Smart Manufacturing and the Clean Energy Smart Manufacturing
- Slides: 58
Smart Manufacturing™ and the Clean Energy Smart Manufacturing Innovation Institute (CESMII) Dean Schneider, Ph. D, PE Co-Director, Gulf Coast Regional Manufacturing Center dean. schneider@CESMII. org, 979 -458 -0251
Overview • Manufacturing USA • Smart Manufacturing™ and the Industry Value Proposition • What is the Smart Manufacturing™ Platform and how can it be employed? • What is a SM™ Portfolio? • How can you engage the Institute? CLEAN ENERGY SMART MANUFACTURING INNOVATION INSTITUTE 2
Manufacturing USA A National Network of Institutes focused on advanced manufacturing technologies DOD Funded: NIST Funded: America Makes 3 D Printing / Additive Manufacturing Youngstown, OH NIIMBL Biopharmaceuticals Neward, DE DMDII Digital Manufacturing & Design Chicago, IL DOE Funded: LIFT Power America Lightweight Metals Detroit, MI Wide Bandgap Semiconductors Raleigh, NC AIM Photonics Rochester, NY IACMI Composites Knoxville, TN Nex. TFlexible Hybrid Electronics San Jose, CA CESMII Smart Manufacturing Los Angeles, CA AFFOA Revolutionary Fibers & Textiles Cambridge, MA RAPID Modular Process Intensification New York, NY ATB Advanced Tissue Biofabrication Manchester, NH REMADE Sustainability in Manufacturing Rochester, NY ARM Advanced Robotics in Manufacturing Pittsburgh, PA CLEAN ENERGY SMART MANUFACTURING INNOVATION INSTITUTE 3
DOE Definition of Smart Manufacturing Technology and work practices that: • Reduce energy, raw material and water intensity by improving and integrating process, plant, and enterprise-wide efficiencies; • Optimize production and improve quality control using cost-effective sensing and control for retrofits and new facilities • Better visibility, decisions and energy management practices across the manufacturing enterprise CLEAN ENERGY SMART MANUFACTURING INNOVATION INSTITUTE 4
Industry Participation Value Proposition CLEAN ENERGY SMART MANUFACTURING INNOVATION INSTITUTE ABB slides used with permission 5
Industry Participation Value Proposition CLEAN ENERGY SMART MANUFACTURING INNOVATION INSTITUTE ABB slides used with permission 6
Industry Participation Value Proposition CLEAN ENERGY SMART MANUFACTURING INNOVATION INSTITUTE ABB slides used with permission 7
Industry Participation Value Proposition CLEAN ENERGY SMART MANUFACTURING INNOVATION INSTITUTE ABB slides used with permission 8
Industry Participation Case Studies CLEAN ENERGY SMART MANUFACTURING INNOVATION INSTITUTE ABB slides used with permission 9
Industry Participation Case Studies CLEAN ENERGY SMART MANUFACTURING INNOVATION INSTITUTE ABB slides used with permission 10
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CESMII Research Areas • • Advanced sensors Controls Platforms Modeling technologies To achieve better management of: • Real-time energy utilization • Productivity • Worker Safety • Waste Smart Manufacturing Encompasses: • Machine-to-plant-to-enterprise-tosupply-chain aspects of advanced sensing and instrumentation • Real-time process monitoring, control, and optimization; • Advanced hardware and advanced software platforms; • Predictive modeling and simulation technologies for industrial automation networked for enterprise and ecosystem optimization. • Verified in testbed environments CLEAN ENERGY SMART MANUFACTURING INNOVATION INSTITUTE 12
The Institute Has a Dual Focus Clean Energy Smart Manufacturing Technology Innovation & Transformative Adoption Education & Workforce Development CLEAN ENERGY SMART MANUFACTURING INNOVATION INSTITUTE 13
How is CESMII Different? Open Architecture Plug ’n Play Infrastructure Common Platform Power of Integration CLEAN ENERGY SMART MANUFACTURING INNOVATION INSTITUTE 14
Plug ’n Play Infrastructure • Vendor Agnostic • No Long Contracts • Modular Adoption • Pay for only what’s needed CLEAN ENERGY SMART MANUFACTURING INNOVATION INSTITUTE 15
