NACFAM:
Speeding Up Manufacturing
through Greater Connectivity
Michelle Pastel
Manager Measurements, Controls &
Systems Innovation
April 9th, 2015
Revised 2/2/2015
Corning Incorporated
Founded:
1851
Headquarters:
Corning, New York
Employees:
34,800 worldwide
2014 Sales:
10 billion
• Corning is one of the world’s leading innovators
in materials science. For more than160 years,
Corning has applied its unparalleled expertise in
specialty glass, ceramics, and optical physics to
develop products that have created new
industries and transformed people’s lives.
• Corning succeeds through sustained investment
in R&D, a unique combination of material and
process innovation, and close collaboration with
customers to solve tough technology
challenges.
Fortune 500 Rank (2014):
343
© 2015 Corning Incorporated
2
Corning Market Segments and Additional Operations
Display
Technology
Environmental
Optical
Communications Technologies
• LCD Glass
• Optical Fiber and • Emissions
Substrates
Cable
Control Products
– Light-duty gasoline
• Glass Substrates • Hardware
Optical and
vehicles
for OLED and
Equipment
Connectivity
–
Light-duty and
high-performance
–Solutions
Fiber optic
heavy-duty on-road
connectivity
LCD platforms
• Wireless
diesel vehicles
products
Distributed
– Heavy-duty nonAntenna Systems
road diesel
vehicles
• Optical Cables for
–
Stationary
Consumer
Networks
• Copper
Connectivity
Components
Life
Sciences
• Cell Culture and
Bioprocess
• Drug Discovery
• ADME/Tox
• Genomics
• Chemistry
• Microbiology
• General
Laboratory
Products
Specialty
Materials
• Corning® Gorilla®
Glass
• Display Optics
and Components
• Optical Materials
• Optical Systems
Other
Products
and Services
• Emerging
Innovations
• Equity
Companies
–
–
–
–
Cormetech, Inc.
Dow Corning Corp.
Eurokera, S.N.C.
Samsung Corning
Advanced Glass,
LLC (SCG)
© 2015 Corning Incorporated
3
Innovation Timeline
First low-loss
optical fiber
2012
2007
1982
Glass
ceramics
1970
Dow
Corning
silicones
1952
1934
1879
Glass envelope for
Thomas Edison’s
light bulb
Active matrix
liquid crystal
display (LCD)
glass
Thin, lightweight
cover glass with
exceptional
damage
resistance
Ultra-slim,
flexible glass
for thin and
lightweight
applications
Ultrabendable
fiber
Label-free
screening
platform for
drug
discovery
Heat-resistant
PYREX® glass
Fusion
overflow
process
1964
1915
Processes
for mass
producing
the television
bulb
Environmentally
conscious
LCD glass
First alloptical
converged
cellular
and Wi-Fi
solution
2013
2006
1972
1947
Ceramic
substrates
for
automotive
catalytic
converters
First EPAregistered
antimicrobial
cover glass
© 2015 Corning Incorporated
4
Growth Through Innovation
• Our culture of innovation is built on the foundation of research
and development
• Our near-term growth will be fueled by several opportunities
– Glass substrates for LCD and OLED displays
– Ceramic substrates and filters for mobile emissions control
systems
– Optical fiber, cable, and connectivity solutions for the world’s
leading carrier, enterprise, wireless, and consumer networks
– Drug discovery tools and solutions
– Chemically strengthened, damage-resistant glass
– Other advanced optics and specialty glass solutions for the
semiconductor, aerospace, defense, astronomy, and metrology
industries
© 2015 Corning Incorporated
5
Research and Development (R&D)
• Our growth is fueled by a commitment to innovation and a
passion for conquering complex material and technology
challenges
• We invest approximately 10% of our sales in R&D
• We maximize the results of our R&D by engaging crossfunctional teams and senior leadership at all stages of
innovation
• Our technology leadership and R&D environment attract
and enable the best scientific minds in the world
© 2015 Corning Incorporated
6
Deep Core Technology Capabilities – Science & Engineering
Corning’s
strength
is based
on a broad
portfolio
of core
technologies…
Inorganic
Materials
and
Processes
Engineering:
- Materials
- Optical
- Process
- Chemical
- Electrical
- Mechanical
Optical
Physics
and
Network
Technologies
Modeling
and
Simulation
Organic
Materials
and
Processes
Core
Capabilities
Materials
Characterization
and
Processes
Network
Integration
and
Connectivity
Research
Biochemical
Sciences
and
Processes
… and the
ability to
integrate
them.
