Improving operational efficiency and Product quality with the help of Internet of Things.

1. IoT in Manufacturing Assignment - 1
Submitted in fulfillment of the requirements of
MMZC449 IOT in Manufacturing
(IoT case study Assignment 1 - )
By
Abhishek Labh
BITS No. 2019ht79017
M.TECH , Sem – 3rd
BIRLA INSTITUTE OF TECHNOLOGY AND SCIENCE,PILANI
WORK INTEGRATED LEARNING PROGRAM

2. Case study 1 – Woodward live
worx case study

3. Introduction –
Founded in 1870 in Loves park IL, Woodward, Inc. Headquartered in Fort Collins,
Colorado,Woodward designs, manufactures, and services energy control systems
and components for aircraft and industrial engines and turbines. The Company's
products and services are used in the aerospace, power generation, oil and gas
processing, and transportation markets, which includes rail, marine, and light and
heavy industrial applications. The company enhances global quality of life and
sustainability using technology that optimizes energy use through improved
efficiency and lower emissions.
Product categories – Engines, Safety System,
Turbines, Power management, Protection Relays .
Presence - Americas, Europe, Asia and the
Middle East
13
Countries
7,540
Members
$2.9
Billion in Sales(2019)

4. Problem Statement -
• To be able to remotely monitor every part of an industrial facility means
and able to vastly improve operational efficiency and product quality.

5. Challenges -
• The major challenges were –
i) Abundance of operational machine data being aggregated from various
systems but lack of process in place to take action as per data.
ii) Automation of manual tasks and data entry.
iii) Anytime a process error occurred and the PLM or ERP systems became
out of sync, Members would have to spend valuable time working to re
sync databases across the organization, greatly impacting productivity.
iv) MES offerings and implementations can take multiple years and will cost
several million dollars.

6. Methodologies/Approach used -
• Woodward choose its existing partnerships and investments to bring
modern technology to the factory without a complete digital disruption.
• They concluded that building upon fully-integrated solutions from PTC in
their manufacturing facilities would be the most cost efficient and
seamless next step.
• They decided to leverage PTC’s ThingWorx Industrial Innovation Platform
as a parallel layer to their existing environment. It offers Industrial
Connectivity powered by Kepware, rapid application development
capabilities, analytics, and support for on-premise or cloud deployment
that make it simple to create a connected solution, deploy at scale, and
realize the business value and impact rapidly.

7. Solution -
• Woodward developed a Manufacturing Information System ,a
manufacturing solution that provides standard work and visual
management in the operations environment.
• Woodward’s MIS is completely integrated with their automated
manufacturing equipment, such as torque wrenches, presses,
laser markers, allowing for seamless communication between machines.

8. Benefits -
• MIS system being used for member’s training certification tracking to
ensure all Members are certified before allowing operations to be
completed. Members are now able to perform calibration tracking, which
stops operations from being completed without calibrated tools.
• Members can now perform calibration tracking, which stops operations
from being completed without calibrated tools . Government compliance
also ensured.
• The automated data capabilities have given Members access to all
information needed, including work instructions and inspection
requirements, tailored to their unique business unit or geography.
• Based on the constant stream of information more informed business
decisions can be taken.
• Improved quality, efficiency and productivity achieved.

9. END of case study 1
THANKS

10. Case study 2 – Complex
Discrete Manufacturing with
Thingworx Analytics

11. Introduction -
• ABC Manufacturing operates 27 global manufacturing facilities,
strategically located throughout the world, to provide direct support and
services in close proximity to the international customers.
• Applicable industries – Equipment & Machinery
• Applicable Functions – Discrete manufacturing

12. Problem Statement-
• To improve factory operations visibility and Intelligence

13. Challenges -
• Two major challenges faced when utilizing the data collected are –
i) First is the size,complexity, and disparity of the data collected that take
lot of man-hours to process and evaluate.
ii) Second is real-time data cannot be put into use due to the nature of data
science analysis.

14. Methods used/Data collected -
Methods used -
• Data Aggregation - Cloud solutions enable aggregation of 'big data' to
automatically detect patterns, anomalies, and flag machines for
maintenance before downtime, manufacturing errors, or yield faults
occurred.
• Remote Device Diagnostics - Real-time status reports enable maintenance
personnel to remotely diagnose the status of a device.
• Data Analytics - Data mining, prognostics, diagnostics, and embedded
intelligence are used to make ABB's production line smarter so that they
can meet their customer's needs.
Data collected -
• Facility Health Status, Humidity, Production Efficiency, Temperature

15. Solution Used -
• ThingWorx Analytics automates advanced and predictive analytics.
Proprietary artificial intelligence and machine learning technology used to
automatically learn from data and discover patterns and build validated
predictive models, and send information to virtually any type of
application or technology.
• Cutting edge technology used.
• Softwares used – i) Thingworx Analytics & ii) Thingworx 8

16. Benefits -
• Particular failure pattern can easily be analyzed based on data available.
• Machine learning technology here used to prevent the errors and faults to
occur again.

17. END of case study 2
THANKS