A Common Platform Development Deployment Performance Reuse as a Service Marketplace as a Service SM Open Platform Infrastructure Bringing Together a Collaboration Buyer/Seller Dashboard Composable Apps & Libraries Toolkits, App & Owner Data Services Application Toolkits Workflow as a Service Validated/Licensed Software Environment Secure Data Connections Secure Data Streaming & Management Private Virtual Computation CLEAN ENERGY SMART MANUFACTURING INNOVATION INSTITUTE ©Smart Manufacturing Leadership Coalition, 2016 16
CESMII Delivers: Insight Control • New sensor technologies • Micro to macro level data generation • Advanced Analytics tools Efficiency Access CLEAN ENERGY SMART MANUFACTURING INNOVATION INSTITUTE 17
CESMII Delivers: Insight • Revolutionary analytics software: ü Control systems and Big Data Control Efficiency Access ü High-fidelity predictive modeling and simulation software • Enhanced flexibility • Faster market-responsiveness • Better information in business realtime for decision-makers CLEAN ENERGY SMART MANUFACTURING INNOVATION INSTITUTE 18
CESMII Delivers: Insight • Overall Energy Efficiency • Energy Productivity Control Efficiency 15% 50% • Implementation costs 25%-80% • Safer work environments • Less waste Access CLEAN ENERGY SMART MANUFACTURING INNOVATION INSTITUTE 19
CESMII Delivers: Insight • The Community • New Tech Control Efficiency Access • Platform and Marketplace ü Affordable and accessible benefits for: ü Manufacturers ü Solution providers CLEAN ENERGY SMART MANUFACTURING INNOVATION INSTITUTE 20
CESMII A National Network of Capability Networks Headquartered in LA Northwest Northeast HQ California Southeast Gulf Coast CLEAN ENERGY SMART MANUFACTURING INNOVATION INSTITUTE ©Smart Manufacturing Leadership Coalition, 2016
Headquarters Accountabilities • DOE coordination and administration • Oversees Regional Centers • Manages Funds Distribution and Awards • Platform & Marketplace Development • Master Planning, Strategy and Governance (Roadmap) • CESMII Certification – Hardware /Software Specifications • Workforce Training and Certification CLEAN ENERGY SMART MANUFACTURING INNOVATION INSTITUTE
Regional Manufacturing Center Accountabilities • Domain Expertise – Aligned to Membership • Proximity to Industry • Drive Membership • Develop/Commercializing Technology – RD & D • Implement SM Projects – Industry Test Beds • Participate in CESMII Roadmap • Regional Workforce Development and Training • Advisory Committee Participation • Regional Budget Management NW NE CA SE GC “Operationalizing Smart Manufacturing” CLEAN ENERGY SMART MANUFACTURING INNOVATION INSTITUTE
Member Benefits • Access to CESMII Community - Academia - Government - Industry • Access to New Technology - IP & technologies developed by institute - Test bed network - Best practices • Access to Smart Manufacturing platform - Marketplace for connecting vendors with customers - Modular adoption - Reduced cost for manufacturers to implement CLEAN ENERGY SMART MANUFACTURING INNOVATION INSTITUTE 24
The Smart Manufacturing Platform CLEAN ENERGY SMART MANUFACTURING INNOVATION INSTITUTE 25
Every Company has an ECO System of “ STUFF” Value Creation Demand Driven Supply Chain Green Light to Convert Green Light to Ship Allergen/Micro Work. Flow Business Applications Optimized Inventory e. COA Finished Product Inventory Raw Mat’l Inventory Optimization Engine Lot Tracking Line Schedule Production Order Demand Plan Core Functions Work. Flow Production History Plant Floor Inventory Direct Consumption Supplier Managed Inv Bin Mgmt Line Supply Trace/Recal Overusage BOM Validation Yard Mgmt Directed Work l Master Data (BOM, Specs, Vendor, Ingredients, FP) Core Systems MQIS MES SAP ERP SAP MRP SAP APO SAP PLM Red Prairie Data Input CLEAN ENERGY SMART MANUFACTURING INNOVATION INSTITUTE Courtesy of General Mills 26
Industry Needs a Platform CESMII has an Open Implementation Platform Power Mgmt & Energy Grid Smart Manufacturing Platform Open Infrastructure • • • Heating & Forging SM Software Marketplace APPs & Toolkits Compose Workflows Cloud Deployment Private/Public Iaa. S Line Operations Suppliers SM Value Proposition Applications Context Private Smart Manufacturing Platform Appliance Distribution Sustainability & Safety Mapping Event Data Calibration & Production Maintenance Models Data Time Series Customers Sensor Data Traditional Manufacturing Automation Environment and Software Tools CLEAN ENERGY SMART MANUFACTURING INNOVATION INSTITUTE 27
