The document discusses the importance of smart, safe, and sustainable manufacturing for the U.S. economy, emphasizing the critical role of federal R&D funding, which has declined over the years. It highlights advancements in manufacturing technologies and energy management strategies aimed at improving efficiency and environmental compliance. The document calls for significant public-private partnerships to establish a 'greenprint' for future manufacturing efforts, focusing on applied research and safer practices.

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. 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
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2008 2

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
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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
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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
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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
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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
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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.
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2008 8

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
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2008 9

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
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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
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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%
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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
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2008 13

14. Questions?
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