Developing your Digital Manufacturing and Design (DM&D) Roadmap with SDMTS. Manufacturing Summit

Transcription

1 Developing your Digital Manufacturing and Design (DM&D) Roadmap with SDMTS Manufacturing Summit 12 September,

2 Introductions South Dakota Manufacturing & Technology Solutions Keith Deibert Business Advisor

3 Goals of this overview: Know what Digital Manufacturing and Design (DM&D) is and how it could impact and benefit your manufacturing operations, Learn about Manufacturing USA and how to engage DMDII solutions, join as a manufacturing partner or leverage R&D services to improve your business, Learn how to work with SDMTS to understand and assess your DM&D readiness and maturity. Assess you business risks. 3

4 History of Factory s of the Future F o r d R i v e r R o g u e P l a n t ( C i r c a ) Vertical Integration and the Manual Assembly Line

5 History of the Factory s of the Factory Virtual Vertical Integration - Across the entire Supply Chain

6 The Fourth Industrial Revolution is poised to generate a new wave of wealth creation Industry 4.0 design principles: Interoperability Information transparency Technical assistance Decentralized decisions All enabled through data 6 Source: Bruce Hoy (CEO Genesis NanoTech), The Fourth Industrial Revolution

7 Digitally connecting products, people, and equipment will enable business and operational decisions

8 Source: McKinsey 8 Manufacturing contributes the most data

9 40 zetabytes globally by ZB = (1e+12) GB Gartner: 21 Billion IoT Devices by

10 Most companies still suffer from DRIP 10

11 An Analogy: The Smart Home We often are thinking of ways to keep our homes warm in the winter and cool and comfortable in the summer. We may take up incremental or comprehensive physical or behavioral improvements. We have several options we can choose from: Adjust our attitude or behavior (about temperature) Perform preventative maintenance or repairs Purchase and install new equipment Seek other ways to continuously improve our home operations

12 Introducing: The Honeywell T87 Round Thermostat Classic industrial design (by Henry Dreyfuss) Textbook definition of residential thermostat Large installed base Reliable and simple UI Cost effective repair/replace Design often copied by competitors Introduced in 1957 and a modern version is still manufactured

13 13 Thermostat Technology has evolved slowly 1957 Honeywell T87 Round Besides introducing new form factors and programmability, they typical residential thermostat has not significantly changed in nearly 60 years Nest disrupts the thermostat industry by launching a smart, learning, connected thermostat and data platform

14 Smart home data leads to information and decisions 14

15 Who is our Smart Home trusted advisor? Distributor? OEM? Integrator? Other?

16 Introducing: The Bridgeport Series II Lathe Classic industrial design Textbook definition of industrial lathe Large installed base Reliable and simple UI Design often copied by competitors Cost effective repair/replace Introduced in the 1930s and a modern version is still manufactured

17 Similarly, manufacturing technologies have evolved slowly. ~300 BC Egyptian lathe New revolution of additive manufacturing seeks to disrupt traditional machine tool industry with digital connectivity out-of-the-box The lathe is the mother of all machine tools Lathes have evolved to be larger, faster, and more capable over the last 2300 years 17

18 Digitally enabled manufacturing data leads to information and decisions Enabling the digital capture of manufacturing data does not need to be complex, difficult, nor expensive. Can and should integrate with existing assets and processes 18

19 Informed Decisions lead to improvement 19

20 Who is your Digital Manufacturing and Design Trusted Advisor? Distributor? OEM? Integrator? Other?

21 Consumer and Enterprise similarities Both operators need information to guide their decisions The goal is to minimize expenses/costs and maximize savings/profits It s important to have a sustainable solution that is supported by seller or provider of the service or product Additional services or products may be requested depending upon the level of education and by previous service or product

22 Transparency across the Design and Manufacturing Processes while human minds are a marvel, they have severe limitations for tasks like these. The fidelity and permanence of our human memory leaves a great deal to be desired. Our ability to create and maintain detailed information in our memories over a long period of time is not very good. - Dr. Michael Grieves, Origins of the Digital Twin Concept

23 Defining Digital Manufacturing & Design (DM&D) Currently, many companies, industries, organizations, and governments are involved in designing, defining, and promoting the next generation of digital manufacturing and enterprise capabilities from their perspective. Several synonymous terms for the next generation of manufacturing include: 24 Industry 4.0 Digital Enterprise Smart Factory / Brilliant Factory Computer Integrated Manufacturing Internet of Things (IoT) Digital Manufacturing and Design (DM&D) Smart Manufacturing

24 Defining Digital Manufacturing & Design (DM&D) Digital Manufacturing is an integrated approach that brings together software, data, and control systems to model, simulate, analyze, control, and optimize both a product and its manufacturing systems performance. Control Simulate Analyze Model Design Optimize

25 What Does Digital Enable? The Digital Thread and Digital Twins The Digital Thread enables information flow between all elements of the product lifecycle creating the channel for real-time collaboration between product stakeholders. Asset Source: GE Reports System The Digital Twin is a virtual representation of an asset or system across its digitally enabled product lifecycle.