Reduce Consumption of Energy Transformations Supply Chain Flow Material Conversion Heating Productivity Measure Quality Right the First Time Drying Context Control Optimize Seams Cooling Variability Reduction Mixing Demand Management Optimize REAL-TIME Test Beds CLEAN ENERGY SMART MANUFACTURING INNOVATION INSTITUTE 28
Smart Manufacturing Layers Industry Testbeds First-of-Kind Application Toolkits for SM Deployment Advanced High Fidelity Modeling Open Standards Software and Communication Platforms Real-Time Data Analytics and Control Systems Advanced Sensors CLEAN ENERGY SMART MANUFACTURING INNOVATION INSTITUTE 29
SM Cloud-Based Infrastructure • Centralized repository of manufacturing intelligence tools CLEAN ENERGY SMART MANUFACTURING INNOVATION INSTITUTE 30
SM Platform™ Reference Model Lightweight Cloud Integration Service Security Interfaces Virtual compartments Scalable Hardware of choice Different Industry marketplace Industry data mgmt Engr Workflow as a Service CLEAN ENERGY SMART MANUFACTURING INNOVATION INSTITUTE 31
Multiple Hardware Sources Multiple Analysis Tools Multiple Platforms Multiple Networks Optimization, Controls, Situations Models, Prediction, Visualization Analytics Data Aggregation Data Sensors The Smart Manufacturing Value Chain Multiple Analysis Tools Multiple Platforms Multiple Computation CLEAN ENERGY SMART MANUFACTURING INNOVATION INSTITUTE 32
A Real Example Praxair Steam-Methane Reformer CLEAN ENERGY SMART MANUFACTURING INNOVATION INSTITUTE 33
SMLC Praxair Testbed Steam-Methane Reformer Furnace AMO – Year 2 Fun Facts: • 400 ft 3 • 360 Tubes • 100 Gas Burners • 50 year old technology 1 F. Beyer. Steam reforming – 50 years of Development and the Challenges for the next 50 years. 2005 CLEAN ENERGY SMART MANUFACTURING INNOVATION INSTITUTE 34
Praxair Smart Manufacturing Data Structure Reduced camera platform TRL 5 Harsh, high temp platform TRL 7 Burn Setting Optimizer Temperature Contextualization IR camera system TRL 9 Dashboard High Fidelity Model Validator Praxair historian TRL 9 Emerson Delta. V DCS TRL 9 SM Platform ROM Prediction CLEAN ENERGY SMART MANUFACTURING INNOVATION INSTITUTE ROM : = Reduced-Order Model 35
Praxair Data Structure Reduced camera platform TRL 5 Harsh, high temp platform TRL 7 TRL 6 -7 IR camera system TRL 9 Praxair furnace contextualized data Furnace contextualized data TRL 7 OSISoft cloud KB TRL 9 Burn Setting Optimizer Praxair Optimizer Matlab Optimizer config TRL 6 -7 Praxair furnace tube model Ansys Fluent ex tube furnace TRL 5 Matlab cloud TRL 9 Temperature Contextualization TRL 6 -7 Mediation, DMZ, secure data TRL 7 Ansys Fluent TRL 9 Wireframe TRL 6 User Interfaces TRL 4 Kepler Data Services TRL 6 UCLA HPC TRL 9 Security IDM TRL 7 TRL 4 OSIsoft TRL 8 Rackspace TRL 9 Dashboard TRL 4 SM Platform Marketplace TRL 4 Tableau TRL 9 High Fidelity Model Validator Praxair historian TRL 9 Emerson Delta. V DCS TRL 9 Praxair Furnace Tube Model Tableau burner display config TRL 7 ROM Prediction TRL 6 Praxair Validator Matlab validator config TRL 4 Matlab cloud Praxair Furnace Tube Model Ansys Fluent Rxn Furnace TRL 4 ROM : = Reduced-Order Model C L E A N E R G Y S M A R T M ATRL N U 9 F A C T U R I N G I N N O Ansys V A T Fluent ION INSTITUTE TRL 9 36
SMLC Praxair Testbed Steam-Methane Reformer Furnace Temperature Distribution Number of tubes Average Temperature 1050 On track 5% gain on 88% efficient furnace 1100 1150 Tube Temperature (K) Accelerated reach 10% gain 75 – 80% furnaces CLEAN ENERGY SMART MANUFACTURING INNOVATION INSTITUTE 37
Composable Apps and Configurations in Market Place More efficient, effective and accelerated approach to engineering RT applications Data to many applications strategy One data structure to solve many problems Highly layered marketplace of connected product configurations that can talk to each other • Marketplace composability and configurability on any cloud platform • • CLEAN ENERGY SMART MANUFACTURING INNOVATION INSTITUTE 38
