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IoT in Manufacturing: Insights and Best Practices

IoT Webcast Manufacturing net

Recently, the second of a two-part Manufacturing.net webcast series on ‘The Internet of Things ’ (IoT) wrapped with a deep dive on the very real business advantages and outcomes that are enabled when IoT is fully applied to Manufacturing operations. One of the speakers, David Gutshall, Infrastructure Design Manager at Harley-Davidson Motor Company, highlighted many advantages he’s experienced with deployments of the Converged Plant-wide Ethernet solution architecture from Cisco and Rockwell Automation. In the webcast, David talked about “greater manufacturing flexibility across the supply chain, where … we can collate data across the factory (and enterprise) … and have experienced a substantial reduction in downtime.”  He described that with an IP-enabled Connected Factory, “what used to take hours or days to triage and troubleshoot problems now takes seconds.” Expanding on the topic, David said “when we bring a new machine online, it essentially works with the network out-of-the-box,” yielding greater flexibility and significantly reducing new model NPI (New Product Introduction) cycles and time to market.

Similar companies, like General Motors, have leveraged this industrial automation and controls system (IACS) architecture, which GM calls ‘Plant Floor Control Network’ (PFCN), to reduce downtime by as much as 75% and to drive out hundreds of $millions in plant engineering, operations and maintenance costs associated with factory expansions and modernizations. Both GM and Harley identify one of the biggest advantages of a standardized yet flexible factory automation infrastructure is the acceleration of NPI offerings and advancement into new markets. Over the past decade, GM with partners has been able to gain a leading share of passenger vehicles produced in China, Brazil and other emerging markets. And as Harley rolls out their recently announced LiveWire electric motorcycle, I suspect that an integral part of their strategy includes the American manufacturing renaissance vision for a dynamic, fun, flexible factory of the future. Take a look at this inspirational video from Harley describing the modernization and transformation of their existing York Manufacturing Facility:

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Imagine the Possibilities with IoT and IoE

Cisco customers have asked me how the Internet of Everything and the Internet of Things are going to affect their everyday life.  My answer:  it can be mind-boggling how interconnected sensors and devices are going to impact our daily lives.

Specifically, in the industrial space, I get to work daily with our manufacturing and mining customers who want to understand best practices and deployments, and figure out how to implement various solutions to add value to their business.  Some of this may be tracking adjacent or similar markets with the nuanced changes to apply to their particular situation.

For example, one customer I have been working with is in the process of integrating 4-5 completely different systems into one tool to do correlation events.  In the past, one person had to have the intelligence to look at each of these disparate systems and then start to tie all of this together.  The issue is with the fact is the single person who has this intelligence is the only one who knows what to do.  This may have been job security for that individual, but the situation creates bottlenecks.

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How Dundee Precious Metals is Reinventing Mining with Internet of Everything

Maciej Kranz, VP and GM of Cisco’s Corporate Technology Group, shares his perspective on Dundee Precious Metals and the Internet of Everything

I’ve traveled a great deal around the globe in the last year and am amazed at the interesting things organizations are doing with technology to connect the unconnected. As we enter the next big phase of the Internet – the Internet of Everything (IoE) – no industry can afford to be left behind. Even the industries that existed long before the Internet was even a glimmer on the horizon, such as manufacturing and mining, can realize great value through IoE. Dundee Precious Metals (DPM) is one example. They’re a manufacturing company that has capitalized on the connections between the people, process, data and things that IoE is enabling, transforming one of the world’s most traditional industries in the process.

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When DPM set a goal to increase production of their flagship mining operation by 30 percent, their IT team needed to find a way to reach the target without increasing manpower or the number of vehicles.

With the help of the connections from IoE, now Dundee can share important information in real time, such as miners’ locations, equipment updates and data such as the number of buckets filled. This lets their teams troubleshoot as they go, instead of just at the end of a shift, keeping crews better on track to meet daily goals. What’s more, miners and mine managers had limited communication options since their Wi-Fi didn’t function well underground. So they leveraged Cisco’s unified wireless network to provide coverage along 50 kilometers of tunnels. This let drivers, supervisors and managers communicate efficiently – above ground or below – with calls and instant messaging. Radio Frequency Identification (RFID) tags placed on miners’ caps and vehicles keep everyone synced up with location tracking via a 3D map for improved worker safety. New collaboration capabilities extend to other DPM locations, making face-to-face collaboration possible between managers, geologists and metallurgists as they discuss production, development and project schedules. This all adds up to better understanding and decision-making across the board.

So what have these changes meant for DPM?

  • Production increased by 400 percent, far exceeding their original 30 percent goal.
  • Miner safety has improved as they track miners’ movements and know where everyone is at all times.
  • Asset utilization of vehicles has also improved via continually transmitted data identifying repair needs.
  • Communication and energy costs have been lowered through more efficient use of resources.

This is just the start of DPM leveraging IoE’s capabilities. The company plans to replicate the same systems in all of its mines, as well as extend the Internet of Everything concept to health monitoring of employees, using connected environmental health sensors.

The Internet of Everything is not just the technology of tomorrow. It is here today, and the networked connections it provides can impact all industries, even those industries with roots from long ago.

