Application of 5g-iiot-ebook-manufacturing.pdf

The key to smarter, more agile high-tech factories

1. THE KEY TO SMARTER, MORE
AGILE HIGH-TECH FACTORIES
Virtual twin experiences fueled by 5G and the IIoT deliver
more insights, improve decision-making and synchronize
responses to market demands
1

2. IIOT ON THE RISE
Today, high-tech manufacturers have to contend with short
product life cycles, ever-changing demands and volatility that
force them to be agile and responsive.
At the same time, the industry is increasingly adopting
the Industrial Internet of Things (IIoT), which is ushering
in a new era of manufacturing to enhance production and
industrial processes.
Also known as the ‘industrial internet,’ IIoT enables
manufacturers to capture and analyze massive amounts
of real-time data. It can come from smart sensors and
actuators on the production line and even from field-deployed
products, and the purpose is to drive business decisions
faster and more accurately.
2

3. LIMITS OF TODAY’S IIOT APPROACHES
However, approaches to IIoT today are still static and
siloed. This means that while high-tech manufacturers
have digitalized aspects of their manufacturing, it is still
difficult for them to quickly understand the impact of
incidents on all aspects of shop floor planning and operation,
including logistics, warehousing and the global supply network.
Siloed and static approaches to IIoT cannot effectively
deal with disruptions — that's because they lack the
capability to model the ‘digital factory’, including all
its physical capabilities and resources that comprise
complex machines and worker operations.
Without such capabilities, high-tech manufacturers will not
be able to accelerate their innovation processes and be agile
enough to restructure operations in response to disruptions.
Furthermore, the actual high-tech products themselves
are an enormous change driver and a complex combination
of software, electronics, hardware and content. Today,
many high-tech products are, in effect, mechatronics
products that need to be more and more configurable and
‘mass customizable.’
While the shop floor has always had connectivity, it has mostly
been ad hoc, proprietary or vendor-specific. IIoT also involved
moving towards the common set of interoperability, connectivity
and monitoring standards. Those standardizations are related
to wireless connectivity, including narrowband IIoT, and
many other standards affecting all levels, down to the
software system.
3

4. If manufacturers want an agile IIoT strategy, they cannot
afford to break at the borderline between the digitalization
of product engineering and its associated production engineering.
They cannot put obstacles in the way of automation that also
hinder the realization of Lean practices in production.
What they need is to:
•Make a big shift towards leveraging 5G and IIoT to
accelerate the aggregation of data from smart machines
•Combine real-time big data and new ecosystems
•Replicate all of these elements in a model-based
virtual twin that links all actors, processes and
resources together
One way they can ensure that they have dedicated

connectivity controls in place to realize their
business objectives with 5G is through a Mobile Private Network
(MPN).
MPNs are private networks for specific business locations
that give high-tech companies more control over their
5G traffic to ensure the success of mission-critical
operations. It also creates a bridge between local and cloud
computing, keeps on-site data secure and can scale to
connect thousands of devices.
1
Let’s further discuss how 5G, in combination with
IIoT, delivers a significant shift towards a more efficient
and faster aggregation of manufacturing data.
4

5. LEVERAGING
5G & IIOT
5

6. 5G is the most ambitious wireless communication system
to date, designed from the outset to meet cross-industry
requirements. It provides high bandwidth, low latency, scalability
and wireless communication security between people, things,
and infrastructure. 5G’s data performance surpasses its
predecessor, 4G, by a quantum leap with:
•
Improved speeds of up to 20 times
• Reduced latency, from 200 milliseconds to 1 millisecond
• Heightened connection density of 1 million connections
per square kilometer
Fawad Noory, an associate engagement manager at
Infosys, says,“ [the clear 5G benefits] include the reimagining
of large, agile workflows in manufacturing to enable the new
digital factory.”
2
This much-improved performance can enhance real-time
monitoring to give manufacturers an accurate picture of what is
happening on the shop floor.
The value of 5G-IIoT to production is game-changing. First,
manufacturers will be able to process more data from many more
sensors. Massive amounts of production data can be aggregated
and contextualized precisely and securely.
Second, they will be able to connect all the internal components
of a factory system with external elements such as global
factories, logistics, suppliers, products in use and maintenance or
environmental data.
6