Back to the SM Reference Model SMR furnace configuration Company SMR configuration Ansys Fluent Single, multi, full tube models Matlab Company Matlab PCA configuration Cloud Integration Services: Security; Machine & Human Interfaces; Virtual Compartments; Interoperability; Standards Converged reference model Company config Industry Marketplace; Reusable Configurations Industry Data management Integration & Composability CLEAN ENERGY SMART MANUFACTURING INNOVATION INSTITUTE 39
So, what is this Portfolio? CLEAN ENERGY SMART MANUFACTURING INNOVATION INSTITUTE 40
SM Cloud-Based Infrastructure • Centralized repository of manufacturing intelligence tools CLEAN ENERGY SMART MANUFACTURING INNOVATION INSTITUTE 41
SM Platform™ Engine Stack Template or Machine Image Template Builder SMP Product SMP Workflow Launch SMP Workflow Dashboard SM Platform Engine Public or Private Cloud CLEAN ENERGY SMART MANUFACTURING INNOVATION INSTITUTE 42
Translation: • The computational framework in the cloud is directly related to FUNCTIONS in the engineering workflow that represents the plant • Do I need sensor models: Yes • Do I need sensor interface (toolkit): Yes • The SM Platform provides an agnostic workflow engine for multiproduct, multi-data source systems • Not just get data, but ACT on it. CLEAN ENERGY SMART MANUFACTURING INNOVATION INSTITUTE 43
Praxair Data Structure Reduced camera platform TRL 5 Harsh, high temp platform TRL 7 TRL 6 -7 IR camera system TRL 9 Praxair furnace contextualized data Furnace contextualized data TRL 7 OSISoft cloud KB TRL 9 Burn Setting Optimizer Praxair Optimizer Matlab Optimizer config TRL 6 -7 Praxair furnace tube model Ansys Fluent ex tube furnace TRL 5 Matlab cloud TRL 9 Temperature Contextualization TRL 6 -7 Mediation, DMZ, secure data TRL 7 Ansys Fluent TRL 9 Wireframe TRL 6 User Interfaces TRL 4 Kepler Data Services TRL 6 UCLA HPC TRL 9 Security IDM TRL 7 TRL 4 OSIsoft TRL 8 Rackspace TRL 9 Dashboard TRL 4 SM Platform Marketplace TRL 4 Tableau TRL 9 High Fidelity Model Validator Praxair historian TRL 9 Emerson Delta. V DCS TRL 9 Praxair Furnace Tube Model Tableau burner display config TRL 7 ROM Prediction TRL 6 Praxair Validator Matlab validator config TRL 4 Matlab cloud Praxair Furnace Tube Model Ansys Fluent Rxn Furnace TRL 4 ROM : = Reduced-Order Model C L E A N E R G Y S M A R T M ATRL N U 9 F A C T U R I N G I N N O Ansys V A T Fluent ION INSTITUTE TRL 9 44
What are the SM Products™? OSI Historian Matlab PCA OSI KB Optimizer Developing and merging models Soft Sensor Ansys Fluent OSI Emerson CFD Validation Tableau Matlab PCA ROM Prediction ROM Change Rackspace ROM : = Reduced-Order Model ROM Prediction UCLA HPC Work Flow Processes @ Modeler Level CLEAN ENERGY SMART MANUFACTURING INNOVATION INSTITUTE 45
Multiple Hardware Sources Multiple Analysis Tools Multiple Platforms Multiple Networks Optimization, Controls, Situations Models, Prediction, Visualization Analytics Data Aggregation Data Sensors Another Look at the Value Chain Multiple Analysis Tools Multiple Platforms Multiple Computation CLEAN ENERGY SMART MANUFACTURING INNOVATION INSTITUTE 46
A Process Institute needs Process: Platform Development Testbeds • Research, Development, and Demonstration (RD&D) • Develop and prove the platform technology • Industry 1 st of a Kind • Implement, Demonstrate, Validate in industrial environment • Industry Replication • Technology Transfer: Replication of validated systems CLEAN ENERGY SMART MANUFACTURING INNOVATION INSTITUTE 47
Test Bed Portfolio Development Process CESMII HQ MEMBERS RMC CLEAN ENERGY SMART MANUFACTURING INNOVATION INSTITUTE 48
How Can You Participate? CLEAN ENERGY SMART MANUFACTURING INNOVATION INSTITUTE 49
Multiple Hardware Sources Multiple Analysis Tools Multiple Platforms Multiple Networks Optimization, Controls, Situations Models, Prediction, Visualization Analytics Data Aggregation Data Sensors The Value Chain Shows the Products Multiple Analysis Tools Multiple Platforms Multiple Computation CLEAN ENERGY SMART MANUFACTURING INNOVATION INSTITUTE 50