26 Enabling a Digital Product Lifecycle Requirements Development Traditionally data is siloed due to segmented work processes and disconnected systems. Sustain & End of Life Manufacture / Assemble Design & Analyze Systems that encourage a one-way transfer of data can lead to costly delays and rework. Building connectivity of data and software systems throughout a product s lifecycle is critical to achieving an organization s goals. Connected systems enable product refinement and optimization throughout the product lifecycle possible.

27 Defining the DM&D enabled Product Lifecycle The Product Lifecycle is the distinct, yet interconnected phases associated from inception, through engineering design and manufacture, to service and disposal of products. Product lifecycle management (PLM) is the process of managing the entire lifecycle of a product or service The methodology can apply to products, processes, or services DM&D enabled Product Lifecycle seeks to use digital tools to interconnect the phases that have traditionally been isolated in manufacturing companies and across supply chains.

28 Requirements Development Traditional: Customer supplies initial product requests, ideas, and information. Sales or project manager iterates with engineering and production staff to establish product requirements, capabilites, budget, and timeline. Final requirements and quote are iterated upon between customer and internal teams. Information is often segmented and progress may be interrupted or delayed by contributors. Digital: Customer supplies initial product requests, ideas, and information, and can receive feedback. Customer and internal teams can work together to concurrently develop requirements and product capabilities. Final requirements and quotes evolve concurrently across internal teams as product requirements take shape. Information channels are open between working parties. Requirements linked across the enterprise Greater cost risk insight Reduced time to quote Greater project execution risk insight Increased capacity to manage complex projects

29 Design & Analyze Create Design Requirements Development Optimize For Manufacturing Simulate Sustain & End of Life Design & Analyze Define Manage Manufacture / Assemble Product Lifecycle Enterprise Digital Thread / Product Data

30 Digital Traditional Design & Analyze Traditional vs Digital 2D Prints are made manually Prototype is constructed based on 2D prints Testing takes place Review and redesign Generated data is stored physically 3D Model is created Part is simulated in digital environment Part is optimized digitally Generated data is stored digitally DESIGN THROUGH PROTOTYPING AND TESTING

31 Manufacture / Assemble Machine & Process Requirements Development Assemble Inspect Sustain & End of Life Design & Analyze Plan & Optimize Operations Material Processing Infrastructure Management Manufacture / Assemble Product Lifecycle Enterprise Digital Thread / Product Data

32 Digital Traditional Manufacture / Assemble Traditional vs. Digital 2D Prints and traveler released Manual machining or programming Part location not tracked Manually recorded Measurements Part passes inspection and data is stored manually 3D Model Machine code Developed and Optimized In CAM Part location tracked Electronically Automatic Recorded Measurements Part passes inspection and data is stored digitally MACHINING AND PROCESSING THROUGH INSPECTION

33 Sustain & End of Life Deploy Requirements Development Operate Maintain Decomission Sustain & End of Life Design & Analyze Repurpose Manufacture / Assemble Product Lifecycle Enterprise Digital Thread / Product Data

34 Digital Traditional Sustain & End of Life Traditional vs. Digital STOP 2D prints of product layout & systems Paper based install instructions Paper operating instructions Manual process monitoring Manual diagnostics Maintenance performed reactively Preventative maintenance strategy Paper - LOTO & maintenance guides FAILING Electronic layout and system models Digital & AR based install instructions Digital & AR operating instructions Remote process monitoring Embedded diagnostics Maintenance performed proactively Predictive maintenance strategy Digital or AR - LOTO & maintenance guides DEPLOYMENT, OPERATION, AND MAINTENANCE TECHNOLOGIES

35 Cybersecurity Concerns in Industry The fourth industrial revolution brings a new operational risk for smart manufacturers and digital supply networks: cyber. In the age of Industry 4.0, cybersecurity strategies should be secure, vigilant, and resilient, as well as fully integrated into organizational strategy from the start. - Deloitte Kaspersky said it had detected roughly 18,000 malware samples belonging to more than 2,500 families on industrial control systems (ICS) in the first half of ICS/SCADA Cybersecurity Conference, 2017 The new form of malware, dubbed Triton, is one of only a handful of malware families known to have been developed for the purpose of attacking industrial processes and core infrastructure we all rely upon for supplies such as gas, oil, and electricity. - ZDNet

36 Cybersecurity in the Product Lifecycle Manufacturing was the 2 nd most targeted industry in 2016* Attacks are up 10% since 2014** Sustain & End of Life Requirements Development Design & Analyze Supply Network Customer Network Product Network Product Lifecycle ~$400 billion in intellectual property is leaving the US each year in attacks*** Manufacture / Assemble Digital Thread / Product Data Digital Enterprise External Connections Cyber Security

