Table Of ContentSmart Manufacturing
The manufacturing industries remain the foundation of local, regional, and global
economies. Manufacturing plants operate in dynamic markets that demand upgrad-
ing with transformational technologies for maintaining profitability, competitiveness,
and business sustainability. Yet most manufacturing plants currently use technolo-
gies that are no longer competitive, and industry leaders face an overwhelming array
of operational challenges that require agile and enhanced transformational solutions.
This book offers manufacturers effective strategies and tools for the adoption and
implementation of advanced operational technologies to ensure long-term innova-
tion, efficiency, and profitability.
• Covers advanced automation integration in manufacturing, including digiti-
zation, AI, machine learning, IIoT, and cybersecurity
• Describes innovation, development, and integration of control technologies
for sustainable manufacturing
• Explains how to upgrade existing manufacturing plants for the global market
• Shows how to apply emerging technologies including asset optimization
and process integration for product lifecycle improvements, plant operation
and maintenance enhancement, and supply chain integration
This book serves as a strategic guide to applying advanced operational technologies
for engineers, industry professionals, and management in the manufacturing sector.
Commercializing Emerging Technologies
Series Editor Hebab A. Quazi
This series features books that focus on commercialization of new and emerg-
ing technologies. Topics of interest include automation, security, sustainability,
smart manufacturing, nanotechnology, and process intensification and are aimed at
researchers and industry professionals interested in advancing their work from the
lab to the commercial marketplace.
Commercializing Nanotechnology
Hebab A. Quazi
Smart Manufacturing: Integrating Transformational Technologies for
Competitiveness and Sustainability
Hebab A. Quazi and Scott M. Shemwell
For more information about this series, please visit:
https://www.routledge.com/Commercializing-Emerging-Technologies/book-series/
CRCCET
Smart Manufacturing
Integrating Transformational Technologies
for Competitiveness and Sustainability
Hebab A. Quazi
and
Scott M. Shemwell
Designed cover image: © Shutterstock
First edition published 2023
by CRC Press
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and by CRC Press
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CRC Press is an imprint of Taylor & Francis Group, LLC
© 2023 Hebab A. Quazi and Scott M. Shemwell
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lisher cannot assume responsibility for the validity of all materials or the consequences of their use.
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Library of Congress Cataloging-in-Publication Data
Names: Quazi, Hebab A., author. | Shemwell, Scott M., author.
Title: Smart manufacturing : integrating transformational technologies for
competitiveness and sustainability / Hebab A. Quazi and Scott M.
Shemwell.
Description: First edition. | Boca Raton, FL : CRC Press, [2023] |
Series: Commercializing emerging technologies |
Includes bibliographical references and index.
Identifiers: LCCN 2022050813 (print) | LCCN 2022050814 (ebook) |
ISBN 9780367742928 (hbk) | ISBN 9780367742935 (pbk) |
ISBN 9781003156970 (ebk)
Subjects: LCSH: Production engineering. | Manufacturing processes.
Classification: LCC TS155 .Q47 2023 (print) | LCC TS155 (ebook) |
DDC 670—dc23/eng/20230130
LC record available at https://lccn.loc.gov/2022050813
LC ebook record available at https://lccn.loc.gov/2022050814
ISBN: 978-0-367-74292-8 (hbk)
ISBN: 978-0-367-74293-5 (pbk)
ISBN: 978-1-003-15697-0 (ebk)
DOI: 10.1201/9781003156970
Typeset in Times
by codeMantra
Contents
Preface.......................................................................................................................xi
Acknowledgments ..................................................................................................xiii
Authors .....................................................................................................................xv
Chapter 1 Smart Manufacturing ...........................................................................1
1.1 Introduction ...............................................................................1
1.1.1 Productivity ..................................................................1
1.1.2 Digitization ...................................................................2
1.1.3 IT/OT/IIoT ....................................................................3
1.1.4 Cybersecurity ...............................................................3
1.1.5 Operational Strategy ....................................................4
1.2 Challenges and Opportunities ...................................................4
1.2.1 Identifying Challenges .................................................4
1.2.2 Targeting Opportunities ...............................................4
1.3 Smart Manufacturing Techniques .............................................5
1.3.1 Transformational Technologies ....................................5
1.3.2 Prototyping ...................................................................6
1.3.3 Transformational-Technology Commercialization.......7
1.3.4 Intellectual Property Protection ...................................7
1.3.5 Risk Management .........................................................7
1.4 Competitiveness and Sustainability ...........................................8
1.4.1 Planning .......................................................................9
1.4.2 Financing ....................................................................10
1.4.3 Competitiveness .........................................................11
1.4.4 Sustainability ..............................................................11
1.4.5 Customer Alliance ......................................................13
1.5 Market Trends and Broader Opportunities..............................14
1.5.1 Artificial Intelligence/Machine Learning ..................15
1.5.2 Digital Transformation ...............................................15
1.5.3 Innovative Infrastructures ..........................................15
1.5.4 Global Warming .........................................................16
1.5.5 Smart Cities ................................................................16
1.5.6 Emerging Markets ......................................................17
Chapter 2 Operational Technologies ...................................................................23
2.1 Introduction .............................................................................23
2.1.1 One Caveat .................................................................23
2.1.2 Key Implementation Action Items .............................24
2.1.3 Managing Complexity ................................................25
