, …), etc.
Positional and/or motion data
Event data – e.g., when an accelerator is
triggered; when gear is shifted
"Alerts" (thresholds breached, etc.)
Real-time Data Exchange
Maintenance Data / Historical Data
Basic asset info (locations, model, age, etc.)
Maintenance-related outcomes Repair history
Preventive & Unscheduled
Fluid analysis
Inspection reports
INSIGHTS
Sub-assembly / component lifetime wear indicators
Leading failure indicators
Engine alerts
Overload / over speed alerts
Example: CPS Worker Safety (2 of 3)
CPS Asset Health
Real-time Data Exchange
Environment-sensing
Temperature
Noise
Oxygen deficiency
Carbon monoxide
INSIGHTS
Sub-assembly / component lifetime wear indicators
Leading failure indicators
Engine alerts
Overload / over speed alerts
Permit to work
Use of safety equipment
Unsafe condition of equipment
Fatigue
Alertness
Fall / Injury
CPS Worker
Accelerometer
Speed-X
Speed-Y
Speed-Z
Bio-sensing
Heart rate
Body temperature
GPS Sensor
Location
Worker equipped with wearables
Real-timeData Exchange
Example: CPS Production Optimization (3 of 3)
CPS Asset Health
INSIGHTS
Sub-assembly / component lifetime wear indicators
Leading failure indicators
Engine alerts
Overload / over speed alerts
Permit to work
Use of safety equipment
Unsafe condition of equipment
Fatigue
Alertness
Fall / Injury
Production real-time status
Equipment utilization
Best time to perform maintenance
Worker productivity CPS Worker
Worker equipped with wearables
CPS Production Optimization
Orders
Customer
Order quantity, price, due date
Production routing
Production data
Production status
Inventory (WIP, FG..)
Equipment status
Workstation status…
Real-timeData Exchange
Real-timeData Exchange
Real-timeData Exchange
Cloud-based, as a ServiceDynamic / Self Configured Processes
Closed LoopCognitive Value Chain / Human Collaboration
CPS-1
CPS-2
CPS-n
Watson
Cloud-based, as a ServicePre-Defined / Automated Processes
Closed LoopHuman Supervision
CPS-1
CPS-2
CPS-n
On- Premise, OwnedProvide insights
Open LoopHuman Required for Action
▲ Specialized Model 1 ▲ Specialized Model 2
IBM Vision & Strategy to realize full potential of
IoT and Industry 4.0
Understanding the 4th Industrial Revolution
IBM Capabilities & Offerings
Strategy for Smart Factory Implementation
Selected Client Cases
Strategy for Smart Factory Implementation
Think about the reason why we need to implement smart factory Future change drivers always comes from customers
Start from your Customers & Markets
There is no one-size-fits all smart factory model to all the plants Every plants need to build their own use cases to cope with the market dynamics
Focus on Use Case & Operational Model
Think big, start small and scale fast!
People
Process
Technology
Design the big picture to harmonize the use cases Build small success cases aligned with big picture.
Think
BIG
Start
Small
Scale
FAST
Smart Manufacturing, IBM’s term for integrating operations, improves visibility and speed and accuracy of decision making
Visibility – know what’s happening
– Digitize everything; measure everything
Smarter Manufacturing speed and accuracy in
decision making
– Improved decision support; Improved collaboration
– Improve prediction and optimization
Smart Manufacturing offers a
customizable strategy and
breakthrough technology based
on an integrated information
framework that allows
connecting aging and newer
facilities, allowing for visibility
across the entire fleet of
chemicals plants
• Health, Safety, Security, Environment (HSSE)• Reliability of equipment and process• Product Quality• Increasing velocity of demands on the plant• Cost control• Energy Optimization / CO2 Minimization• Inherent process complexity – non-linear changes• Margin Maximization – Economic optimization• Address aging workforce, scarce skill sets and increasing reliance on contractors• Address increasing supply chain speed and complexity
Market & Industry Drivers
Requires…
Fundamental misalignments of Plant Operation
Planning and Scheduling (P&S) Decision Time Scales: Days and Weeks
Organization: centralized
Paradigm: Change to follow market
Misalignment 1: between Planning &
Scheduling and Operations Operations and the Real World Decision time scales: real time
Plant dynamics: real time
Organization: Distributed
Paradigm: Stable operations
Operate for Stable performance Stay far away from constraints; reduce alarms
Reduce operational changes
Reduced set of operational parameters
Plant Autonomy Paradigm:Plant meets profit obligations in its own way
High performing plants can reach their full potential
Processes optimized for local conditions and culture
Knowledge transferred via assignment rotation
Global optimization not possible
Operate for Economic Optimum Push the units to their constraints
Flexible operations to meet changing
economics
Increased set of operational parameters
Corporate Standardization Paradigm: Global standardization / optimization
Standard processes and infrastructure reduces
costs and facilitates cross-plant comparisons
Global optimization possible
Misalignment 2: between Operations
Stability and Economic Optimization
Misalignment 3: between autonomous
plants and need for standardization
Decisions not integrated
Sub-optimal plans
Plans not followed
Driving to economic
optimum difficult
Margin maximization and
