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Technology Convergence Enabling Factories of the Future


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- To learn about possible technology convergence scenarios that will lead to innovative solutions.
- Identify the key enabling technologies for a smarter factory
- Find out potential opportunities for new product developments by adopting emerging technologies

Published in: Technology

Technology Convergence Enabling Factories of the Future

  1. 1. Technology Convergence Enabling Factories ofTechnology Convergence Enabling Factories of the Futurethe Future Smart and Sustainable Manufacturing key for Industrial Revolution 4.0Smart and Sustainable Manufacturing key for Industrial Revolution 4.0 Sumit Kumar Pal, Research Analyst Technical InsightsTechnical Insights 10 April, 2014 © 2014 Frost & Sullivan. All rights reserved. This document contains highly confidential information and is the sole property of Frost & Sullivan. No part of it may be circulated, quoted, copied or otherwise reproduced without the written approval of Frost & Sullivan.
  2. 2. Today’s Presenter Functional Expertise • Detailed oriented analytical and research skills which includes market and technology analysis within the Automation and Electronics domain. • Generating research service reports and technical alerts. Industry Expertise • Experience base covering a broad range of sectors, leveraging long-standing working relationships with leading industry participants’ Senior Executives in • Sensors • Microelectronics 2 What I bring to the Team • Technical expertise in Electronics and Instrumentation • Strong Problem Solving and Analytical Skills • Presentation Skills Career Highlights Research Associate in Automation & Electronics – Technical Insights group of Frost & Sullivan since April 2012 Education Post Graduate Programme in Business Management from Praxis Business School, Kolkata, India Bachelor of Technology from Future institute of Engineering and Management, West Bengal University of Technology, Kolkata, India Sumit Kumar Pal Research Analyst Technical Insights Frost & Sullivan GIC Chennai
  3. 3. The Industrial Revolution Timeline 1st Industrial Revolution 2nd Industrial Revolution 3 Industrial Revolution 1818thth CenturyCentury 1919thth CenturyCentury 2020thth CenturyCentury 3 2025 3rd Industrial Revolution Industry 4.0 2020 CenturyCentury 2121stst CenturyCentury Focus on Cyber- Physical Systems
  4. 4. Agenda Factories of the Future – Focus on 3P’s Smart, Connected & Virtual factories Key DriversTechnology Enablers 4 Convergence Scenario Notable Developments & initiatives Global Footprint & Funding Scenario Impact on Megatrend Future Factories – 2025 Outlook Technology Convergence and Innovation Opportunities
  5. 5. Factories of the Future Focus on 3P’s – People, Process, Production Customization Decrease in Production Time Workforce Management Condition Monitoring People Process Production 5 Plant-wide Optimization for Manufacturing Intelligence Flexibility Reduce Wastage Worker Safety Collaboration Workforce Management Supply Chain Management Plant and Enterprise wide Integration Predictive Diagnostics Condition Monitoring
  6. 6. Progressive Outlook of Future Factories Smart, Virtual & Connected Factories Smart Factories • Maximize Resource Utilization • Sustainable Manufacturing • Reconfigurable Processes and Systems • Minimal Downtime • All devices are connected to each other 6 Connected Factories Virtual Factories • All devices are connected to each other • Components include Sensors, Actuators, Transducers, Controllers, Display, Computers, Workstations • Integration with Business Decision Making • 3D Modelling of Entire Plant • Access to all processes from a workstation • Real world simulation prior to implementation
  7. 7. Key Driving Factors Towards Realization of Smarter Factories Short Medium Long Comments Sustainability •Efficiency, Waste Reduction, Energy Consumption reduction Flexibility •Shorter Product life cycles •Multiple products in the same factory Drivers 7 Flexibility •Multiple products in the same factory Low Downtime •Non stop production to maximize output Return on Investment •Smart factories promise high ROI even though capital investment can be high HighLow Medium Impact
  8. 8. Technology Enablers ICT – A Key Enabling Technology ICT – A Key Enabling Technology Sensors – The Source of Data • Big Data •Cloud Computing •Augmented Reality •Wireless Communication •Visualization •WSN •Smart Sensors • Condition Monitoring Sensors (Vibration, Temperature, etc) •Machine Vision Electronics •Processors •Microcontrollers •LED •MEMS •Displays Advanced Manufacturing •Mobile Robots •Collaborative Robots •Additive Manufacturing 8 •Machine Vision •RFID •M2M Communication •Remote Monitoring •Real Time Information •Virtual Factory •Condition Monitoring •Process Monitoring •Product Testing •Product Tracking & Accountability •Internet of Things •High Performance Terminals •Demand based lighting •Human-Robot Collaboration •Rapid Prototyping