2.1.4 Rapid Response Management ....................................25
2.1.5 Guide to This Section .................................................26
v
vi Contents
2.2 Information Technology Operational Technology ..................27
2.2.1 Human vs. Machine ...................................................29
2.2.2 Human Factors Engineering.......................................30
2.2.3 Human Systems Integration .......................................31
2.2.4 High Reliability Management ....................................32
2.3 Value Proposition ....................................................................34
2.3.1 Expected Value of Marginal Information ..................35
2.3.2 Maximizing Capital Efficiency ..................................36
2.3.3 Conclusion ..................................................................37
2.4 Environmental, Social, and Governance .................................37
2.5 Maturity Models ......................................................................38
2.5.1 Smart Manufacturing Maturity ..................................38
2.5.2 Software and Data ......................................................39
2.5.3 Digitalization ..............................................................40
2.5.4 Process ........................................................................40
2.5.5 Governance .................................................................41
2.5.6 Conclusion ..................................................................42
2.6 Technology Take-Up ...............................................................42
2.6.1 Adoption Model ..........................................................43
2.6.2 Gartner .......................................................................44
2.6.3 Magic Quadrant ..........................................................45
2.6.3.1 Hype-Cycle .................................................46
2.7 Reference Architecture ............................................................47
2.7.1 Conclusion ..................................................................48
2.8 Process Integration and Optimization .....................................48
2.8.1 Processes and Methods ..............................................49
2.8.2 Enabling Tools ............................................................50
2.8.3 Strong Bond Governance ...........................................51
2.8.4 Data Lessons from Covid-19 ......................................52
2.8.5 Finally.........................................................................52
2.9 Standards .................................................................................53
2.9.1 Manufacturing ............................................................53
2.9.2 Information Technology .............................................53
2.9.3 Standards Mapping Initiatives ...................................53
2.9.4 Vocabulary .................................................................54
2.9.5 Conclusion ..................................................................54
2.10 Supply Chain Management .....................................................54
2.10.1 Enterprise Resource Planning ....................................55
2.10.2 User Interface .............................................................55
2.10.3 SCADA .......................................................................56
2.10.4 Digital Thread ............................................................56
2.10.5 Digital Twin ................................................................56
2.10.6 Blockchain ..................................................................56
2.10.7 Conclusion ..................................................................57
2.11 Risk Mitigation ........................................................................57
2.11.1 Barrier Risk Models ...................................................58
Contents vii
2.11.2 Enterprise Risk Management .....................................59
2.11.3 Systemic Errors or Data Bias .....................................60
2.11.4 Latent Variable Analysis ............................................61
2.11.5 Cyber Security ............................................................61
2.11.6 Personnel and Equipment Shortages ..........................62
2.11.7 Integration with the Existing Systems........................62
2.11.8 Perception ...................................................................63
2.11.9 Systemic vs. Systematic .............................................63
2.11.10 AI, Machine Learning ................................................64
2.11.11 Glitches .......................................................................65
2.11.12 Final Thoughts ...........................................................65
2.12 Enabling Tools .........................................................................65
2.12.1 Software .....................................................................65
2.12.1.1 Workflow Engines.......................................68
2.12.1.2 Drones .........................................................68
2.12.1.3 Remote Automation and Data
Acquisition ..................................................68
2.12.1.4 Customer Relationship Management ..........69
2.12.1.5 Asset Integrity Management .......................69
2.12.2 Concluding Thoughts .................................................70
2.12.3 Economic Value Capital Assessment .........................71
2.13 Best Practices ..........................................................................72
2.13.1 Operations Management System ................................72
2.13.2 Core Foundation .........................................................73
2.13.3 Operations ..................................................................74
2.13.4 Safety and Environmental Management
System (SEMS) ..........................................................75
2.13.5 The Learning Organization ........................................75
2.13.6 Conclusion ..................................................................77
2.14 Organizational Transformation Process ..................................77
2.14.1 Career Opportunity? ..................................................77
2.14.2 Implementation ...........................................................78
2.14.3 Executive Sponsor ......................................................78
2.14.4 Project Management Office (PMO)............................78
2.14.5 Third-Party Management ...........................................79
2.14.6 Scope of Work ............................................................79
2.14.7 Start Small ..................................................................79
2.14.8 Re-Imagine .................................................................80
2.14.9 Framework ..................................................................80
2.14.10 Model Mapping ..........................................................81
