Module 1 Introduction to Smart Manufacturing
- 1. SMART MANUFACTURING Department of Robotics & Automation JSS Academy of Technical Education, Bangalore-560060 (Course Code: 21RA732)
- 2. Books 1. A. McEwen and H. Cassimally, Designing the Internet of Things, 1st edition, Wiley, 2013 2. N. Vengurlekar and P. Bagal, Database Cloud Storage: The Essential Guide to Oracle Automatic Storage Management, 1st edition, McGraw-Hill Education, 2013 3. M. Kuniavsky, Smart Things: Ubiquitous Computing User Experience Design, 1st edition, Morgan Kaufmann, 2010
- 3. MODULE 1: Introduction to Smart Manufacturing What is “Smart Manufacturing" and how does it differ from conventional/legacy manufacturing Smart Manufacturing Processes - Three Dimensions: (1) Demand Driven and Integrated Supply Chains (2) Dynamically Optimized Manufacturing Enterprises (Plant + Enterprise operations) (3) Real-time, Sustainable Resource Management (Intelligent energy demand management, production energy optimization and reduction of GHG) Syllabus
- 4. Course Learning Objectives (CLO) • To present a problem-oriented in-depth knowledge of Smart Manufacturing. • To address the underlying concepts and methods behind Smart Manufacturing • To identify different areas of IoT & Smart Manufacturing
- 5. Smart Manufacturing The flow of industrial revolutions
- 8. PRODUCT LIFE CYCLE MANAGEMENT
- 11. • Smart manufacturing (SM) describes a new approach to production with the “industry 4.0” trends. • The potential of I4.0 is data networking, information technology, Big data processing, artificial intelligence, and intelligent robots, leading to improved factory output while cutting energy and labour costs. • SM allows machines and tools to be interconnected with one another • It also refers to the adoption of cutting-edge cyber technologies, including enhanced sensing, control, modelling, and platform technologies in the I4.0 environment. INTRODUCTION
- 15. Benefits of Smart Manufacturing 1. Productivity and Efficiency: how a plant is performing and reduced downtime and maximum productivity with more efficient scheduling and rapid preventive maintenance. 2. Flexibility: Quickly adapting to changes in customer demand, reducing operating costs, and accommodating more prospects with new business verticals 3. Advanced technology automatically identifies fluctuations in manufacturing demand, enabling rapid supply chain response. 4. Improved Working Life - Reducing boring tasks and opening up new and different job opportunities. 5. Worker Safety - Gathering detailed worker, machine, and corporate datasets can afford overall safety and productivity through the use of intelligent automation.
- 16. Benefits of Smart Manufacturing 6. Cost Reductions - Identifying waste and increasing forecast accuracy are two ways that connecting operations and enterprise systems can ultimately reduce costs. 7. SM also provides better insight into inventory levels, delivery status, and demand cycles, reducing the cost of superfluous inventory.
- 24. Three Dimensions of Smart Manufacturing (1) Demand Driven and Integrated Supply Chains (2) Dynamically Optimized Manufacturing Enterprises (Plant+ Enterprise Operations) (3) Real-Time, Sustainable Resource Management (Intelligent energy demand management, production energy optimization and reduction of GHG)
- 25. Three Dimensions of Smart Manufacturing (1) Demand Driven and Integrated Supply Chains • Demand-driven manufacturing refers to a production approach where decisions and operations are primarily guided by real-time customer demand rather than forecasts or predictions. • This approach aims to reduce excess inventory, minimize waste, and align production closely with actual market needs
- 26. Common challenges and demand-driven solutions for different manufacturing environments.
- 27. Three Dimensions of Smart Manufacturing (1) Demand Driven and Integrated Supply Chains 1. Real-Time Data: By using real-time data from various sources, including customer orders, sales data, and market trends, manufacturers can adapt their production schedules and inventory levels promptly. 2. Pull System: Instead of pushing products through the supply chain based on forecasts, a demand-driven approach uses a pull system where production and inventory decisions are based on actual customer demand. 3. Flexibility and Responsiveness: This approach allows manufacturers to respond quickly to changes in customer preferences or market conditions, which is particularly valuable in industries with high demand variability or fast-changing trends.
- 28. Three Dimensions of Smart Manufacturing (1) Integrated Supply Chains • Integrated Supply Chains involve creating a seamless and consistent system where all parts of the supply chain—from suppliers to manufacturers to distributors and retailers— are interconnected and work together harmoniously
- 31. Three Dimensions of Smart Manufacturing (1) Integrated Supply Chains 1. End-to-End Visibility: Integrated supply chains use advanced technologies to provide visibility across the entire supply chain, enabling real-time monitoring and data sharing. 2. Collaborative Planning: With an integrated supply chain, different entities within the supply chain collaborate more effectively. This includes joint planning, forecasting, and replenishment efforts, helping to align supply and demand accurately. 3. Technology Integration: IoT, advanced analytics, and cloud computing are employed to integrate various systems and processes. This ensures that data flows smoothly between different parts of the supply chain and that all stakeholders are on the same page. 4. Improved Efficiency: Integration helps in streamlining operations, reducing redundancies, and improving overall efficiency. It can lead to cost savings, faster time-to-market, and better service levels.