7. Production agility is improved when you can work around
constraints and reduce your response time, making or breaking a
new product introduction.
While companies see 5G delivering the critical network
architecture that will help transform their business, Mahesh
Deshpande, Senior Director for the high tech industry at
Dassault Systèmes, cautions that the value of 5G is just starting
to be exploited in manufacturing industries.
“IIoT is a long-term journey to connect manufacturing
equipment, devices, controls, products, operations,
business processes, people and data. 5G supports this
journey by providing continuous real-time connectivity
with ultra-reliable low latency and high throughput.
“However, the lack of interoperability, connectivity and
monitoring standards, the absence of best-practices – these
fence 5G implementations to narrowly defined areas and
near horizons.
“As companies are learning and re-adjusting their 5G-IIoT
initiatives, they will see sustainable, large-scale benefits to an
organization or ecosystem over time,” he said.
7

8. THE NEW 5G-IIOT ECOSYSTEM
The factory of the future depends on successfully orchestrating
new ecosystems to work together in new ways. These
5G-IIoT ecosystems consist of various key players providing
equipment, wireless connectivity infrastructure and execution
platforms to manufacturers, all built on a common business
strategy framework.
Key players in the new 5G-IIoT ecosystem include:
•
Manufacturers applying 5G-IIoT in their smart factories
• Machine and the equipment providers that make the
factory happen — and production possible
•Companies providing the wireless connectivity
infrastructure as well as network as a service (NaaS)
• Execution platform providers managing operations
and data
“The ultimate goal for all the parties in the 5G-IIoT

ecosystem is to enable improved wireless connectivity for
manufacturers based on a range of standards and protocols.
As consortiums work on these standards and protocols, vendors
of the connectivity providers implement those standards
into their actual equipment and machine offerings,” said Mahesh.
8

9. “At the same level, we have 5G connectivity. So, right
now, many places have 4G, some have LTE, but the problem
is that you don’t get the low latency that is truly needed to
realize some mission-critical use cases.
“That’s where 5G comes into play — 5G’s promise is to deliver
real time connectivity, at low latency and with high throughput.
There’s a tremendous amount of data all these machines are
producing. And so it’s raw data that has to be acquired and, at
times, even locally analyzed.
“Before, network equipment providers would go to companies
in the wireless telecom world, who were the intermediaries
to connectivity for individuals as well as companies.
“But now things are changing. 5G equipment providers
are going directly to manufacturers to provide connectivity.
5G was announced in terms of standards availability rollouts
last year, and you’re seeing the early pilots — they’re mostly
happening with the telecommunication operators.
“You also have the world of information and digital systems.
It runs on platforms for manufacturing and operations execution
that encompasses material synchronization, maintenance, quality
warehouse tracking and more“.
9

10. “In parallel, you have the engineering and innovation platforms
because you want to connect the product and design information
directly in the production environments with all the design and
production engineering capabilities.
“Above that, you have, thanks to all this data, real-time
data analysis: Predictive analytics, prescriptive analytics
enabled by artificial intelligence, machine learning
and more.
“Finally, you need an environment for visualization alerts,
mechanisms, wherein you can interrupt, monitor and make
sense of production. So, this is the kind of architectural stack we
mean by IIoT and 5G,” concluded Mahesh.
In the next chapter, we will discuss the role of virtual twin
experiences in relation to the production twin.
10

11. Dassault Systèmes is an active member of the
5G Alliance for Connected Industries and
Automation. It is a consortium of various
stakeholders, including operational technology,
information and communication technology,
and academia, to improve the integration
of industrial 5G networks, focusing on 5G
standardization and regulation. The consortium
discusses and evaluates technical, regulatory
and business aspects of industrial 5G.
11

12. VIRTUAL TWIN
EXPERIENCES
12

13. SUPPLY CHAIN
Transformation
of the value
creation model
VALUE NETWORK
Product-centric Experience-centric
Slow Fast
Rigid Agile
Static Dynamic
PHYSICAL ASSETS
Transformation
of operational
model
PRODUCTION TWIN
Bound by assets Bound by imagination
Localized Global
Siloed Collaborative
Transactional and
directional
Model-based and
closed-loop
STRATEGIC CHANGE ENABLED
BY VIRTUAL TWIN EXPERIENCES
After high-tech manufacturers have successfully integrated
5G-IIoT and new ecosystems, the first strategy they’ll need
to execute to make manufacturing more agile is to modelize
and simulate the supply chain and physical assets .
The second is to ensure end-to-end traceability across
processes on the production line. Both can be realized with
virtual twin experiences.
13