37 Cybersecurity Concerns - Implications N O T Y O U R E V E R Y D A Y C O U N T E R F E I T S Lockheed Martin F-35B Shenyang J-31 Northrop Grumman X-47B UCAV Lijan Sharp Sword UCAV General Atomics MQ-1 Predator UAV Chendu Wing Loong Pterodactyl UAV Counterfeits of Consumer Goods General HMMWV Humvee (US) Dongfeng EQ2050 Brave Soldier US M-4A1 Chinese CQ 5.56mm Assault Carbine FGM-148 Javelin Hongjian-12 Red Arrow Images sourced from news.usni.org

38 Some Common Attacks & Vulnerabilities Approx. 60% of all attackers are insiders, malicious and inadvertent Theft of files, documents, physical assets, and data in transit Phishing exposure to malware laden Spearphishing attempts at accessing passwords and personal information Zero-day exploits, unpatched software and systems Most recent: Spectre and Meltdown hardware vulnerabilities Thousands of others in the wild Most IoT/IIoT hardware is orphaned by developers Will likely never see a firmware or software update to improve security Customers don t know how to patch security gaps even if they were aware

39 NIST Cybersecurity Framework The Framework is voluntary guidance, based on existing standards, guidelines, and practices, for critical infrastructure organizations to better manage and reduce cybersecurity risk 40

40 NIST DFARS 41

41 DMDII Overview D M D I I. O R G

42 The Manufacturing USA program exists to allow U.S. manufacturers to lead the disruptive innovation impacting their industries D M D I I. O R G 47

43 DMDII exists to transform American manufacturing competitiveness by accelerating the development and adoption of digital technology across the manufacturing enterprise D M D I I. O R G 48

44 The Digital Manufacturing and Design Innovation Institute (DMDII) W h o W e A r e Where Manufacturers Forge Their Future The Institute was established in 2014 with a $70M cooperative agreement with the US Department of Defense DMDII fosters development and implementation of digital manufacturing technology throughout supply chain We address underinvestment in pre-competitive applied R&D that can advance the entire industrial base We foster increases in productivity through the development and implementation of digital technologies In partnership with our over 300 industry, academic and government partners we are dedicated to the advancement of manufacturing in United States We help US manufacturers make every part better than the last U I L A B S. O R G N O T F O R D I S T R I B U T I O N 49

45 DM&D Technology Adoption Intermediate Advanced Basic Passive The goal is to move your capabilities along the continuum of DM&D technology adoption.

46 Enterprise Support Operations Supply Chain Data Exchange Design and Engineering Digital Factory Floor Cyber Security Step 1 - Assessment The process begins with SDMTS performing a current state DM&D Assessment at your facility, engaging in discussion about your digital readiness and capability. Assessment along DM&D categories: Enterprise Support Operations, Supply Chain Data Exchange, Design and Engineering, Digital Factory Floor, Cyber Security

47 Enterprise Support Operations Supply Chain Data Exchange Design and Engineering Digital Factory Floor Cyber Security Step 2 Discovery Lack of a CAD system increases design process costs No CAM system requires operators to translate 2D prints to G-code Lax data security policy and procedures Minimal simulation hinders product development time to market Lack of operational data forces assumptions and guesses when quoting new products.

48 Enterprise Support Operations Supply Chain Data Exchange Design and Engineering Digital Factory Floor Cyber Security Step 3 Solutioning ASSESSED GAPS LEAD TO DIGITAL MANUFACTURING OPPORTUNITIES Validated 3 rd party, commercially available DM&D solutions and services DMDII developed and curated solutions and partners DMDII R&D resources at through an individual, bespoke project basis

49 Are you ready for DM&D? Do you create and maintain manufacturing data digitally within your company? Do you exchange technical and/or business data digitally regarding your products and processes with your customers and/or suppliers? Do your design, production, and quality assurance test machines exchange data digitally about designs, products, or processes, with each other, or with external entities? 59

50 Are you ready for DM&D? Are you being asked by your customers and/or suppliers to exchange technical and/or business data with them electronically? Are you familiar with, or interested in learning more about, Digital Manufacturing and Design (DM&D) and how it works and could benefit your company? 60

51 Who is your Digital Manufacturing and Design Trusted Advisor? Distributor? OEM? Integrator? Other? U I L A B S. O R G N O T F O R D I S T R I B U T I O N 61

52 SDMTS as your Trusted Advisor SDMTS is well suited to serve as your trusted advisor of Digital Manufacturing and Design technology, methodology and improvements for you:

53 Contact Information South Dakota Manufacturing & Technology Solutions Keith Deibert Business Advisor

54 Thank you (and Q&A) 64