What are the SM Products™? OSI Historian Matlab PCA OSI KB Optimizer Developing and merging models Soft Sensor Ansys Fluent OSI Emerson CFD Validation Tableau Matlab PCA ROM Prediction ROM Change Rackspace ROM : = Reduced-Order Model ROM Prediction UCLA HPC WF Processes @ Modeler Level CLEAN ENERGY SMART MANUFACTURING INNOVATION INSTITUTE 51 51
Test Bed Portfolio Development Process CESMII HQ MEMBERS RMC CLEAN ENERGY SMART MANUFACTURING INNOVATION INSTITUTE 52
Smart Manufacturing Product™ Development • Researcher/Company Subject Matter Expertise • Working with regional partners to develop testbed project proposals • Collaborative with regional/national partners • Responsive to Technology Roadmap • Scope and Budget Templates for projects • Participate in Institute Strategic Planning Activities at both Regional and National Levels – Work with the region and industry partners • Subscribe to Institute and Regional Communications Channels to stay up-to-date with opportunities CLEAN ENERGY SMART MANUFACTURING INNOVATION INSTITUTE 53
CESMII Membership Model CLEAN ENERGY SMART MANUFACTURING INNOVATION INSTITUTE 54
CESMII Membership Model Basic Services: • Introductory training curriculum to include primers on Smart Manufacturing, Platform, Testbed and Business Case Development. Curriculum offerings subject to change • Institute communications: access to SM concepts, knowledge, resources, reports, and Institute intranet • Forums for networking and sharing: Access to meetings, events, and workshops • Network and build relationships • Growth opportunities through SM business, markets, and skills Advanced Services: • Intermediate-level training curriculum to include Smart Manufacturing Platform Train-the-Trainer, Platform Evaluation, and Proposal Development. Curriculum offerings subject to change • Product exposure to provide members with access to product information (for applications, toolkits, etc. ) across the Institute • Testbed consultation, workshops, and non-proprietary testbed and project information • Access to and training on SM Platform™ for evaluation and demonstration CLEAN ENERGY SMART MANUFACTURING INNOVATION INSTITUTE 55
CESMII Membership Model Extended Services (negotiated and fee based): General Notes: • Dedicated product support and advanced implementation training, including role-focused curriculum on corporate Smart Manufacturing Roadmap Development and Value Proposition, SM Installation and Operations, and Project and Cost-Share Planning • Cost-sharing commitments other than membership fees can be allotted over five years as members deem appropriate • Service-Level Agreements on SM Platform™ and SM Marketplace™ licenses for development, and production • Toolkit development and promotion • Commercialization planning • Testbed implementation planning, design, and integration involving Institute expertise on control strategies, modeling and simulation, and sensor placement • Personnel, product, and systems (hardware or software) certifications • Under Consortium Membership type, reciprocal agreements will be negotiated with Associations on a case-by-case basis • Standing Committees include Technology, Business, and Outreach, with supporting working groups as needed • Any exceptions need to be approved by the CEO of CESMII Industry Size Definitions: • Small Companies have fewer than 100 employees • Medium Companies have more than 100 employees and fewer than 500 employees • Large Companies are 500 employees or more CLEAN ENERGY SMART MANUFACTURING INNOVATION INSTITUTE 56
CESMII A National Network of Capability Networks Headquartered in LA Northwest Northeast HQ California Southeast Gulf Coast CLEAN ENERGY SMART MANUFACTURING INNOVATION INSTITUTE ©Smart Manufacturing Leadership Coalition, 2016
Let’s Review… • Manufacturing USA • Smart Manufacturing and the Industry Value Proposition • What is the Smart Manufacturing™ Platform and how can it be employed? • What is a SM™ Portfolio? • How can you engage the Institute? CLEAN ENERGY SMART MANUFACTURING INNOVATION INSTITUTE 58
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