The Killer IoT Apps in Manufacturing

© 2013 Cisco and/or its affiliates. All rights reserved.
1
The Killer IoT Apps in Manufacturing:
Achieving Plant Downtime Reduction
Tony Shakib, VP, CISCO IOE Vertical Solutions Group
October 14-16, 2014 • Chicago, Illinois
In Industrial Segments, Downtime Reduction is the Killer IOT App
Mining
Manufacturing
Utilities
Single day of
stoppage costs
Single minute of
downtime costs
Annual theft
or loss costs
$5M
$22K
$1B
© 2013 Cisco and/or its affiliates. All rights reserved.
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The Killer IoT Apps in Manufacturing: Achieving Plant Downtime
Reduction
 Strategies How to Transform the Speed to See & Resolve Causes of
Downtime
 Today and Tomorrow Solutions Implemented and Business Outcome
 Overcoming Challenges: Business, Technical, & Change Management
 Analytics and Data Explosion
What to do with the data
How much data is being generated
How to analyze & make sense of all the data
© 2013 Cisco and/or its affiliates. All rights reserved.
Cisco Confidential
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The Killer IoT Apps in Manufacturing: Achieving Plant Downtime
Reduction
Jason Tsai, Ph.D.
General Manager
Product Development
FANUC Robotics
Todd Lucey
General Manager
Sales Center USA
Endress+Hauser
Blake Moret
Senior Vice President
Control Products & Solutions
Rockwell Automation
© 2013 Cisco and/or its affiliates. All rights reserved.
5
The Killer IoT Apps in
Manufacturing: Achieving Plant
Downtime Reduction
Jason Tsai, Ph.D., GM Product Development, FANUC Robotics
October 14-16, 2014 • Chicago, Illinois
CNC | ROBOT | ROBODRILL
FANUC
FANUC is based at the foot of Mount Fuji covering 1.5
million square meters
Per month production capacity
•30,000 CNCs
•250,000 Servo Motors
•5,000 Robots
•5,000 ROBODRILLS
•250 CO2 Lasers
Using over 2,000 robots in our own production
© 2013 Cisco and/or its affiliates. All rights reserved.
FANUC America Corporation CONFIDENTIAL - Not To Be Re-Distributed In Any Form
7
FANUC Core Technology
> 250,000 robots installed
worldwide
> 12.7 million servo motors
installed worldwide
> 2.4 million CNCs installed worldwide
> Leading supplier of small machining centers, electric
injection molding machines and wire EDMs
© 2013 Cisco and/or its affiliates. All rights reserved.
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Zero Down Time Initiative
• Customers production facilities are operating at high volume and Unexpected downtime creates
considerable consequences, and the strategies using IOT are :
– Proactively detect and inform a potential robot, controller, or process problem before unexpected
downtime occurs.
– Provide predictive maintenance to extend the mechanical life and reduce maintenance cost
Motion/Mechanical
Health
Process
Health
System
Health
Maintenance
Reminder
ZDT Data Base
© 2013 Cisco and/or its affiliates. All rights reserved.
9
The Killer IoT Apps in
Manufacturing: Achieving Plant
Downtime Reduction
Todd Lucey, GM Sales Center USA, Endress + Hauser
October 14-16, 2014 • Chicago, Illinois
The Endress+Hauser Group After 60 Years:
The Killer IoT Apps in Manufacturing -- Endress + Hauser
•
A family owned company
•
Presence in 40+ countries with own Sales Centers and Additional 70 countries by independent
reps.
•
Manufacture in 11 countries at 19 different locations.
•
2013 turnover of 1.85 billion Euro ($2.5 billion)
•
Just over 10,000 associates
•
Approx. 70% equity ratio
• Invest 10% of sales in R&D each year; an additional 10% invested in manufacturing
and automation annually
• More than 400 patents issued in last two years
Endress + Hauser/Todd Lucey
© 2013 Cisco and/or its affiliates. All rights reserved.
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Overall Strategy: Use Technology and Data Analytics to
Shorten Project Cycle and Improve Asset Utilization
Plant optimization
Plant performance/availability
Predictive diagnostics System
Driver
Performance monitoring
Quality /Metrology
Driver
: DCS, PLC/SCADA
: Process Control
Process Mgmt
Target availability/efficiency
: CMS (Calibration)
Unlocking The Value
: Quality
Quality Mgmt
Process Manager
System
: MES, EMS (Energy)
Driver
: Efficiency
Diagnostics
System
Operator
37 Million Installed HART Devices – Fewer Than 25%
System
Are Utilizing Digital Data
Unexpected failures Driver
Build
Engineering, Procurement,
Energy
Mgmt
Install/Commission
Shorter time
Maintenance
Operate & Maintain
Safety
: SiS (Safety)
: Safety, Reliability
Safety Mgmt
Logistics
Systems
: PAM, CMMS (Asset)
System
: ERP (Material Management)
Driver
: Reliability, Availability
Driver
: Delivery, Flexibility
High availability and plant performance
Inventory Mgmt
Asset/Life Cycle Mgmt
Endress + Hauser/Todd Lucey
© 2013 Cisco and/or its affiliates. All rights reserved.