Thin Films
and
Surface
Sciences
© 2015 Corning Incorporated
7
Awards and Recognitions
• Four-time National Medal of Technology winner
• Institute of Electrical and Electronics Engineers (IEEE)
Milestone Award for the invention of low-loss optical fiber (2012)
• Edison Award gold medal in Materials Science for Corning® Gorilla® Glass (2012)
• Thomson Reuters Top 100 Global Innovatorsm (2013, 2012, 2011)
• Massachusetts Institute of Technology’s list of disruptive innovators (2013)
• “Most Innovative Companies” (2013) and “Innovation All-Star” (2010) by Fast
Company magazine
• The American Ceramic Society Corporate Technical Achievement Award (2010)
• One of Fortune magazine’s most admired companies (2010, 2009)
© 2015 Corning Incorporated
8
The Corning Values
Our Values are the historic strength of our company, guide our every
move, and continue to set us apart from others.
All seven,
All around
the world.
All the time.
© 2015 Corning Incorporated
9
Corning Summary Remarks
• We’ve succeeded for 160 years … few other U.S. companies have
• How have we done it?
–
–
–
–
–
–
Successive waves of innovation
Deep understanding of glass and ceramic materials
`
Strong process and manufacturing
capabilities
Collaboration with customers and partners
An exceptionally talented and dedicated workforce
A conservative financial structure and patient capital
© 2015 Corning Incorporated
10
Smart Manufacturing
Leadership Coalition
www.smartmanufacturingcoalition.org
NACFAM - Speeding Up Manufacturing
through Greater Connectivity
Michelle Pastel - Corning, Inc.
Smart Manufacturing
Leadership Coalition
www.smartmanufacturingcoalition.org
Smart Manufacturing
“Information that drives the
next century’s structural shift
in manufacturing.”
Smart Manufacturing
Leadership Coalition
(SMLC) – 501c (6)
Making real-time info available:
• when it is needed,
• where it is needed
• and in the form it is needed
throughout the Manufacturing
ecosystem
An Industry-Driven Open
Architecture
Shared Infrastructure
SMLC Partnerships
American Council for an Energy
_Efficient Economy (ACEEE)
AMP Socal
Alcoa
American Institute of Chemical
Engineers (AIChE)
American Society of Quality ARC
Association of State Energy
Research and Technology
Transfer Institutions (ASERTTI)
Corning
Department of Energy (DOE)
Emerson
Electric Power Research Institute
General Dynamics
General Electric
General Mills
General Motors
Manufacturing Enterprise
Solutions Association (MESA)
MT Connect
National Association of State
Energy Officials (NASEO)
North Carolina State University
Nimbis Services
NIST
National Science Foundation (NSF)
OSISoft
Owens Corning
Pacific Northwest National Laboratory
Pfizer Inc.
Praxair
Purdue University
Rensselaer Polytechnic Institute
Rockwell Automation
Savigent Software
Schneider Electric
Society of Manufacturing Engineers
Southwest Research Institute - SWRI
Sustainable Solutions
Texas A&M Engineering Experiment
Station (TEES - TAMU)
Tulane - PolyRMC
University of California, Berkeley
University of California, Los Angeles
University of Texas - Austin
West Virginia University
SMLC’s Industry-Driven Strategy
Smart Manufacturing
Leadership Coalition
www.smartmanufacturingcoalition.org
Implementation Plan:
Roadmap: Operations &
Review & Refine
Collaboration Roles &
Technology for SM systems
Alignment
Action Plan: Implementing 21st
SMLC Forum
Century Smart Manufacturing
Workshop
NSF
Workshop
Establish Work Groups:
Identify & Drive Priority areas
•
•
•
•
Board Meetings,
Calls, Advisory
Groups, Focused
Workshops, etc.