14. Prevent stock-outs and minimize
operating costs A virtual twin of a supply chain transforms it into a
value network where physical assets can be modeled as a
production twin.
The historical divide between manufacturers
and their supply chains disallows suppliers
to be embedded in the production innovation
process. This leaves a tremendous amount of
value on the table, besides also being too slow
to respond when fast innovation is required to
overcome disruptions.
14

15. A value network unlocks the ability for partnerships to
form, and production agility is accelerated with more data
clarity, improved decision-making and traceability.
On the other hand, virtual twin experiences leverage
connected virtual models of the physical assets so that
high-tech manufacturers can assess multiple scenarios and
imagine production possibilities by aggregating data from
the production line, manufacturing equipment, people and
production plans. It includes a three-dimensional representation
of physical assets coupled with intelligent analytics and
real-time insights.
With virtual twin experiences, manufacturers can monitor and adjust shop floor activities in real time with 5G-IIoT, encompassing:
•Equipment status and behavior
•Production, operational, material and quality statuses
•Safety-relevant aspects
•Throughput issues
Manufacturers can reconfigure machines virtually
to predict real-world performance, spot quality
issues, anticipate parts failure and identify points for
product improvements.
15

16. A virtual twin experience powered by 5G-IIoT gives
manufacturers more flexibility to simulate the factory flow.
This includes the flow of materials or work-in-progress
products through the various operations, factory layout,
intermediate machines and equipment, material handling
systems and work-in-progress inventories that inform
manufacturers of inventory issues.
“In high-tech, automotive and aerospace manufacturing,
tooling and production flow is constantly changing to
accommodate new products and variants,” said Jonathan Oakley,
High-Tech Director at SIMULIA.
“The shop floor should be dynamic and reconfigurable within
in a short timeframe, which is not the case with traditional
wired networking. 5G will enable higher flexibility with
multiple connected IoT sensors on every machine, driverless
transport and precision tools. However, to meet fully the
promise of 5G and the IoT, the coverage and reliability
of the wireless systems and connections will be critical.
Virtual simulation of the transmit/receive point and IoT
antennas and how they propagate in a complex and dynamic
environment will be key to a successful deployment,” he added.
Imagine if you could validate your 5G antennas’
position inside a 3D representation of your future
factory to get the best network coverage — while
considering the movement of workers and equipment
within this 3D space.
16

17. HOW VIRTUAL TWINS CAN BE USED
Virtual twin experiences with the production twin and
end-to-end-traceability delivers business transformation and
agile production. Here’s how it affects conceptualization,
comparison and collaboration:
Conceptualization
Humans and computers process information differently, with
humans being more predisposed to relying on visual sight
to conceptualize things. Virtual twins maintain that
visualization ability in 3D throughout the production
process and delivers a common perspective between
physical and virtual product information. A real-life example
would be that, instead of looking at a written report of
the shop floor, virtual twins enable individuals to track the
progress of a physical product through the production line
while being able to refer to its characteristics, trend lines
as well as designed and actual parameters in real time and 3D.
17

18. Comparison
Virtual twins replicate physical product information digitally,
making comparisons easy. This enables manufacturers to, for
example, quickly compare tolerance corridors and quickly
make decisions about such differences. These measurements
can encompass any product characteristic, be it quantitative
or qualitative, across a range of products or even just a single
product. Improved comparison capabilities also enable
future operational adjustments to increase efficiency
and quality further down the production line.
Collaboration
Democratizing production is an empowering capability
for manufacturers. When people can collaborate, they can
unlock more intelligence, richer perspectives, faster problem
solving and accelerated innovation to the production line.
In such value networks, multidisciplinary teams can share
their conceptualizations visually regardless of how many
individuals are involved in the process, anywhere they are.
Imagine being able to connect your global factories and
leverage virtual twins to overlay virtual product information
over its physical counterpart. This is where teams can track
their performance vis-a-vis performance of factories in another
geographical location. If there are issues in that factory,
solutions can be quickly rolled out to other factories globally.
18

