High-speed 3D Printer & IoT Could Really Revolutionize Design & Manufacturing

There’s a new high-speed 3D printer on the horizon which, coupled with the IoT, could really revolutionize product design and manufacturing.

I’ve raved in the past about 3D printing’s revolutionary potential, but I’ll admit I was still thinking primarily in terms of rapid prototyping and one-off repair parts.  Now, according to Bloomberg, HP is going to transfer its ink-jet printer expertise to the 3D printer field, with a $130,000 model set for release later this year that, for the first time, could make 3D printing practical and affordable for large-scale manufacturing, with “parts at half the expense and at least 10 times faster than rival printers — and likely [using] lower-cost materials.”

Combined with the IoT, that would go a long way toward making my “precision manufacturing” vision a reality, with benefits including less waste, streamlined products (a single part replacing multiple ones that previously had to be combined into the final configuration),  factories that are less reliant on outside parts and encouraging mass customization of products that would delight customers. 

Customers are already lining up, and see manufacturing-scale 3D printing as a game-changer:

Jabil Circuit Inc. [itself a digital supply-chain innovator] plans to be an early adopter of HP’s device, printing end plastic parts for aerospace, auto and industrial applications that it currently makes using processes such as injection molding, John Dulchinos, vice president of digital manufacturing at the electronics-manufacturing service provider, said in an interview.

“‘We have use cases in each of these segments,’ Dulchinos said. ‘Parts that are in hundreds or thousands or tens of thousands of units — it’s cheaper to 3D print them than mold them.’”

Other HP partners in the venture include BMW, Nike, and and Johnson & Johnson. The article cites research by Wohlers Associates predicting that manufacturing using 3D printers could “eventually grab at least 5 percent of the worldwide manufacturing economy, and translate into $640 billion in annual sales.”

3D Systems is also making the transition to large-scale 3D printing.

As I’ve written before in regard to GE’s leadership in the field, toss in some nanotech on the side, and you’ve really got something.

 

Industry Week Survey: Most Manufacturers Don’t Get IoT

A new Industry Week survey shows that most manufacturers are, at best, just testing the IoT waters, and few have made the management changes necessary that show they understand the IoT’s revolutionary potential to change every aspect of their products, manufacturing, and even their management.

 The Internet of Things: Finding the Path to ValueThe survey, “The Internet of Things: Finding the Path to Value,” (underwritten by SAS) was conducted late last year.  478 companies completed it.  The survey’s major finding was that:

Despite the fact that they’re already collecting such (i.e., IoT) data, and two- thirds believe the Internet of Things technology will be critical to their future success, only one third of manufacturers report that they have a specific IoT technology strategy.” (my emphasis)

One finding was particularly damning, because it shows senior management really doesn’t get the full value of IoT data and how it must radically alter their decision making:

“… two out of three say they rely more on management experience [than the IoT] when addressing key business issues.”

On the other hand, 28% said they think they’re outpacing their competitors in use of the IoT. Pardon my skepticism..

Here’s the finding that clearly indicated to me that these executives don’t get it that the vast amounts of data yielded by the IoT requires new analytical tools (HANA and its ilk) and new skill sets (i.e., data scientists): ”

It should come as no surprise … that well over half (57%) of manufacturers report that they are using spreadsheets to analyze sensor data.” (my emphasis)

Really?? Those guys gotta download the Managing the Internet of Things Revolution e-guide I wrote for SAP, which explained that the way to ease your way into the IoT is to begin by acquiring data mining and visualization tools and beefing up your cloud storage, which will benefit you with your current operations, as well as building the data analysis skills such as predictive analytics — and attitudes — necessary to capitalize on the IoT.  If you’re analyzing sensor data with spreadsheets, your priorities are totally out of wack…

On the positive side, 45% are integrating and supplementing IoT data regarding product quality, and 43% integrating production data.

I see little indication from the findings that most companies (a few, such as GE and Siemens, excepted) are fully integrating the IoT into day-to-day operations, resulting in what I’ve called “precision manufacturing.”

Long way to go, folks, long way to go…

 

Day 2, Live Blogging from SAP’s IoT2016 Internet of Things Event

I’m up first this morning, & hope to lift attendees’ vision of what can be achieved with the Internet of Things: sure, cool devices and greater efficiency are great, but there’s so much more: how about total transformation of businesses and the economy, to make them more creative, precise, and even environmentally sustainable?