DOE Workshop
Spin-off parallel activities
Membership Expansion
2006-09
Test Bed
Platform
People
Business
2010
2011
2012
2013
AMTech
ACCELERATE
AIChE Workshop
Infrastructure Specification:
Increasing SM Platform Definition
& Development
Forward
Technical
Meetings
SMLC Incorporates as 501c6:
DOE, NSF, NIST Awards:
$13 million in Project Work to
develop SM Platform Prototype
Building Capacity & Resources;
Leveraging Resources; Advocacy for SM
Smart Manufacturing
Leadership Coalition
www.smartmanufacturingcoalition.org
EDI transaction
& quality
certifications
General Mills NetworkedBased Manufacturing
Recipe Management
Mapping formula into operating
recipes
Business
Systems, ERP
Mapping SAP information
Into operation
Customer
Supply Chain
Smart
Factory
Smart Grid
Distribution Center
FDA Tracking &
traceability
Green Light
Analyze - to put into production
Make – right ingredients – confirmation on recipe
Release – meet requirements to release
Graphics courtesy of Rockwell Automation
GMI’s ECO System of “STUFF”
Smart Manufacturing
Leadership Coalition
www.smartmanufacturingcoalition.org
Demand Driven Supply
Chain
Green Light
to Ship
Allergen/Micro WorkFlow
Line Schedule
Production
Order
Demand Plan
WorkFlow
Production
History
Plant Floor
Inventory
Direct
Consumption
Overusage Trace/Recall BOM Validation
Core Functions
Bin Mgmt
Line Supply
Yard Mgmt
Directed Work
Finished Product
Inventory
Supplier Managed Inv
eCOA
Optimization
Engine
Business Applications
Optimized
Inventory
Raw Mat’l
Inventory
Green Light
to Convert
Lot Tracking
Value Creation
Master Data
(BOM,Specs,Vendor,Ingredients,FP)
Core Systems
Data Input
MQIS
MES
SAP ERP
SAP MRP
SAP APO
SAP PLM
Red Prairie
EERE DOE “Project Smart
Manufacturing”
EERE DOE “Project Smart
Manufacturing”
Smart Manufacturing
Leadership Coalition
www.smartmanufacturingcoalition.org
Development of an Open Architecture, Widely Applicable Smart Manufacturing Platform
Test Bed: Praxair
Design
Operations
Supply Chain
Manufacturer
(OEM)
Data Center Monitoring -- Global Map
Distribution/Reseller
Retailer
Customer
Supplier
Logistics
Dynamic Energy Risk Management & Cross Unit Performance
Test Bed: General Dynamics
Cutting & Machining
www.army.mil
Heating & Forging
Integrated Line Operations Management
Power Mgmt & Energy Grid
Smart Manufacturing
Leadership Coalition
www.smartmanufacturingcoalition.org
Technical and Business Drivers for
Shared Infrastructure
Achievable Meaningful Use Goals
and Magnitude of Impact
Issues Beyond Individual Company
• ROI constrained or prohibitive
- Requires broader infrastructure investment to scale
• Demand-driven efficient use of resources and supplies in
more highly optimized plants and supply
- Incremental investment difficult
– 25% reduction in safety incidents
- Requires IT investment with 70% of cost non-value
– 25% improvement in energy efficiency
- Depends on other companies - supply chain
– 10% improvement in overall operating efficiency
- Need 80% lower cost implement modeling/simulation
– 40% reduction in cycle times
- 10x reduction in cost of sensors/sensor infrastructure
– 40% reduction in water usage
• ROI opportunity comprehensive
• Product safety
–
Product tracking and traceability throughout the supply
–
–
–
Multiple systems
Integrated global performance metrics
Aggregating data
• Sustainable production processes for current and future
• Installed base of serviceable manufacturing facilities
critical industries
– $60 B in IT investment
– 10x improvement in time to market in target industries
– Retrofit
– 25% reduction in consumer packaging
• Risk
• Maintain and grow existing U.S. industrial base
– Major change & New business model
– Environment for broad innovation
– Uncertain about technology, security & IP