19. Virtual twins make physical location irrelevant.
Everyone can access shared 3D visualizations, engage
in comparisons and collaborate with the most
up-to-date data.
Adrian Wood, Director of Strategic Business Development at
DELMIA, explained,“ The high-tech industry is very competitive.
It’s all about who’s first on time and first with quality.
“With production twins, it’s not just a connection between the
physical and the virtual worlds, but a synchronized closed loop
that helps companies plan and execute better, and to do both
holistically, versus independently.”
The key to making virtual twins a success is the integrated
platform.
INVENT RUN
Virtually validated
•Validate and optimize
design with simulation
•Design multidiscipline
scalable models
Digitally augmented
•Virtual connecting
•Augment run activities
with design data
IMPROVE LEARN
Virtually validated
•Capitalize
•Improve
•Predict/prescribe
Continuously updated
•Enrich data
•Interpret data in context
•Formulate and test hypotheses
Virtual designs optimize the consumer experience
Real life insights enrich the design
VIRTUAL REAL
19

20. THE INTEGRATED
PLATFORM
20

21. Virtual twin experiences take place on an integrated platform
that is model-based and multiscale:
It can model all production systems, including mechanical,
electronics and software systems, physical and functional
behaviors, manufacturing processes, requirements,
tests, failure analysis models, and the actual product
being produced.

It is multiscale, meaning it can replicate the smallest
part of the microchip or battery electrolyte formulation
up to the scale of their entire network of global factories
while considering product flow across this global model.
This is a single environment for planning, operating and
adapting the global production system because manufacturers
can orchestrate all stakeholders on a single point of reference.
21

22. With powerful apps hosted on the integrated platform,
manufacturers can manage the engineering process of the
product, then progress that towards determining:
• How the product will be manufactured
• Which equipment will be used, and
• Where the product will be manufactured
As a result, complexity is reduced and production becomes
more agile, with zero redundancy in the production
process. Stakeholders can make better decisions and change
production with secure access anytime, anywhere, as well as
foster concurrent engineering that results in better products.
These capabilities help manufacturers capture and reuse
knowledge, simulate and predict events, and improve
decision-making and outcomes. Here’s how it happens in the
real world.
22

23. IIOT USE CASES
5G-enabled IIoT, with the support of the virtual twin
experience, creates new business value for the smart factory by
supporting business processes, workflow and coordination, data
management, and product integrity and performance on the
model-based integrated platform.
The first example shows four use cases in which IIoT
and 5G connectivity, with the support of virtual twin
experience, delivered new business value in the smart factory
of a major telecommunications equipment manufacturer:
Interactive shop floor and live monitoring
Wherever shop floor supervisors or manufacturing executives
are, they can visualize their global network of manufacturing
plants and logistics assets in operation. The KPI-based, real-time
dashboards help them:
•Ensure planned delivery lead-times
•Better quality and rapid defect containment
•Improved flow and asset performance
23

24. Virtual commissioning
Virtual commissioning allows plant managers to model the
installation and behavior of new controllers, robots or a
new factory layout. Simulating resources and facilities with
model-based 3D technology delivers:
•First time right quality of products
•Faster verification of new line concept
•Optimized/reduced production downtime
Virtual and augmented reality training Shop floor operators can virtually train to use work instructions realistically, ergonomically and in the right physical, process and product contexts. This enables:
•Reduced assembly time
•Better build quality
•First time right production
Human-robot collaboration 5G-IIoT connectivity links the actual robot controller and the data the controller produces in a virtual environment that delivers high accuracy and fidelity in terms of the robotic envelope and articulation. As such, high-tech manufacturers can accelerate deploying robots on the production line while ensuring:
•Fail-operational mode for increased safety
•Better worker productivity and ergonomics
•Increased throughput
24

25. The second example illustrates a use case on production
asset monitoring and predictive maintenance achieved with
machine learning.
While the production twin always delivers an accurate virtual
representation of this battery factory, a tremendous amount
of data is generated by each piece of hardware that can be
leveraged to extract more value.
Various data pipelines can be aggregated and have intelligent
filtering applied to it so that the data can be cleaned,
processed and have machine learning applied to it.
Powerful algorithms are involved in training machines to
learn historical patterns with regard to the maintenance
schedule of a particular asset and predict when the next
maintenance interval is due.
IoT Platform
Data
MES/MOM
Data
Kafka
Consumer
Intelligent
filtering
Data
aggregation
Edge
analytics
Streaming
data
visualization
IoT data
monitoring
dashboard
Write data to data lake
25

