Smart, Safe and Sustainable Manufacturing

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Mr. John Bernaden

On Friday, September 25th, Alliance to Save Energy hosted “Smart Manufacturing: Modernization to Marketplace,” in the Rayburn House Office Building. This briefing, moderated by the Alliance’s Vice President of Programs, Jeffery Harris, explored the merits of smart technologies—including sensors and wireless controls—in a modern manufacturing environment.

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Smart, Safe and Sustainable Manufacturing

  1. 1. Smart, Safe and Sustainable Manufacturing John Bernaden Efficient Enterprises: Powering American Industry September 25, 2009 Copyright © 2009 Rockwell Automation, Inc. All rights reserved.
  2. 2. Federal R&D and the U.S. Economy • American science and engineering innovations underpin our economy • Science and technology investments drove between 50 to 85 percent of U.S. economic growth over the past half-century • Two-thirds of productivity gains in recent decades attributable to scientific and technological advances Federal R&D Funding • Federal R&D funding is half the 1970’s Engineering/Physical Science Source: American Physical Society of Public Affairs rates as a percent of GDP 0.3 Percent of GDP 0.25 • Applied research funding declined 0.2 40 percent from 1990 to 1998; and 0.15 0.1 is 30 percent behind basic science 0.05 0 1970 1980 1990 2000 2009 Manufacturing innovation especially needs applied research Copyright © 2009 Rockwell Automation, Inc. All rights reserved. 2008 2
  3. 3. Smart Manufacturing 1.0: Islands of Efficiency Batch Continuous Motion Drive Energy-efficient Combined Distributed Smart Motors Heat & Control Machines Power Systems (CHP) (DCS) Discrete Safety Programmable Logic Controllers (PLC) Today, most plants use multiple separate manufacturing technologies Copyright © 2009 Rockwell Automation, Inc. All rights reserved. 3
  4. 4. Smart Manufacturing 2.0: Plant-wide Integration Industrial Energy Batch Continuous Management Motion Drive Discrete Ethernet/IP Safety • ACEEE estimates +2x energy savings • Able to measure and manage carbon footprints per product line • More flexible, safer and productive factories in the future Essential first step to the connected enterprise Copyright © 2009 Rockwell Automation, Inc. All rights reserved. 4
  5. 5. Smart Manufacturing 2.0: IT-Connected Plants an interconnected world… voice, data, mobile, etc. Business Systems, ERP Customer Supply Chain Distribution Smart Center Factory Modern, smart factories will be Smart interconnected via Ethernet/IP with the Grid supply chain, distribution, customers, and business systems Copyright © 2009 Rockwell Automation, Inc. All rights reserved. 5
  6. 6. Major Business Benefits OPTIMIZED WITH BUSINESS RISK MGMT Enterprise Business Systems Machine Factory Enterprise Customer Relationship -Track/Trace -Analytics / Reporting Management -Key Process Indicators –Batch Records Supply Chain Management Enterprise Production Management Customer Supply Chain HIGHER PRODUCTIVITY / LOWER TOTAL FLEXIBLE: FASTER TIME TO MARKET COST OF OWNERSHIP Distribution Center -Simulation / Advanced Control -Software Integration -Mechatronics -Safety / Security -Wireless -Autonomous Control …..-Prognostics Copyright © 2009 Rockwell Automation, Inc. All rights reserved. 6
  7. 7. Sustainable Production Benefits OPTIMIZED WITH BUSINESS RISK MGMT ENERGY EFFICIENT Enterprise Business Systems -Industrial Energy Management Customer Relationship -Environmental Compliance Management -Product Safety Supply Chain Management Enterprise Production ALTERNATIVE POWER Management HIGH EFFICIENCY -Smart Grid Ready -Regeneration -Clean Power Copyright © 2009 Rockwell Automation, Inc. All rights reserved. 7
  8. 8. Manufacturing the Future • “Intelligent & Integrated Manufacturing” recommended as one of three top federal priorities for manufacturing R&D by the National Science & Technology Council interagency working group in March, 2008. • European Union is ahead of the U.S. with an approved 1.2 billion Euros for a new “Factories of the Future” research program to develop and apply advanced manufacturing technologies. Copyright © 2009 Rockwell Automation, Inc. All rights reserved. 2008 8