- 32. Three Dimensions of Smart Manufacturing 2. Dynamically Optimized Manufacturing Enterprises • Dynamically Optimized Manufacturing Enterprises (DOME) refer to organizations that utilize advanced technologies and strategies to enhance their manufacturing processes and overall enterprise operations. • The goal of DOME is to create a flexible, responsive manufacturing environment that can quickly adapt to changing market demands, optimize resource utilization, and improve overall efficiency.
- 33. Three Dimensions of Smart Manufacturing 2. Dynamically Optimized Manufacturing Enterprises 1. Advanced Technologies • IoT: Sensors & connected devices monitor equipment & processes in real-time, providing valuable data for decision-making. • AI&ML: Algorithms analyze data to predict maintenance needs, optimize production schedules, & enhance quality control. • Automation and Robotics: Automated systems increase efficiency & reduce human error in repetitive tasks. Key components
- 34. Three Dimensions of Smart Manufacturing 2. Dynamically Optimized Manufacturing Enterprises 2. Data-Driven Decision Making • Real-Time Analytics: Data from various sources (machines, supply chain, customer feedback) is analyzed in real-time to inform operational decisions. • Predictive Analytics: Uses historical data to forecast trends, enabling proactive adjustments to production and inventory levels. Key components 3. Agile Manufacturing • Flexible Production Systems: systems can quickly switch between different products or processes, accommodating varying customer demands without significant downtime. • Rapid Prototyping: Techniques like 3D printing allow for quicker iterations in product design and development.
- 35. Three Dimensions of Smart Manufacturing 2. Dynamically Optimized Manufacturing Enterprises 4. Supply Chain Integration • Collaborative Networks: Partnerships with suppliers, distributors, and even customers to ensure smooth information and material flow. • Just-In-Time (JIT) Inventory: Reduces holding costs and increases responsiveness by aligning production closely with demand. Key components 5. Sustainability and Efficiency • Resource Optimization: Focus on minimizing waste and energy consumption through smarter processes and technologies. • Circular Economy Practices: Incorporating recycling and reusing materials to create a more sustainable manufacturing model.
- 36. Three Dimensions of Smart Manufacturing 2. Dynamically Optimized Manufacturing Enterprises 6. Employee Empowerment and Training • Skill Development: Continuous training programs ensure that workers are equipped with the skills needed to operate new technologies. • Collaborative Culture: Encouraging input and feedback from employees can lead to innovative solutions and improvements. Key components
- 37. Three Dimensions of Smart Manufacturing 3. Real-time sustainable resource management 1. Smart Grids: Allow for better communication between energy providers and consumers. They can adjust supply based on demand, optimizing energy distribution. 2. Demand Response Programs: These programs incentivize consumers to reduce or shift their energy usage during peak periods, helping to flatten demand spikes & reduce the need for fossil fuel-based plants. 3. IoT and Automation: IoT devices collect data on energy use, enabling automated adjustments to heating, cooling, & lighting in buildings, which helps save energy Intelligent Energy Demand Management • Real-time sustainable resource management is a comprehensive approach that focuses on optimizing energy use while minimizing greenhouse gas (GHG) emissions. • Using advanced technologies & data analytics to monitor & control energy consumption in real-time.
- 38. Three Dimensions of Smart Manufacturing 1. Renewable Energy Integration: Utilizing solar, wind, and other renewable sources reduces reliance on fossil fuels, directly cutting GHG emissions. 2. Energy Storage Solutions: Technologies like batteries and pumped hydro storage help balance supply and demand, storing excess renewable energy for use when production is low. 3. Process Efficiency: Implementing energy-efficient technologies in industrial processes—like combined heat and power systems—can significantly reduce energy use and emissions. Production Energy Optimization • Improving the efficiency of energy production processes to minimize waste and lower emissions.
- 39. Three Dimensions of Smart Manufacturing 1. Carbon Capture and Storage (CCS): This technology captures CO2 emissions from sources like power plants and stores it underground, preventing it from entering the atmosphere. 2. Lifecycle Assessments: Evaluating the environmental impact of products from creation to disposal helps identify areas where GHG emissions can be reduced. 3. Sustainable Practices: Encouraging practices such as energy-efficient buildings, sustainable transportation, and circular economy principles (reducing, reusing, recycling) helps lower overall emissions. Reduction of GHG Emissions • Strategies aimed at decreasing the amount of greenhouse gases released into the atmosphere.
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