26. But what the machine and a human “sees” is different.
All the information that’s coming from the shop floor needs to
be visualized for fast decision-making. Here we can see different
colors representing the statuses of the equipment and the
timelines for maintenance.
The speed and bandwidth afforded by 5G-IIoT makes it
easier for machines to find patterns more quickly and process
them to derive more agile reactions to production conditions.
It can automate various production processes so that
manufacturers can more quickly adapt their manufacturing
strategy to a challenge or disruption.
26

27. Real-time information can also be used to predict
or influence product quality. David Nicolaides,
Solutions Consultant at Dassault Systèmes, shared
that companies can leverage predictions to build the
first-mover advantage in niche markets.
“In battery manufacturing, machine-learning models
can be used to shorten multi-cycle tests. The battery
behavior over the first few hundred cycles can
help manufacturers predict the next thousands of
cycles and avoid prolonging testing,” he said.
27

28. GET STARTED WITH
5G-IIOT-ENABLED
AGILE MANUFACTURING
28

29. Global competitive pressures in the high-tech space are enormous,
and business risks have been — and continue to be — very high.
Today, disruptions can occur at any time; it is the new normal
for the industry. This learning is coupled with an increasing
realization of the necessity of resilience in production and
the transformation of one’s supplier network to become key
competitive and growth drivers.
As we have discussed in this ebook, the benefits brought by
virtual twin experiences are myriad, and it allows production
to achieve very high agility. However, manufacturers can only
achieve this if they close the loop between:
•Planning and real-world operations
•The components of their global system of factories
•Their production lines and supplier network, including logistics
•Manufacturing and upstream engineering, whether in-house
or with partners in their ecosystem
5G-IIoT can substantially enrich a manufacturer’s digitalization strategy to accelerate towards the agile factory of the future.
This technology enables massive amounts of real-time data from edge computing and the cloud to be aggregated, contextualized and analyzed.
Such data can be leveraged in real time because the
low-latency and high-bandwidth characteristics of 5G-IIoT
deliver the ability to interface with many physical assets across
the globe.
While standards and best practices are still emerging, being
devised by consortiums and fora made up of the leading players
in the 5G-IIoT space, tangible benefits can be realized now: What
you’ve read in this ebook is the big picture of 5G-IIoT-enabled
agile production. As such, only the sky’s the limit when it
comes to accelerating your manufacturing success.
29

30. The virtual twin experience on the integrated
platform is the competitive differentiator that
offers companies end-to-end visibility, efficiency
and control. It is a collaborative space built for
many roles — a product researcher, designer,
developer or manufacturer — so that they can
make production more agile together.
30

31. Our 3DEXPERIENCE® platform powers our brand applications, serving 11 industries, and provides a rich portfolio of industry
solution experiences.
Dassault Systèmes, the 3DEXPERIENCE Company, is a catalyst for human progress. We provide business and people with collaborative virtual environments to imagine sustainable innovations. By creating
‘virtual experience twins’ of the real world with our 3DEXPERIENCE platform and applications, our customers push the boundaries of innovation, learning and production.
Dassault Systèmes’ 20,000 employees are bringing value to more than 270,000 customers of all sizes, in all industries, in more than 140 countries. For more information, visit www.3ds.com.
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However, we need to be cognizant that transformation
is
driven by — and done for — people. A transformative
experience is required for people to facilitate and accelerate
de
cision-making. To achieve such transformation goals,
high-tech manuf
acturers need to enable collaboration
across their silos of expertise.
T
his happens when manufacturers have scalable,
b
est-in-class execution platforms and ap ps that bring
them
closer to the agile, knowledgeable and trustworthy
partners in the new and dynamic 5G-IIoT ecosystem that

is forming.
R
egardless of where you are on your transformation
j
ourney, there are many use ca ses that can be
r
eferred to no matter the priorities, size or nature of
your production line.
Click here
to start accelerating your transformation today to
the
factory of the future.
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