I’ve just revised my 4 IoT Essential Truths, the heart of my presentation, bumping make privacy and security the highest priority from number 4 to number 1 because of the factors I cited last week. I’ll draw on my background in crisis management to explain to the engineers in attendance, who I’ve found have a problem with accepting fear because it isn’t fact-based, how losing public trust could kill the IoT Golden Goose.

I’ll go on to explain the three other Essential Truths:

  • Share Data (instead of hoarding it, as in the past)
  • Close the Loop (feed that data back so there are no loose ends, and devices become self-regulating
  • Rethink Products so they will contain sensors to feed back data about the products’ real-time status, and/or can now be marketed not as products that are simply sold, but services that both provide additional benefits to customers while also creating new revenue streams for the manufacturer.

I’ll stress that these aren’t just truisms, but really difficult paradigm shifts to accomplish. They’re worth it, however, because making these changes a reality will allow us to leave behind old hierarchical and linear organizational structures that made sense in an age of limited and hard-t0-share data. Instead, we can follow the lead of W.L. Gore and its cyclical “lattice management,” in which — for the first time — everyone can get the real-time data they need to do their jobs better and make better decisions. Equally important, everyone can share this data in real time, breaking down information silos and encouraging collaboration, both within a company and with its supply chain and distribution network — and even with customers.

Amen.


Back with Michael Lynch of SAP!

  • we can change the world and enhance our understanding greater than ever.
  • can help us solve global warming.
  • great case study on heavy truck predictive maintenance in GoldCorp Canadian gold mines.
  • IoT maturity curve:
  • Critical question: who are you in a connected future?  Can lead to re-imaginging your corporate role.
  • UnderArmour is now embedding monitors into clothing.
  • Tennant makes cleaning equipment. Big problem with lost machines, now can find them quickly.
  • Asset Intelligence Network — Facebook for heavy equipment — SAP will launch soon.
  • example of a tractor company that’s moving to a “solutions-based enterprise.” What is the smallest increment of what you do that you could charge customer. Like the turbine companies charging for thrust.

SAP strategy:

  • “Our solution strategy is to grow by IoT-enabling core industry, and providing next generation solutions for millions of human users, while expanding our platform market by adding devices.”
  • they have an amazing next-gen. digital platform. More data flow through there than Alibaba & Amazon!
  • CenterPoint Energy — correlating all sorts of data such as smart meter & weather. Better forecasting.
  • Doing a new home-based diabetes monitoring system with Roche.
  • Doing a lot of predictive maintenance.
  • Connected mining.
  • Building blocks:
    • Connect (SAP IoT Starter Kit)
    • Transform
    • Re-imagine

Ending the day with my presentation on first steps for companies to take in beginning an IoT strategy, with special emphasis on applying analytical tools such as HANA to your current operations, and building “precision operations” by giving everyone who needs it real-time data to improve their job performance and decision-making. Much of the presentation will focus on GE, with its “Brilliant Factories” initiative!

Testing the IoT Waters: 1st Steps in Creating an IoT Corporate Strategy

What if you’re interested in the Internet of Things, but are a little scared of making a major commitment and making major expenditures until you build your familiarity level and start to enjoy some tangible results?

That concern is understandable, especially when prognosticators such as I emphasize what a transformational impact the IoT will have on every aspect of your operations and strategy.

So where to begin?

I’ll speak on this issue at SAP’s  IoT 2016 Conference, Feb. 16-19, in Las Vegas, and hope you can attend. But, if not, or if a teaser might convince you to make the plunge, here’s a summary of my major points, which I hope will motivate you to act sooner, rather than later!

Managing_the_Internet_of_Things_RevolutionThis is an issue that I first visited with my “Managing the Internet of Things Revolution” e-guide to IoT strategy for C-level executives, which I wrote in 2014 for SAP, and which has been successful enough that they’ve translated it into eight languages.