safety misaligned
Natural “tension” between
two modes
Large gaps between plants
Knowledge transfer
inhibited
Market Dynamics
Market Dynamics
Results
Addressing the fundamental misalignments of Plant Operation
Misalignment 2: between Operations
Stability and Economic Optimization
Misalignment 3: between autonomous
plants and need for standardization
Misalignment 1: between Planning &
Scheduling and Operations
Addressing Misalignment 1Increase accuracy
Increased planning and scheduling model accuracies
Coordinate operations
Controls to unit optimums
Understands unit effects on other units
Faster decisions / more flexible operations
Increased planning frequency
Increased operations flexibility
Addressing Misalignment 2Improve predictions
What-if analyses, on demand
Improved modeling capability
Improve knowledge of the optimum
Local and global optimization
Effect of one unit on others
Improve operations ability to push constraints
Improved process control and RTO
Detailed and consistent “safe production” parameters
Addressing Misalignment 3 Collaborative Environments to establish Best Practices
Standard Performance Measurement systems
Advanced Knowledge Management Systems
Advanced visibility into operations across the enterprise
Addressing the fundamental misalignments of Plant Operation
Plant Operation misalignments Principles of Smart Factory for Operation Model Development
Addressing Misalignment 1
Increase accuracy
Increased planning and scheduling model accuracies
Coordinate operations
Controls to unit optimums
Understands unit effects on other units
Faster decisions / more flexible operations
Increased planning frequency
Increased operations flexibility
Addressing Misalignment 2
Improve predictions
What-if analyses, on demand
Improved modeling capability
Improve knowledge of the optimum
Local and global optimization
Effect of one unit on others
Improve operations ability to push constraints
Improved process control and RTO
Detailed and consistent safety parameters
Addressing Misalignment 3
Collaborative Environments to establish Best Practices
Standard Performance Measurement systems
Advanced Knowledge Management Systems
Advanced visibility into operations across the enterprise
Prediction Make Equipment Smarter via smart sensors and software
Enhance Process Modeling to enable prediction
Visibility Turn data into contextual information leading to quicker, smarter actions
Information available at all levels Enhance visibility throughout
Collaboration Bring the jobs to the experts
Leverage remote expertise
Increase speed of response & reduced cost through virtual presence
Optimization Enhance Process control Leverage existing models
Build additional capabilities to enable unit and refinery-wide optimization on demand
Understanding the 4th Industrial Revolution
IBM Capabilities & Offerings
Strategy for Smart Factory Implementation
Selected Client Cases
Case: Cognitive Engineering & Construction at a Major EPC Firm
CPS Predictive Analytics
Results
Increase bid win rate
Better project estimation
Immediate identification of events that can cause
impacts in project execution
Improved ability to deliver projects on-budget and
on-time
Reduced risks
Eliminate margin erosion
CPS Prescriptive Analytics
Watson
CPS Cognitive Analytics
Suppliers
Purchase Order Status
Production Status
Completion Date
Shipping Status
ETA, Deliver Confirmation
Project Systems &
Historical Data
Materials Management
Project Schedules
Contracts, Documentation
On-going Projects
Project History
Fabrication Yards
Materials Inventory
Fabrication Status
Completion Date
Shipment Status
Shipping Companies
Design Loads
Load Vessels
Track Shipment
ETA
Delivery Confirmation
Construction
Equipment
Equipment status
(empty, loading,
dumping, hauling etc.)
Fuel and tire consumption
Construction Site
Employee safety monitoring
Equipment availability
Material availability
Personnel availability
Resources utilization
Task execution status
Weather Forecast
Weather conditions (e.g., wind,
precipitation, temperatures,
humidity
Historical Data Real-time Data Exchange Real-time Data Exchange Real-time Data Exchange Real-time Data Exchange
Realtime Data Exchange
Case: Cognitive Advisor for Cement Plant Operations
CPS Cognitive Analytics
Results
Expert level support to plants to maximize
performance
Decrease energy cost
Increase production capacity
Eliminate forced shutdown
Decrease maintenance cost
Reduce exposure to knowledge leak
Reduce exposure to critical emergence situation
CPS Real Time Insights
Real Time Local Special
Conditions
Plant maintenance history
Location (climate, ambient
temperature, locally sourced
materials, etc.
CPSMachine Learning
Watson
Ready-Mix Plants Logistics ClientsQuarries Terminals
Cement Plants
Historical Data
Realtime Data Exchange
Real Time Operating Variables
Input materials (granularity, type, humidity, fuel mix, etc)
Operating variables (temperatures, milling times)
Energy consumed
Quality of output material
200 variables
Real-timeData Exchange
Historical Data
Plant Information Documents
Plant processes
Operating manuals
Understanding of machine behavior
(milling time for each type of machine)
Test results (grindability, mineralogy)
Documents
Historical Data
Expert
Expert Knowledge
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