IoT Impact on the Manufacturing Industry (Part 2)

Continuing on from my last blog post, another example for IoT use in manufacturing would be for the asset management to distribute work orders and configurations to the tools or the different stages of production. And vice versa, calibration information can be fed back to the Enterprise Resource Planning (ERP) system to associate them to the bill of material (BOM). Big data and NoSQL technology is an enabler in this regard, as they can allow for the management of huge volumes of heterogeneous, multi structured data about the production process, from the data types discussed, to even images from AOI (Automated Optical Inspection) systems and other production modules. With recalls a concern point in global manufacturing, this can be an ally in the fight to keep costs down for manufacturing.

IoT can also have an impact is in intelligent edge devices and their use in improving supply chain optimization and modularity of manufacturing. Consider surface mount technology (SMT), where there is so many moving parts, calibration, types of technology used in the placement and verification of board level components. IoT sensors could be utilized to centralize SMT line asset management and to read calibration information via the factory WLAN. The asset management can form the link between the SMT tools and the ERP (Enterprise Resource Planning) and MES (Manufacturing Execution Systems) that oversee the manufacturing process.

A challenge that presents itself to the manufacturing industry is the ageing workforce, and this means that anything that speeds up the manufacturing process is critical. The advancement in mobile technology is a key enabler in ensuring that passing information to the shop floor becomes quicker, improving response time, visibility, and accessibility of operations. The recent advancement of wearables also will have an impact on enhanced visibility on the shop floor.

Building Blocks for IoT in Manufacturing

Business owners need to look at four technology elements that provide the foundation for smart manufacturing. These include (but not limited to):

  • Security: IT security is a major obstacle to setting up smart factories. Operations managers need to make sure that necessary safeguards are built into the solution including security procedures such as physical building security, hardware encryption and network security for data in transit. Security and networking solutions must also be engineered to withstand harsh environmental conditions, such as moisture and temperature, that aren’t present in typical networks. Identity and authentication structures will also need to be updated to support such “things” as well as people.
  • More Advanced Networking: Smarter manufacturing environments need a standardized IP-centric network that will enable all the devices/sensors in a plant to communicate to enterprise business systems. Cisco research states that only 4 percent of the devices on the manufacturing floor are connected to a network. A standard IP network also makes it easier to connect and collaborate with suppliers and customers to improve supply chain visibility. Manufacturers need robust networks that can cope with Radio Frequency (RF) challenges in the plant, harsher environmental conditions and need stability for transmission of alarms and real-time data processing.
  • Big Data Analytics: While manufacturers have been generating big data for numerous years, companies have had limited ability to store, analyze and effectively use all the data that was available to them, especially in real time. New big data processing tools are enabling real-time data stream analysis that can provide dramatic improvements in real time problem solving and cost avoidance. Big data and analytics will be the foundation for areas such as forecasting, proactive maintenance and automation.
  • Engineering Software Systems: Today’s IoT data is different than the data we use to operate our systems. It requires collecting a wide range of data from a variety of sensors. These software systems and models must translate information from the physical world into actionable insight that can be used by humans and machines. Toyota is using Rockwell’s software for real time error corrections in the plant. Toyota has minimized rework and scrap rates in its Alabama plant, which has resulted in an annual cost saving of $550,000.3

Building blocks for end-to-end infrastructure enabling manufacturing intelligence from the factory floor to the data-center (Intel) [4]
Building blocks for end-to-end infrastructure enabling manufacturing intelligence from the factory floor to the data-center (Intel) [4]
With IoT, IP networks and analytics, manufacturers can become more efficient, improve worker safety and offer new exciting business models. IoT will help manufacturers improve resource efficiency, safety and return on assets. Manufacturers that master this new dynamic will have a variety of new opportunities for revenue growth and cost savings.

References

3: How IoT will help manufacturing

http://www.industryweek.com/blog/how-will-internet-things-help-manufacturing

4: Industrial Optimization IoT (Intel)

http://www.intel.ie/content/dam/www/public/us/en/documents/white-papers/industrial-optimizing-manufacturing-with-iot-paper.pdf