I suggested that the best reason to begin now on creating and executing an IoT strategy was that a lot of the requisite tools for an IoT strategy were also critical to optimize your current operations:

  • invest now in analytical tools (such as SAP’s HANA!), so that you can make sense of the rapidly-expanding amount of data (especially unstructured data) that you are already collecting, with new benefits including predictive analytics that allow you to better predict the future.
  • even before capital equipment is redesigned to incorporate sensors that will yield 24/7 real-time data on their operations and status, consider add-on sensors where available, so you can take the guesswork out of operations.
  • where possible, process sensor data “at the edge,” so that only the relevant data will be conveyed to your processing hub, reducing storage and central processing demands.
  • develop or contract for cloud storage, to handle vastly increased data.
GE Brilliant Factory benefits

GE Brilliant Factory benefits

As I’ll explain my speech, even without launching any major IoT projects such as product redesign or converting products into services, initial IoT projects such as these will dramatically boost your profits and efficiency by allowing unprecedented precision in operations.  I’ll emphasize the example of GE, whose “Brilliant Factory” initiative is aimed at increasing both its own manufacturing efficiency and its customers’ as well. They make a modest, but astonishing claim:

“GE estimates that a 1% improvement in its productivity across its global manufacturing base translates to $500 million in annual savings. Worldwide, GE thinks a 1% improvement in industrial productivity could add $10 trillion to $15 trillion to worldwide GDP over the next 15 years.”

Remember: that’s not exploiting the full potential of the IoT, but simply using it to boost operating efficiency. I see this as bringing about an era of “Precision Manufacturing,” because everyone who needs real-time data about the assembly line and production machinery will be able to share it instantly — including not only all departments within your company but also your supply chain and your distribution network.

In many cases, resupply will be automatic, through M2M processes where data from the assembly line will automatically trigger supply re-orders (and may lead to reshoring of jobs, because the advantages of true “just-in-time” delivery of parts from a supplier located a few miles away will outweigh the benefits of using one on the other side of the world, where delivery times are measured in weeks).  Instead of the current linear progression from supply chain to factory floor to distribution network, we’ll have a continuous loop uniting all of those components, with real-time IoT data as the “hub.”

Again, without making a full-fledged commitment to the IoT, another benefit that I’ll detail is how you’ll be able to dramatically improve workplace safety, especially inherently chaotic and fast-changing worksites such as construction projects and harbors, whose common elements include unpredictable schedules, many companies and contractors, many workers, and many vehicles — a recipe for disaster given current conditions!  However, the combination of simply putting location sensors on the equipment, vehicle, and people can radically decrease the risk. For example,  in Dubai — home to 25% of all construction cranes in the world — SAP partnered with a worldwide leader in construction site safety, SK Solutions. Sensors are located on machinery throughout every site, reporting real-time details about every activity: machinery’s position, movement, weight, and inertia and critical data from other sources (as with the GE Durathon factory’s use of weather data), including wind speed and direction, temperature, and more. Managers can detect potential collisions, and an auto-pilot makes instant adjustments to eliminate operator errors. “The information is delivered on dashboards and mobile devices, visualized with live 3-D images with customizable views.”

As I’ll tell the conference attendees,

“Equally incredible is the change at the Port of Hamburg, Germany’s biggest port, which must juggle 9 million containers and 12,000 vessels a year, not to mention a huge number of trucks and trains. You can imagine the potential for snarls and accidents. Since installing HANA, all of these components, including the drivers and other operators, are linked in real time.  Average waiting time for each truckload has been cut 5 minutes,  and there are 5,000 fewer truck hours daily. The coordination has gotten so precise that, if a trucker will be held up by a bridge opening, the nearby coffee shop will send a discount coupon to his iPad.”

I’ll conclude by mentioning a couple of the long-term components of an IoT strategy, such as redesigning products so that they can be controlled by apps and/or feedback constant information on their status, and considering whether to market products instead as services, where the customer only pays for the products when they’re actually being used, and creating optional data services that customers may choose to buy because they’ll allow the customer to optimize operating efficiency.

But the latter are the long-term challenges and benefits.  For now, I’ll tell the audience that the important thing is to begin now investing in the analytical tools and sensors that will help them boost efficiency.

Hope you can be there!


Oh yeah. Why get started on your IoT strategy now, rather than wait a few more years? Last year, former Cisco Chairman John Chambers said that 40% of the companies attending a recent seminar wouldn’t survive in a “meaningful way” within 10 years if they don’t begin now to embrace the IoT. Sobering, huh?