Why Businesses Need to Digitally Transform? - Your Future is Here!! R. N. Mohanty

1 2 3 4 5 6 7 The Future is Here Transformation is Essential Disruptors viz-a-viz Disrupted Impact of Disruptions on Manufacturing 5 6 7 Transformation of Manufacturing Automation Strategies to Align to Disruptions Next Wave of Transformation

The Future is here Business need to digitally transform The four great disruptive forces Shifting focus of economic activities and centre of economy. Disruptive force by the acceleration of scope, scale and economic impact of the technology. The demographic redistribution The connected world.

The Future is here Business need to digitally transform The paradigm shifts at play The Disruptive dozen. Changing building blocks of things. Re-thinking energy - comes of age. Machines working for us. IT and how we use it.

Transformation is Essential & Inevitable The impact of transformation In last 15 years, 52% of Fortune 500 companies have disappeared being disrupted by digital disruptors It used to take Fortune 500 companies, an average of 20 years to reach a billion dollars valuation, but the digital starters are reaching the same milestone in an average of 4 years. Some of them in less than one year. There are 2 sides of digital divide, either you are a disruptor or a target of disruption. Many conventional manufacturing companies have transformed to become technology companies for competitive growth.

Disruptors viz-a-viz Disrupted Companies are compelled to innovate for survival in new era Airbnb disrupted the Hotel industry to become the biggest Hotel Chain. In India OYO did the same. Uber and Ola disrupted the public transportation services.

Impact of Disruptions on Manufacturing Manufacturing has seen massive changes in their approach In manufacturing domain, operational technology had digitalization since 1970 in form of DCS, PLC etc. The new technologies such as IIOT, RPA and artificial intelligence changed the manufacturing automation substantially. Basic difference between convention automation to IIOT/ AI automation is the distribution of the intelligence throughout all the automation elements in the value chain. Yet another difference is the learning capacity of automation agents by Machine learning/ Deep Learning and with augmented and virtual reality. On top of these automation elements, digital twins can be modelled for simulating ‘What-If’, and gaining other insights quickly, non destructively and reversibly.

Transformation of Sensors Transformation of Manufacturing Automation The first element of smart automation is the intelligent sensor Intelligent sensors are nano control systems with compute memory, logic unit and communication facilities built in. These type of sensors also used in edge computing reduces the load on the communication system, the cost of automation system and can be implemented in very small to very large manufacturing units. Presently, these intelligent sensors are not easily available. Reduction in cost of intelligent sensors both continuous and discrete is driving the IIOT revolution further.

Transformation of Communication Infrastructure Transformation of Manufacturing Automation The next element of the smart intelligence automation in smart factory 4.0 is the appropriate communication possibilities Communication system/ protocols such as LoRa, LPWAN, BLE, WiFi, 5G, in addition to the existing communication systems, protocol such as RS-232 / 485, OPC , MQTT, EtherNet etc. have made it possible to communicate between the sensors to control centres, to other control elements and cloud. Most of these industrial networks and protocols being bidirectional, helps availability of intelligence, data knowledge etc. very easily as and when required. The fundamental change from the DCS/ PLC and the smart automation system is the possibility of using humongous parameters, defining manufacturing equipment & processes, precisely by using big data analytics and artificial intelligence.

Transformation of Execution Infrastructure Transformation of Manufacturing Automation The next element is the cloud in different forms Types of cloud Implementations i.e: Private Hybrid Public Fog Smart grid The automation and advance control in manufacturing domain benefits most from the unconstrained availability of data and knowledge in the cloud easily, instantly, at low cost on subscription mode.

Transformation of Product Delivery Ecosystem Transformation of Manufacturing Automation With the elements already described, the product delivery ecosystem changes drastically. The products are unique and mass customised. The supply chain is disintermediated. Manufacturing using flow chemistry, micro reactors and process intensification, delivers exactly the quantity used by the user, hence minimises the waste. By using computational chemistry and green engineering, green manufacturing is facilitated taking care of planet earth. Alternate green routes, non toxic routes in process of manufacturing are being evolved by micro scale, modular, molecular reaction of manufacturing eliminating waste generation.

Strategies to Align to Disruptions Aligning Manufacturing Operations to these Disruptions is unavoidable Automation and Mechanization are the backbone for achieving the new manufacturing ecosystem. Precise and low cost control at the edge with advance control at control centres and cloud facilitates cost effective and safe manufacturing. Collaboration between human being & robots helps to manufacture in extreme condition and hazardous atmosphere continuously without any human error and fatigue.  Automation and control have got a next level boost by the computing capacity available with super computers and quantum computing which can be shared resources, breaking all geographical boundaries. What was in text books of control engineers, are being implemented and practised in control using advance algorithms, fractal, relative gain analysis, Z and other transformations etc.

Next Wave of Transformation More is coming Automation in manufacturing have reached an advance stage however, the real advancement in the near future are: Use of quantum computing Block Chains The other important features are New functional materials Shape memory alloy materials Functional ceramics 3D printed light tissues and organs Availability of new elements from meteors and deeper space.

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