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deniscanty

DENIS CANTY IS EXCITED TO BEGIN IN JULY 2017 WITH MCKESSON, A FORTUNE 5 COMPANY – AS THEIR SENIOR DIRECTOR OF CYBER SOFTWARE ENGINEERING IN CORK. HIS LAST ROLE (TO JUNE 2017) WAS AS THE LEAD TECHNOLOGIST FOR IOT WITH JOHNSON CONTROLS INNOVATION GROUP BASED IN CORK, IRELAND. THAT ROLE MEANT COLLABORATING EXTENSIVELY BETWEEN HIS TECHNICAL AND SALES TEAMS TO DRIVE FURTHER COMMERCIALISATION OPPORTUNITY THROUGH TECHNOLOGY (BOTH OUR OWN AND PARTNERS/STARTUPS) INTO OUR SALES CHANNELS, SPECIFICALLY LOOKING AT THE EMERGING SMART BUILDING MARKET. THE PROJECTS INCLUDE OUR EXISTING TECHNOLOGIES – BUILDING SECURITY, RETAIL, HVAC AND BUILDING ENERGY – AND EMERGING TECHNOLOGIES SUCH AS IOT, AR AND MACHINE LEARNING. A KEY COMPONENT WAS TAKING KEY INPUT FROM NUMEROUS STAKEHOLDERS AND PROCESSES TO DELIVER ROI FOR CUSTOMERS AND PARTNERS. HE THEN LED THE TEAM TO BUILD AND DEPLOY THE SOLUTIONS IN AN LEAN AGILE MANNER. DENIS SPOKE ON THE NATIONAL AND INTERNATIONAL CIRCUIT FOR JOHNSON CONTROLS AT NUMEROUS TECHNOLOGY CONFERENCES. HIS LEADERSHIP STYLE IS LEADERSHIP THROUGH TRUST AND DELIVERY, AND I TAKE RESPONSIBILITY FOR MY TEAM, COMPASSION AND HUMILITY ARE ALSO IMPORTANT AS A LEADER IN MY OPINION. I LIKE TO BUILD A BALANCED CULTURE, WITH THE PEOPLES PERSONALITIES IMPORTANT INPUTS INTO THAT. DENIS HAS A DEGREE IN ELECTRONIC ENGINEERING (2H) FROM CORK INSTITUTE OF TECHNOLOGY, A MASTERS IN MICROELECTRONIC CHIP DESIGN (1H) FROM UNIVERSITY COLLEGE CORK AND A MASTERS IN COMPUTER SCIENCE (1H) FROM DUBLIN CITY UNIVERSITY. PRIOR TO JOHNSON CONTROLS, DENIS HELD A POSITION OF PRINCIPAL DATA ARCHITECT AND DEVELOPMENT MANAGER WITH EMC FROM 2010 TO 2015, SPENDING 2011 IN SILICON VALLEY. HE LED A TEAM FOCUSED AT REDUCING AND CONSUMING NINE TEST AUTOMATION PLATFORMS FROM EXTERNAL MANUFACTURERS TO ONE EMC CLOUD HOSTED PLATFORM. HE ALSO WORKED ON A NUMBER OF WORKFLOW AUTOMATION SOFTWARE REPLACING TEDIOUS MANUAL EXTRACT, SEARCH AND REPORT COMPILATION THAT RESULTED IN EFFICIENCY GAIN (WRITTEN IN PYTHON). I ALSO BUILT PREDICTIVE ANALYTICS APPLICATION IN MANUFACTURING AND DATA SCIENCE MODELS FOR THE CUSTOMER VERTICAL WITH THE CTO OFFICE. DENIS BROUGHT MICROSERVICES BASED DESIGN ALONG WITH DISTRIBUTED STORAGE AND PROCESSING TO THE GROUP, CHANGING THE DEVELOPMENT CULTURE IN THE PROCESS. DENIS WAS ALSO A MEMBER OF EMC’S GLOBAL INNOVATION COUNCIL AND AS AN AMBASSADOR WITH THEIR OFFICE OF THE CTO, LEADING THEIR CUSTOMER INSIGHT SOFTWARE DEVELOPMENT. DENIS WON TWO GLOBAL INNOVATION AWARDS IN HIS TIME WITH EMC, IN THE AREAS OF SUSTAINABILITY AND E-SERVICES, AND HAS A PATENT IN INTELLIGENT POWER MANAGEMENT ON STORAGE ARCHITECTURE. HE ALSO WORKED PREVIOUSLY FOR ALPS AUTOMOTIVE DIVISION FROM 2005-2010, IN A VARIETY OF ROLES, INCLUDING AS THE LEAD COMPUTER VISION ENGINEER, AND THE LEAD TECHNOLOGIST ON EUROPEAN RESEARCH PROJECTS IN THE AREAS OF IN-VEHICLE DISTRACTION MONITORING AND SMART HOME DEVICES. DENIS ALSO SPENT TIME CONSULTING IN THE START-UP WORLD, SUCH AS A HEALTHCARE INFORMATICS CONSULTANT WITH ACE HEALTH, LEADING THE DEVELOPMENT FOR AN APPLICATION WHICH HELPS HEALTHCARE SERVICE PROVIDERS ACHIEVE BETTER PATIENT OUTCOMES AND CUT COSTS THROUGH A REGULATOR-APPROVED PREDICTIVE ANALYTICS PLATFORM IN THE DUTCH AND US MARKETS. HE ALSO HAD HELPED NUMEROUS STARTUPS ON BUILDING THEIR TECHNOLOGY ROADMAP TO ALIGN WITH DEFINED TARGET MARKETS AND CUSTOMER BASES.

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