  9. 9. Convergence Scenario 1 The Power to Remotely Control a Plant Using Your Hands Augmented Reality Big Data Analytics Cloud Computing Data ServerData Server Industry Initiatives British Oxygen and Linde have ventured into Wireless monitoring of process plants located in remote locations Ubiquitous Wireless Sensors 9 Remote Monitoring of the Industrial Plant Highly reliable, fool proof sensors and data communication will be made a possibility in the next 6-7 yearsSmartness and Greenness Prevails in setting up Industrial Plants (Infrastructure) facilitated by: • Efficiency in Plant Management • Personnel-Free Location Monitoring • Downtime Reduction • Safety • Reduction in Operational Expenditure 2013 20202014 2016 2017 2018 20192015 YOI – 2019-2020
  10. 10. Convergence Scenario 2 Demand based Lighting: Energy Savings by Switching Off Light When Not Needed Microchips Occupancy Detection Sensors 10 Communication Technology Demand Based Lighting on the Work floor
  11. 11. Convergence Scenario 3 Condition Monitoring Using Self-Powered Wireless Sensor Networks Energy Harvesting Sunlight/Thermal /Vibration 11 Sensors Condition Monitoring Using Self-Powered Wireless Sensor Networks
  12. 12. Notable Developments & Initiatives Cisco Connected Factory Designed for industrial applications Complete IT integration (OT and IT) Rockwell Automation: Factory Talk® Services Platform Integration of Factory Floor Live Data Central Administration of Key Functions Multi-vendor ConnectivityIntel Collaboration with Cologne University of Applied Sciences and Computacenter Developing Solutions for Smart IT Infrastructure Siemens Siemens electronics factory in Amberg, Germany 12 Infrastructure Ford Motor Company Plans to enable more flexibility and reduce downtime Adoption of advanced techniques such as 3D printing LG CNS: Smart factory Solution Provides one-stop services from factory design consulting to software/hardware establishment and operation Optimizes the entire software-based factory Siemens electronics factory in Amberg, Germany PLM Software Virtual Simulation of Machines Intelligent control of Manufacturing Process Hidalgo: BlackGhost ISAW Worker monitoring solution Integrates real-time worker health data, sensor data and other information
  13. 13. Global Footprint & Funding Scenario Europe Focusing Heavily on Factories of The Future North America Europe APAC • Funding for Smart manufacturing not as • 150 R&D Projects under the 7th • JSCA (Japan Smart Community Alliance) 13 Intensity of Technology Development & Adoption Very High High Medium Source: Frost & Sullivan manufacturing not as intense as Europe • Major scope in Automotive manufacturing under the 7th Framework Programme • Factories of Future Project of EU • Indicative budget within Horizon 2020: EUR 1.15 billion Community Alliance) established in 2010 • Focus in Public-Private Partnership and University collaborations • Developments in the field of Smart manufacturing prominent in South Korea
  14. 14. Impact on Megatrends Highest Impact on ‘Innovating to Zero’ Smart is the New Green Connectivity and Convergence Innovating to Zero Medium Term Long Term Medium Term Long Term Medium Term Long Term 14 • Reduction of negative impacts to zero levels • Companies to shift focus and develop products that “Innovate to Zero” • E.g. Zero Emissions, Zero breaches of security, Zero Defects, and so on • Convergence of Products (E.g. Electric cars) • Convergence of Industries (E.g. Healthcare IT) • Convergence of Technologies (E.g. Smart Home Hub) • Intelligent Sensing Technology • Smart Products replacing Green Products • Smart products being connected to the internet • Products react and communicate to changing environments, optimizing operations, and improving efficiency
  15. 15. Future Factories – 2025 Outlook Flexible Manufacturing Zero Defect Products Near Zero Downtime Remote Control of Multiple Products on Same Production Line Accurate production technologies as well as efficient product testing can help companies achieve zero defects in products Demand based integration of workstations and production Controlling and monitoring of processes from remote location using 15 Remote Control of Processes Human – Robot Collaboration Green Manufacturing Mass Customization Controlling and monitoring of processes from remote location using visualization and cloud based services Sharing of workplace between humans and robots in a safe manner Energy efficient manufacturing that has minimal effect on the environment Meeting every customer’s demand while manufacturing in mass scale
  16. 16. Technology Convergence and Innovation Opportunities Homalnd security 4 7 5 6 1 4 3 3 2 16 Factories of Future Factories of Future 1 2 3 4 4 7 51 6 2 2 Cloud Computing Additive Manufacturing Big Data AnalyticsWireless Sensors Nanosensors Energy Harvesting Condition Monitoring Collaborative Robots Product Testing Manufacturing Environment Monitoring5 1 1 2 3 4 5 3 MEMS 1 1 4 1 3 1 Remote Controlling Solutions Solution Providers Plant management Software Miniaturized Sensors2 1 Remote Control6 6 8 High Speed Communication
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  20. 20. For Additional Information Britni Myers Corporate Communications Industrial Automation & Process Control (210) 477.8481 Sumit Kumar Pal Research Analyst Technical Insights +91-44-66814101 20 Kasthuri Jagadeesan Program Manager Technical Insights +44-(0)-1865-398-625 Bernard Weber Sales Director, Technical Insights (Europe) +44 207 343 8352