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The Killer IoT Apps in
Manufacturing: Achieving Plant
Downtime Reduction
Blake Moret, SVP, Control Products & Solutions, Rockwell Automation
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October 14-16, 2014 • Chicago, Illinois
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Delivering the Connected Enterprise
Talent and Technology
Technology Innovation
Domain Expertise
Scalable Computing
Remote Experts & Services
Mobility
Workforce Efficiency
Secure Network Infrastructure
Network & Security
Consulting & Design
Multi-discipline
Control & Information
Automation Design Expertise
Smart Assets
Deep Application Knowledge
© 2013 Cisco and/or its affiliates. All rights reserved.
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The Killer IoT Apps in
Manufacturing: Achieving Plant
Downtime Reduction
Jason Tsai, Ph.D., GM Product Development, FANUC Robotics
October 14-16, 2014 • Chicago, Illinois
ZDT Production Examples
Server
PLC
Web Reports
Servo Gun Diagnosis
ITV Diagnostics
Z
D
T
Turbine, shaping
Eliminate Down Time
ZDT
ZDT
ZDT
Motor torque monitoring
• Results/Status from the robot’s ZDT
suites are regularly transferred to server.
• Reports will be generated on a per robot
basis.
• Notifications sent to cell PLC, Server, or
Applicator
smart phone
Diagnosis
air regulator
Motor
Evaluation
Axis: 5
Units: Q_Current
Caution: 6.0
Alert : 8.0
Robots
RV Reducer
Reducer
Condition monitoring
Torque
Condition Canister
Monitoring
Motor torque monitoring
Motor Evaluation
Axis: 5
Units: Q_Current
Caution: 6.0
Alert : 8.0
© 2013 Cisco and/or its affiliates. All rights reserved.
16
The Killer IoT Apps in
Manufacturing: Achieving Plant
Downtime Reduction
Todd Lucey, GM Sales Center USA, Endress + Hauser
October 14-16, 2014 • Chicago, Illinois
Products
Solutions
Services
Example: Process Reliability Program
Improve Asset Utilization, Lower Operational and Life Cycle Costs, and
Reduce Risk
10/16/2014
Endress + Hauser/Todd Lucey
The Killer IoT Apps in Manufacturing -- Endress + Hauser
Data Analysis – Operating within Control Limits
In-Cell
Top Scrubber
Deviation (pH)
Deviation (pH)
0.60
2.00
0.40
1.50
1.00
0.20
0.50
0.00
0.00
0
0
-0.20
-0.50
20
10
20
40
30
40
60
50
80
60
100
70
80
90
120
100
-1.00
-0.40
-1.50
-0.60
-2.00
Time Between Calibrations (Days)
Time Between Calibrations (Days)
• Calibrations
Redundant sensors
and maintenance
behaving similar
must be
inbrought
same application
in <90 days
environment.
to stay within
Control
operating
• Calibrations and maintenance can be extended OR control limits tightened.
parameters.
limits
can be set by loop and viewed over multiple time horizons.
Endress + Hauser/Todd Lucey
© 2013 Cisco and/or its affiliates. All rights reserved.
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The Killer IoT Apps in Manufacturing -- Endress + Hauser
Program Milestones
 No safety incidents at either of the hub locations! (Hub #1 - 4295/ Hub #2 5321, safe man hours for 2013 through September)
 Electrolyzer Six Sigma study – exceeded expectations with 1.13 sigma
improvement compared to the 1.00 sigma target ($300K/yr)!
Overall
 Additional analysis increases related savings to $3.5MM/yr!!!
Field Data and Associated Analytics Provide the Platform for
- decreases
impurities in the product
Improvedchlorate
Business
Decisions
- debottlenecks downstream chlorine recovery system
- reduction of treatment chemicals used (caustic/sodium bisulfite)
• Additional yield of chlorine and energy cost savings have also been
realized but not yet quantified.
Endress + Hauser/Todd Lucey
© 2013 Cisco and/or its affiliates. All rights reserved.
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The Killer IoT Apps in
Manufacturing: Achieving Plant
Downtime Reduction
Blake Moret, SVP, Control Products & Solutions, Rockwell Automation
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October 14-16, 2014 • Chicago, Illinois
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© 2013 Cisco and/or its affiliates. All rights reserved.
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