1. The document discusses intelligent manufacturing systems and Industry 4.0, describing how increased connectivity through technologies like the Internet of Things, cyber-physical systems, and sensors is allowing for more customized, flexible production and new areas of innovation. 2. Key aspects of Industry 4.0 include deep learning, quantum computing, advanced artificial intelligence, new IOT platforms, cloud-based analytics services, and partner ecosystems to deliver IOT solutions. 3. Examples are given of new technologies like autonomous robotic systems from companies like Festo and ABB, as well as smart factory approaches from German research initiatives and automakers like Volkswagen integrating digital technologies into new products and customized, digitally-driven production.

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Intelligent Manufacturing System Integration
Harish Pant
Managing Director

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97% of Indians find themselves in the bottom
60% of the world’s population when ranked
according to incomes.
Irony of our country being a low cost country….
Labor is cheap so keep it Not Intelligent and without system – only short
pulses of Jugad!

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• Who is Not Intelligent ?
• What should be intelligent and how much?
• What an intelligent device does? e.g. The Best Smart Phone vs Ordinary Phone
Why Intelligent?

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Why Intelligent?
To achieve better
• Quality, Cost, Delivery, Safety, Security, Reliability
• Environment, Sustainability, Comfort, Convenience
• Seamless / Integrated Service
• Futuristic Products and services: Quantum Research
>> Innovations to meet Uncertain, Volatile and ever Changing World
.. Return on investment (ROI) vs Survive on Investment (SOI)

5. Human
Can do Can’t do
Machine
Phase 1 - Human and Machine
Phase 2 - Human Vs. Machine
Phase 3 - Machine to Machine
Phase 4 - Internet of Things
Phase 5 – Intelligence to Intelligence
Information
Intelligence
Integration
IOT
Capacity and Capability
Can do Can’t do

6. 1. Principles of Motion Economy
2. Motion Study
3. Workstation Design
4. Application of Ergonomics
5. Fatigue Studies
6. Productivity/Safety/Comfort Device
Design
7. Standardization of Operator Methods
8. Operator training
9. Incentive Systems
10. Job Evaluation
11. Learning effect capture
12. Work Measurement - Time Study
1. Process/op Analysis/OR
2. Six Sigma
3. Value engineering
4. Statistical quality control ,
5. Statistical inventory control and ABC
6. Variety reduction
7. Standardization
8. Waste reduction or elimination
9. Activity based management
10. Business process improvement
11. Learning effect capture and
continuous
12. 5S, SMED, Lean system
Technique
s
Value
Human Motion Method
Productivity
Traditional
In Built
IE FrameworkInnovation/Disruption

7. Context
Technology
Competition
Sustenance
Environment
Social
Economic
Integration
Seamless
Whole /
Total
End to End
User
controlled
Value
• Disruptive Impact
• Beyond “As desired”
or “perceived”
• Authentic / Real
The last mile/end changes are changing the structure / base creating multiple
disruptions
>>>
>>>
Value - Increasing Envelop
New Value Preposition

8. Chapati Making
Prepare Dough
Roll
Bake in oven
Prepare Dough
Press and Bake
Fill Flour and
Water
Select roti
thickness
• The next…..Grains Fill and auto operate…auto recognition….
• Disruptive Change in Human Motion and Method: everything changed
• Skill and knowledge required – a disruptive change!

9. Eliminations
Wastes (Muda) >>> Variations (Mura) >>> Strain (Muri)
Improvements
Quality, Cost, Delivery…..)
Disruptions
Mobility and scalability, Internet of things, Free
of Cost – Knowledge/Info/across the globe
Innovation
Unique, New, Different
• The roti maker has to become expert in many dimensions
• Streamlining processes and cutting cost is just 18th century
• Complexity is managed by simple rules and constraints actually spur the
innovation
Changing Change @

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Manufacturing System Elements Interplay
Interplay of
5M’s
Man – Attendance, Attention, Availability
Machine
Idle time
Changeovers
Reduced lot size
Money
Cash Flow
Margins
Material
Lead time
Availability
Global Supply chain
Method
Changing requirements
Improvements
disruptions

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Systems System
• Quality System, EHS System
• Customers requirements
• CAD/CAM
• Machine Programing software
• Machine controllers
• ERP
• DOC Management System
• Quality Lab Management
• Out Source – In Source Interface
• Individual Hardware / software/App
• Social Media
• Search engines
System Issues
• Standards
• Compatibility
• Availability
• Affordability
Manufacturing System

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Information Technology (IT) Operational Technology (OT)
Internet of Things (IOT)
Internet of Things (IOT) as Service
Industry Era – 4.0
A world in which digital technologies are deeply embedded and in abundance.
The Future Factories
• The Internet of Things on the Plant Floor
• 3D Printing and Emerging Production Technologies
• Digital Manufacturing

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A future for manufacturing in which
• Pervasive connectivity,
• Sensor networks,
• Cyber-physical systems, and
• Increased production flexibility
promise to drive the creation of ever-more customized and smarter products.
A new levels of digitization, automation, and integration within an enterprise, and many
new areas of technical and software innovation.
http://www.gilcommunity.com/blog/hannover-highlights
The mantra of Industry 4.0