– 25% revenue in adjacent industries
– 25% revenue in new products and services
• Organization
– 2x current SME’s addressing total market
– IT capability lacking or IT not talking to operations
– More highly skilled sustainable jobs created
– Workforce skills
– Collaboration
Smart Manufacturing
Leadership Coalition
www.smartmanufacturingcoalition.org
Manufacturing Health
& Sustainability
Smart Manufacturing
Leadership Coalition
www.smartmanufacturingcoalition.org
Smart
Machine Line
Operations
In-Production
High Fidelity
Modeling
What is SMART
Test Bed Smart Systems
Dynamic Decisions
Enterprise &
Supply Chain
Decisions
Design, Planning
& Model
Development
Machine product Better management
management
complex behaviors
Performance
management global
integrated decisions
Variability
reduction
Design models in
production
Benchmarking
Rapid qualification
machine-product components
interactions
products materials
Untapped enterprise
degrees of freedom in
efficiency, performance
time
Risk and
compliance
management
Product/material
in-production ability
Tracking
traceability
genealogy
New product,
material technology
insertion
Machine-power
manage
management
Adaptable
machine
configurations
Integrated
Business operational
computational
tradeoff decisions
materials engineering
External
Configurable data
partner
and analyses for
integration into
rapid analytics and
business
model development
process
www.smartmanufacturingcoalition.org
Design
Data
Prototype
Materials &
Process Tech
Product
Manufacturing
Control & Automation
Macro Layer
10s
control loops
Time – days
Meso Layer
100s
control loops
Time -hours
1000s
control loops
Time - minutes
Micro Layer
In
Qualification Service
Focus: 10x Multiple
Pass Variability
Reduction; Supply
Chain Information
Focus: 100x Event
Variability/Tradeoff
Adjustment; Dynamic
Performance Mgmt.;
Integrated Metrics
Focus: Insertion,
Qualification, ICME, High
Fidelity Dynamic
Operations
Business Systems
Smart Manufacturing
Leadership Coalition
Smart Manufacturing: Multi-Layered
Seams, Time, Data & Action - Materials
Dynamic Manufacturing Ecosystem
Smart Manufacturing
Leadership Coalition
www.smartmanufacturingcoalition.org
Smart Manufacturing Platform
Bridging Seams Extending the
Real-Time Infrastructure
Power Mgmt &
Energy Grid
Heating &
Forging
Open-Architecture Infrastructure
& Marketplace
• APPs & Toolkits
•Composable Systems
• Cloud Deployment
• Private/Public IaaS
Line Operations
Suppliers
Applications
SM Value Proposition
Context
Sustainability
& Safety
Distribution
Mapping
Customers
Data
Event Data
Production
Models
Real-Time Data
Calibration &
Maintenance
Sensor
Data
Smart Manufacturing
Leadership Coalition
www.smartmanufacturingcoalition.org
Building Infrastructure
Powering Smart Decisions
Smart Manufacturing
Leadership Coalition
www.smartmanufacturingcoalition.org
US Mfg Needs Smart Sensors & Systems
Need to Overcome Adoption Barriers
• Low Initial Cost- open
• Low Cost to Install- robust wireless
• Easy to Maintain- high uptime, increase mfg
efficiencies
• Secure
• Information- Respect What’s Not Yours
• Bridge Workforce Generation Expectations
• Make Smart Manufacturing a Prudent Risk
with <2 yrs. ROI
Smart Manufacturing
Leadership Coalition
www.smartmanufacturingcoalition.org
•
•
•
•
•
US Mfg Needs Mindset Changes to Win
in a Global Economy
Expect Information- expect interoperability
Think Eco-system Broadly- physical and cyber
Integrate Existing Organization Silos- IT & engr
Place Increased Value in Data- knowledge
Automate What We Know- opens time to
solve the next problem
• Re-Evaluate Roles- expanded skills required
• Expect Lifelong Learning- facilitate achieving it
Smart Manufacturing
Leadership Coalition
www.smartmanufacturingcoalition.org
Institute Structure