2.14.11 Culture ........................................................................82
2.14.12 Safety ..........................................................................84
2.14.13 Diverse Groups ...........................................................84
2.14.14 Change Management Model ......................................84
2.14.15 R B C ..........................................................................85
2.14.16 Key Performance Indicators .......................................85
viii Contents
2.14.17 Decarbonization .........................................................87
2.14.18 Center(s) of Excellence ...............................................87
2.14.19 Center of Excellence Construct ..................................88
2.14.20 Final Thoughts ...........................................................90
2.15 Roadmap Framework ..............................................................90
2.15.1 Current Status .............................................................90
2.15.2 Smart Manufacturing Mind Map ...............................91
2.15.3 Maturity ......................................................................91
2.15.4 Filling the Skills Gap .................................................94
2.15.5 Conclusion ..................................................................95
Notes ...................................................................................................95
Chapter 3 Transformational Technologies: Adoption and Integration in
Operating Plants ...............................................................................105
3.1 Introduction ...........................................................................105
3.1.1 Strategic Planning ....................................................105
3.1.2 Planning Team ..........................................................106
3.1.3 Business Plan ............................................................106
3.1.4 Financial Planning ...................................................107
3.1.5 Value Proposition .....................................................107
3.1.6 Return-on-Investment...............................................108
3.1.7 Customer Care ..........................................................108
3.1.8 Roadmap Planning ...................................................108
3.2 Technology Adoption and Integration ...................................109
3.2.1 Adoption Considerations ..........................................109
3.2.2 Integration Challenges .............................................109
3.3 Performance Challenges ........................................................109
3.3.1 Economics and Pricing.............................................110
3.3.2 Technological Opportunities ....................................110
3.3.3 Customers’ Preferences ............................................110
3.3.4 Competitors’ Program Dynamics.............................110
3.3.5 Regulatory Challenges .............................................110
3.4 Competitiveness Tracking .....................................................111
3.4.1 Tracking Competitions .............................................111
3.4.2 Market Trends ..........................................................111
3.4.3 Global Economic Forecasts ......................................111
3.5 Sustainability Challenges ......................................................111
3.5.1 Market Forecasts ......................................................112
3.5.2 Competitiveness Trends ...........................................112
3.5.3 Customers’ Preferences ............................................112
3.5.4 Performance Trends .................................................112
3.6 Smart Manufacturing Roadmaps ..........................................112
3.6.1 Strategic Options ......................................................112
3.6.2 Operational Changes ................................................113
3.6.2.1 Operational Modifications
Requirements ............................................113
Contents ix
3.6.3 Competitiveness Challenges .....................................113
3.6.4 Sustainability Challenges .........................................113
3.6.5 Quality, Safety, and Security ....................................113
3.6.6 Performance Forecasting ..........................................114
Chapter 4 Roadmaps for the Adoption and Integration of
Transformational Technologies in Key Manufacturing Plants ........115
4.1 Introduction ...........................................................................115
4.2 Petroleum Refining Roadmaps ..............................................116
4.2.1 Petroleum Refining Roadmap – 1 ............................116
4.2.1.1 Re-Visiting Goals and Objectives .............116
4.2.2 Petroleum Refining Roadmap – 2 ............................116
4.2.2.1 Operational-Modifications Planning ........116
4.2.3 Petroleum Refining Roadmap – 3 ............................116
4.2.3.1 Competitiveness Challenges .....................116
4.2.4 Petroleum Refining Roadmap – 4 ............................117
4.2.4.1 Sustainability Challenges .........................117
4.2.5 Petroleum Refining Roadmap – 5 ............................117
4.2.5.1 Quality, Safety, and Security
Management .............................................117
4.2.6 Petroleum Refining Roadmap – 6 ............................117
4.2.6.1 Performance Targets .................................117
4.3 Plastic Product Manufacturing Roadmaps ............................118
4.3.1 Plastic Product Manufacturing Roadmap – 1 ..........118
4.3.1.1 Re-Visiting Goals and Objectives .............118
4.3.2 Plastic Product Manufacturing Roadmap – 2 ..........118
4.3.2.1 Operational-Modifications Planning ........118
4.3.3 Plastic Product Manufacturing Roadmap – 3 ..........119
4.3.3.1 Competitiveness Challenges .....................119
4.3.4 Plastics Products Manufacturing Roadmap – 4 .......119
4.3.4.1 Sustainability Challenges .........................119
4.3.5 Plastic Product Manufacturing Roadmap – 5 ..........119
4.3.5.1 Quality, Safety, and Security
Management .............................................119
4.3.6 Plastic Product Manufacturing Roadmap – 6 ..........120
4.3.6.1 Performance Targets .................................120
4.4 Pulp and Paper Industry ........................................................120
4.4.1 Pulp and Paper Industry Roadmap – 1 .....................120
4.4.1.1 Re-Visiting Goals and Objectives .............120
4.4.2 Pulp and Paper Industry Roadmap – 2 .....................121
4.4.2.1 Operational Modifications Planning .........121
4.4.3 Pulp and Paper Industry Roadmap – 3 .....................121
4.4.3.1 Competitiveness Challenges .....................121
4.4.4 Pulp and Paper Industry Roadmap – 4 .....................121
4.4.4.1 Sustainability Challenges .........................121
4.4.5 Pulp and Paper Industry Roadmap – 5 .....................122