  9. 9. Federal Government Benefits Smart, Safe and Sustainable Manufacturing 2.0 is key to several federal agencies’ ability to achieve their missions: • Commerce: Helps enable the U.S. to maintain and grow its leadership in manufacturing • Energy: Essential to industrial energy management and “green” manufacturing • EPA: Carbon footprints for each product • FDA: Safer foods and drugs and faster recalls • Labor: Sustainable, safer, green jobs All these agencies will play an important role in the evolution of Smart, Safe and Sustainable Manufacturing 2.0 Copyright © 2009 Rockwell Automation, Inc. All rights reserved. 2008 9
  10. 10. Significant Potential for Energy Savings • By 2020, industrial sector will consume 52% of the (2020)* energy in the U.S. with estimated reduction potential of 18% yielding potential savings of $47b / year (McKinsey, 2009) • Of the approximately 4 billion kWh electrical energy used per day in industrial operations in the U.S., a 10% reduction during peak demand translates to savings of $6b/year * McKinsey Report, 2009 • Energy management for industrial operations is more complex than for buildings since Potential Peak Load Reduction (MW) stopping/starting processes can increase production costs – domain knowledge is required Wholesale Other • Energy management is manual and fragmented in Industrial industrial operations today Commercial Residential – Leverage integrated architecture, sensors, and advanced analytics to automate energy 0 2500 5000 7500 10000 12500 15000 management “Greenprint” needed for industrial energy management Copyright © 2009 Rockwell Automation, Inc. All rights reserved. 10
  11. 11. Industrial Energy Management “Green Print” Six steps toward the next generation of energy-efficient manufacturing: 1. Facility Energy Monitoring and Demand Management • Equipment runtime decisions that lower energy consumption / cost 2. Plant Floor Energy Monitoring • Energy optimization in a manufacturing process 3. Energy on the Production Bill of Materials • Understand the cost of energy associated with manufacturing a specific product 4. Production Modeling & Optimizing • Model energy as a process variable utilizing advanced modeling tools 5. Production Demand Management Measure • Schedule production with energy as a variable (responds to water or electricity restrictions) Sense & 6. Demand Response to Regulation • Respond to external market signals (like the smart grid) to optimize demand to real-time supply and provide continuous emissions monitoring Copyright © 2009 Rockwell Automation, Inc. All rights reserved. 11
  12. 12. Public Support for U.S. Manufacturing Factory automation important to U.S. economic growth 82% Use stimulus $$ to increase factory automation 70% U.S. losing its competitive edge 42% Copyright © 2009 Rockwell Automation, Inc. All rights reserved. 12
  13. 13. Call to Action • Establish $2 billion in public-private partnership funding to research and develop a manufacturing “greenprint” for Smart, Safe, Sustainable Manufacturing 2.0 • Establish “applied research “demonstration projects in collaboration with manufacturers to refine and improve the “greenprint” model across the five industries with the highest energy intensity – petroleum, chemical, metals, minerals and food processing, to achieve the following: • Plantwide optimization of resources, including water, compressed air, natural gas, electricity and steam (WAGES) • Industrial energy management that enables "real-time" inclusion of energy or emissions as part of a product's cost • A safer working environment for employees • Safer products and the ability to more efficiently meet federal regulations, especially for faster recall tracking and tracing • Establish educational and outreach programs about the “greenprint” model for Smart, Safe and Sustainable Manufacturing 2.0 Copyright © 2009 Rockwell Automation, Inc. All rights reserved. 2008 13
  14. 14. Questions? Copyright © 2009 Rockwell Automation, Inc. All rights reserved. Copyright © 2009 Rockwell Automation, Inc. All rights reserved. 14

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