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Innovation and Production:
Advanced Smart
Manufacturing Technologies,
Trends, challenges and
Implications.
TSINGHUA UNIVERSTY CERTIFICATE PROGRAM ON –
INNOVATION & ENTREPREUEURSHIP
Hamza Blala - School of Mechanical Engineering and Automation, Beihang University, Beijing, China - blala.hamza@yahoo.fr
Wenjing Jin - CyberInsight Inc. Beijing, China - wj.jin@cyber-insight.com
Kris Singh - Program Director.
SEPT. 2019
Contents:
Introduction Application
What is Smart Manufacturing?
Smart Manufacturing Standards
Applications of smart manufacturing
Benefits of Shifting to Smart
Manufacturing
The Smart Manufacturing Platform
CASE STUDY
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INTRODUCTION
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Industry 4.0
From Industry 1.0 to 4.0
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Smart Manufacturing
What is Industry
4.0 (Source:
Roland Berger,
Think Act
Industrie 4.0)
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Characteristics of a Smart Factory
Connectivity, Optimization,
Transparency, Proactivity, and Agility.
Each of these features can play a role
in enabling more informed decisions
and can help organizations improve the
production process.
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2
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4
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Robotics and Adaptive Automation
Equipment in manufacturing that can replace or augment
human labour during manufacturing
Additive and Precision Engineering:
3D printing and rapid prototyping
Continuous Manufacturing of Pharmaceuticals and
Biomanufacturing:
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Next-Generation Electronics:
Advanced circuits using non-silicon materials, less
processes and exible
3
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Nanoengineering of Materials and Surfaces:
Materials at the nanoscale and microscale from the
ground up; materials do not exist in nature
6
6Green Sustainable Manufacturing
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Applications of Smart Manufacturing
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Vertical Digitalization may Include:
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Smart Manufacturing Integration
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Anticipated Value Drivers from Digital
Manufacturing Technology Implementations50
Smart Manufacturing Integration
Keys to Successful integration
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Benefits of Shifting to Smart Manufacturing
Streamlined and Automated Data:
Predictive Maintenance:
Significant Cost Reductions
Reduce Workforce Challenges
Enhanced Productivity
Smart technologies automate data collection and provide advanced
production analytics, so managers can make more informed
decisions.
With better visibility, manufacturers can predict and resolve
maintenance issues before they lead to downtime or product-quality
issues.
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Shift From Traditional Supply Chain to Digital Supply Network
Benefits for the Supplier
A More Informed & Fluid Value Chain Path
Benefits for Software Vendors and 3rd-
Party Integrators.
Better User App Development &
Feedback
Benefits for the Manufacturer
Affordable Access to New Technology &
Innovation
Benefits for the Customers
KNOW What They’re Buying
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The Benefits of Smart Manufacturing to the Value Chain
#
IoT can help manufacturers better manage their supply chains.
BMW: Knows the real-time status of all machines
producing all parts/components from all suppliers going
into vehicles.
Toyota: Reduces recalls by knowing exactly what
machine produced which components of which vehicles.
HP: Integrates network analysis and data visualization
into its supply chain management and monitoring; has
reduced the time for supply chain management projects
by up to 50%.
IoT and Supply Chain Management
;
IoT and Manufacturing Operating Efficiency
Explosion of low-cost sensor technologies has made every manufacturing process and component a potential data
source.
Ford: Placed sensors on virtually every piece of
production equipment at its River Rouge facility.
GM: Uses sensors to monitor humidity conditions during
vehicle painting; if unfavorable, the work piece is moved
elsewhere in plant or ventilation systems adjusted.
Raytheon: Keeps track of how many times a screw has
been turned in its factories.
Merck: Improves vaccines by conducting up to 15 billion
calculations to determine what environmental and process
factors influence quality of final product.
2
IoT and Predictive Maintenance
Monitor the status of production equipment in real-time.
Intel: Uses predictive modeling to anticipate failures,
prioritize inspections, and cut monitoring costs, save $3M.
Ford: Downstream machines can detect if work pieces
they receive are off in a particular minute dimension,
indicating possible problems in upstream machines.
GE: “Brilliant Factories” initiative doubled production of
defect-free dishwashers and washing machines.
IoT and Inventory Optimization
IoT helps manufacturers better manage inventory.
Wurth USA: Developed an “iBins” system that uses
intelligent camera technology to monitor the fill level of a
supply box and wirelessly transmit the data to an inventory
management system that automatically reorders supplies.
IoT can drive inventory optimization measures that can
save 20 to 50% of factory inventory carrying costs.
CASE STUDY
Bird Strike Damage
Structure Failure
Space Debris
Fuel Savings Aircraft Weight Reduction
Smart Aerospace Structures- Sensors Embedded in Structure for Collecting Data
Fiber Metal Laminates (FMLs) are multi-
component materials using metals, fibers and
matrix resins. Tailoring their properties is
readily achievable by varying one or more of
these components. Established FMLs like
GLARE use aluminum foils, glass fibers and
epoxy matrices.
Fiber Metal Laminates (FMLs):
CASE STUDY
Smart Aerospace Structures- Sensors and for:
Collecting data :
Flaw Detection
Temperature
Pressure
Load
Vibration
Structure Crack initiation
Structural health monitoring systems
The main issues about business transformation are
connected not only to technological evolution, but also to the
people involvement and organizational aspects. Also, for
Industry 4.0, there are huge expected impacts from the
introduction of digital technologies, which involves new
workforce’s skills and operational models.
Summary
Thank you For Your Attention