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Theinfusionofintelligencethattransformsthewayindustriesconceptualize,designandoperatethemanufacturingenterprise.SmartManufacturingasaReal-TimeNetworkedInformationEnterpriseJimDavisUCLA/InstituteforDigitalResearchandEducationandTomEdgarUTAustinSMLC(501c6)://smartmanufacturing.comWhatisSmartManufacturing?SmartManufacturingenablesallinformationaboutthemanufacturingprocesstobeavailablewhenitisneeded,whereitisneeded,andintheformthatitisneededacrossentiremanufacturingsupplychains,completeproductlifecycles,multipleindustries,andsmall,mediumandlargeenterprises.TechnologyRoadmapReport(2009)31.MotivatingSmartProcessManufacturing2.TheBusinessCaseandtheBusinessTransformation3.TheTechnicalTransformation4.TheSmartProcessManufacturingRoadmap5.ThePathForward4Priorityactionsinfourcategories:•IndustrialCommunityModelingandSimulationPlatformsforSmartManufacturing•AffordableIndustrialDataCollectionandManagementSystems•EnterpriseWideIntegration:BusinessSystems,ManufacturingPlantsandSuppliers•EducationandTraininginSmartManufacturingImplementing21stCenturySMReport(2011)SMLCProgramAgendaforaSmartManufacturingPlatformLowerthecostforapplyingadvanceddataanalysis,modeling,andsimulationincoremanufacturingprocessesBuildpre-competitiveinfrastructureincludingnetworkandinformationtechnology,interoperability,andsharedbusinessdataEstablishanindustry-shared,community-sourceplatformandassociatedsoftwarethatfunctionsasan“apps”storeandclearinghouseCreateandprovidebroadaccesstonext-generationsensors,includinglow-costsensingandsensorfusiontechnologiesEstablishtestbedsforsmartmanufacturingconceptsandmakethemavailabletocompaniesofallsizesIndustrialGasManufacturingSteelEnergyBio/PharmaElectronicsHealthcareEnergySupplyProductionandDeliveryCustomersOurcustomersdemandcapitaldisciplineandhighreliabilityOurgoalistomeettheirdemandsandmaintainhighenergyefficiencySmartManufacturingHelpsMeetOurGoals•Hostedcomputingimprovesresultsatalowercost•CommoninfrastructurefacilitatessupplychaincollaborationDesignOperations•LowcostsensorsandwirelessenablerealtimedecisionsMachineOperations&LineManagementTrade-OffsMachineFunctionBenchmarking&IntegratedLineandEnergyManagementManagingPowerfromtheGridGeneralDynamicsFORDIn-ProductionVirtualAluminumCastingsAgingtemperature240Cfor5hrs210230205Agingat250Cfor3hrsOptimizedHeatTreatmentProcessFasterandStronger!!220InitialHeatTreatmentProcessTargetStrength=220MPaJohnAllisonAIChE2010GeneralMillsFarmingDistributorSupplyChainCustomer•Customers“pushing”demands•Tracking&TraceabilityManufacturingPlant11SupplyChainDistributionCenterCustomerBusinessSystems,ERPSmartGridSmartFactoryRecipeManagementMappingformulaintooperatingrecipesEDItransaction&qualitycertificationsFDATracking&traceabilityGeneralMillsNetworked-BasedManufacturingIntelligence&CollaborativeManufacturingGreenLightAnalyze-toputintoproductionMake–rightingredients–confirmationonrecipeRelease–meetrequirementstoreleaseMappingSAPinformationIntooperationMasterData(BOM,Specs,Vendor,Ingredients,FP)DirectConsumptionCoreSystemsDataInputCoreFunctionsRawMat’lInventoryFinishedProductInventoryProductionHistoryPlantFloorInventoryDemandPlanProductionOrderLineScheduleMQISMESSAPERPRedPrairieSAPAPOSAPPLMSAPMRPValueCreationGreenLighttoConvertGreenLighttoShipDemandDrivenSupplyChainWorkFlowLotTrackingOverusageOptimizationEngineTrace/RecallBOMValidationYardMgmtOptimizedInventoryBusinessApplicationsDirectedWorkSupplierManagedInvLineSupplyBinMgmtAllergen/MicroWorkFloweCOAGM’sECOSystemof“STUFF”TestBedGeneratedSMSystemsSmartMachineOperations•Inproductionmachine-productmanagement•Benchmarkingmachine-productinteractions•Integrateddynamicmanagementofmachine-electricalpowerinteractions•AdaptablemachineconfigurationsInProductionUseofHighFidelityModelingandSimulation•Highfidelitymodelingforbettermanagement•RapidqualificationofcomponentsandproductsInProductionDecisionMakingwithGlobalIntegratedMetrics•DynamicBusinessandOperationalTradeoffDecision-Making•Dynamicperformancemanagementofglobalintegratedmetrics•UntappedcrossfactorydegreesoffreedomforoptimizingefficiencyandperformanceandcompressingtimeSupplyChainManagement•Supplychainvariabilityreductionandmanagementofrisk•TrackingandtraceabilityIndustryTestBedStrategyIndustry-DrivenDefinedfromTestBedsystemsMETA4InteroperableSupplyChainNetworkControl,Automation,OptimizationManagement&DecisionMeta2Demand-DynamicCustomertoSourceVariabilityPlanningMulti-DimensionalSmartManufacturingMeta3HigherFidelityProductionReal-timeQualificationIntegratedComputationalMaterialsEngineeringMaterials&EnergyMgmt.Meta1IntegratedWorkforce,Cyber,PhysicalSystemPerformanceVariabilityReductionBenchmarkingChallenge2Integrationofmanufacturingenterprisedata,control,automation,managementandoptimizationinfrastructuresChallenge4Precompetitiveandcompetitivecommunitysourcemodelinginnovation&simulationassimilationplatformChallenge1FactoryandsupplychaindemonstrationssitesofappliedmanufacturingintelligenceChallenge3Real-timesyncingvirtualmodelsandphysicaloperat