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• Dramatically change the products we manufacture and use, making them smart,
connected, and, ultimately, more autonomous.
• The IoT era will require much tighter and more agile collaboration between what
historically have been stove-piped organizational functions such as IT, engineering,
R&D, service, and manufacturing.
• Manufacturing companies create what he called “Unified Data Groups,” led by
Chief Data Officers, that would be tasked with turning the mountains of data
generated by IoT infrastructure into competitive assets that could truly be
exploited by existing business units
• Whether manufacturers decide to graft the data management function onto their
existing organizational structures, set up new centers of excellence, or partner for
expertise, the structural changes forced by IoT are likely to be, at least for a time, a
source of conflict or a source of Collaboration.
• Require a new generation of manufacturing employees with a unique combination
of not just mechanical and software engineering skills but also data science skills
and knowledge of domains such as post-sales product service and support.
Internet of Things
Excerpts from M.Poter

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• Deep Learning : Hardware's designed for the Machine Learning Techniques
• Many gadgets will be able to understand images and video thanks to chips designed to run
powerful artificial-intelligence algorithms."
• Companies like Google have made breakthroughs in image and face recognition through deep
learning, using giant data sets and powerful computers...
• Quantum Computing Algorithm for advanced Artificial Intelligence
• The Dutch government, research institute TNO* and other organisations have agreed to
invest Euro 135 m
• New design recognized speed-limit signs in footage from a car.
• A home security camera could start sending data over the Internet only when a human entered the
frame.
• Being able to do things like analyze images on a device without connecting to the Internet can make
apps faster and more energy-efficient because it isn’t necessary to send data to and fro
New Advances in Artificial Intelligence

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To offer a range of services including
• A new IOT platform-as-a-service offering, that will allow developers to integrate
IOT-generated data with existing business applications such as enterprise
asset management;
• A cloud-based service that IBM, its customers, and its partners can use to
design and deliver analytics applications that are focused on specific vertical
industries; and
• An ecosystem of partners that will deliver IOT solutions based on IBM’s
platforms.
• Working with Cummins and Pratt & Whitney, to create IOT solutions that
monitor the functioning and health in the field of products such as engines.
• Partnering with the University of South Carolina to create IOT-enabled
analytics tools and skills that can enhance predictive maintenance.
- See more at: http://www.gilcommunity.com/discussion/ibm-will-invest-3-billion-internet-things-
initiative/#sthash.5EQlNY1N.dpuf
IBM Will Invest $3 Billion in Internet of Things

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Futuristic Festo R&D program, the partially 3D-printed
BionicANTS communicate with each other to coordinate
both their actions and their movements to achieve
cooperative tasks. Each ant takes autonomous decisions
but is always subordinate to the common objective
http://www.gilcommunity.com/blog/hannover-highlights
The electro-mechanical e-Motion Butterflies, meanwhile,
autonomously coordinate their flying patterns using indoor
GPS, a collection of spatial infrared cameras and
controller, plus on-board guidance and monitoring systems
so they never collide.
New Developments
ABB --- YuMi – combines a vision system, grippers,
touch-sensitive sensors, software, and integrated safety
components in a form factor that weighs 38 Kg and
consumes one square foot of space. YuMi is designed for
consumer product manufacturing applications such as
electronics, phones, and various small parts

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SmartFactory’s Plug and Produce Approach
Pioneering German research initiative, SmartFactory KL e.V., and the German Center for Artificial
Intelligence demonstrated how the Industry 4.0 concept can be integrated into existing industrial
applications.
Harting’s Customized Production Line
Though still in development, Germany’s Harting Technology Group is showcasing a prototype modular
factory line able to create individually customizable products with the speed and efficiency of mass
production volumes. Called the Harting Integrated Industry 4 You (HIIA4YOU) project, it connects an
eShop customer selection system, with an SAP ERP network, and finally the production and assembly
machinery in a three-cell production line.
Volkswagen’s e-Golf and Factory Powerwall
The digital networking will become an essential part of the auto industry in the future, featured
A number of digitally-driven production and product developments, including augmented reality
systems that show where specific parts are installed in the body of a car, the e-Golf electric vehicle
which features wireless charging and a digital key that can be operated by smartphone, and what it
calls the Powerwall – a virtual wall screen, adapted from a similar technology used earlier in vehicle
design and engineering, that now allows factory teams to simulate a plant and plan and refine an entire
production process for a new product in a virtual world before any physical changes are made to the
factory itself.
- See more at: http://www.gilcommunity.com/blog/hannover-highlights-day-1-industry-40-clever-
collaborations-and-plug-and-produce/#sthash.DejGlQbr.dpuf
New Developments…

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Impact on Education System
• CS/IT/Analytics to be embedded in all courses
• Projects to be done with across the branches of various discipline
• Create infrastructure throughout the campus to facilitate cutting edge research
• Very active involvement of Industry – Academia – Research and Development
• Content no more important and to be made available online – application is important
• Create similar experience in running the Education Institute
• Create a platform for Intelligent Manufacturing System for active participant of Faculties, Students
and various Research scholars
• Carry out an India specific research on where IOT will bring immense benefits to industry and society
• More collaborate and then compete
• Be a Role Model