Read the full case study here: http://www.cisco.com/web/tomorrow-starts-here/manufacturing/index.html

Join the conversation on Twitter with the hashtag #InternetofEverything.

Read more #InternetofEverything Perspectives

Transforming Property Management with IoE by Roger Vasquez — Director of Engineering of Transwestern

Integrating Cities with IoE and City24/7 by Tom Touchet — CEO of City24/7

Driving Smarter with Technology and UPS by Dave Barnes — CIO of UPS

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The Digital Renaissance Is Here. Is Your Company’s Culture Ready?

Sooner or later we all feel like throwing up our hands and cursing the complexity of modern life. But while technology may seem the chief culprit in making things unmanageable, it is also the ultimate solution to complexity.

In the Internet of Everything (IoE) era, it is particularly important for business leaders to understand the power of technology to simplify our lives and support JBradleySAPinformed decision making. And this was a core theme at Sapphire Now 2014, an event in Orlando, Fla., that I was privileged to attend last week.

By using network technology to integrate people, process, data, and things, IoE counters complexity in unprecedented ways. In a city, this can involve something as simple as cutting the time it takes to find a (connected) parking space. Or IoE technologies can scale up to reroute traffic lights; for example, to head-off highway backups before, during, and after a large event.

In a brick-and-mortar retail setting (a key area of discussion at Sapphire Now), IoE can alleviate the complexity of managing customers, staffing, and products. With data from multiple sources comes heightened, real-time awareness, empowering managers to react faster than ever. For example, they can then stock shelves and reorganize staff in response to constantly changing levels of demand. With predictive analytics they can even respond before a customer rush begins.

The idea of hyper-aware, real-time decision-making resonated during a Sapphire Now panel discussion titled Thrive in the Digital Networks of the New Economy. I was honored to share the panel with such luminaries as Erik Brynjolfsson of MIT; Michael Chui of McKinsey Global Institute; and Jai Shekhawat, Deepak Krishnamurthy, and Vivek Bapat of SAP. And there was much discussion on the impact of bad decisions on failed organizations. Which is why we all take such an interest in technology that enables good ones.

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Cisco Supply Chain Operations Places in Top 10 of Gartner Ranking

Congratulations to the Cisco Supply Chain Operations (CSCO) team. For seven consecutive years, Cisco has placed in the Top 10 of Gartner’s prestigious ranking!

Led by Cisco Senior VP John Kern, the supply chain operations team here at Cisco has undergone an extensive transformation and continues to be recognized globally as a best-in-class practitioner. With more than a thousand contract manufacturing and component suppliers, logistics (3PL) and other service partners, along with more than 25,000 orderable product IDs—which are broadly mixed amongst build cycles of engineer-to-order, configure-to-order, build-to-order and build-to-stock—the complexity and global scale of what our Cisco-resident supply chain gurus deal with on a daily basis could be staggering for some organizations but is managed with excellence by CSCO. Beyond the outstanding development and fulfillment supply chain and manufacturing management services rendered, CSCO has served as a tremendous expert asset and executive connection for our go-to-market expansion with manufacturing customers’ lines of business, particularly related to the Internet of Everything (IoE) market transition.

The splashy ad below illustrating a vision for the Internet of Things (IoT) has become much more of a reality and the technologies and products shown are in use within Cisco’s supply chain ecosystem today.

Recently, two Cisco colleagues — Edna Conway, VP CSCO and Chief Security Officer and Bob Dean, Director, Manufacturing and Energy Vertical, co-authored an excellent article for Manufacturing Leadership Journal entitled ‘The Fourth Dimension of Supply Chains’. The article highlights how new technologies are empowering supply chains as never before, and how they are also exposing enterprises and ecosystems to new risks.  Cisco’s comprehensive approach to mitigate risks and bolster confidence across the supply chain focuses on the four areas of malicious modification/substitution of technology, counterfeit products (both raw materials and finished goods), the security component of supply chain resiliency and misuse of intellectual property.

Discipline surrounding that fourth topic of securing intellectual property has become an even greater concern in the face of new business models and innovations with the application of IoE in manufacturing. Best-in-class manufacturers are, like Cisco, increasingly leveraging their supply chains and ecosystems to develop offering portfolios balanced between sustaining and disruptive innovations that are derived from scrutinized customer segmentation and guided by such principles as value-driven design discipline, cross-BU portfolio platform awareness and rationalization, differentiated solution-service bundling, and connected system-level lifecycle services (e.g., Product as a Service). All of these design and innovation processes require immersive and intimate collaboration with customers and across supply chains.

Cisco’s relevance to enable manufacturing supply chain and innovation strategies to achieve more transformative business outcomes has never been greater:

  • Virtualized and distributed compute with Application Centric Infrastructure (ACI) and Supply Chain Collaboration accelerating time-to-market with value-oriented product and service offering innovation;
  • IoE-enabled ‘3D Value Chains’ with ubiquitous visibility accelerating portfolio rationalization decisions, improving throughput and enabling more sustainable supply chains;
  • Business video with IoE-enabled connectivity accelerating lifecycle service offerings throughout the supply chain, like remote access, monitoring and diagnostics with mobile expert/advisor.

What are some of the challenges, innovations and opportunities in your global supply chain today?  Join the conversation below and let me know.  Thanks for reading.

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