FORWARD

FORWARD
Next-Generation Manufacturing
A CSC Magazine for
Innovators in Manufacturing
INSIDE
Engage One on One with Chris Fangmann,
CTO, Global Manufacturing Industries, CSC
Visit go.csc.com/meet-the-expert
Putting IoT Within Reach
Connected Cars Drive Value

Letter from the Editor
Dear Reader,
It’s an exciting time in manufacturing — not only for those
of you on the frontlines, but also for companies like ours that
serve the industry and provide next-generation technology.
Perhaps at no age since the Industrial Revolution has the field
been primed for such dramatic change with such grand potential.
CHAT WITH CHRIS!
Chris is looking to
engage one on one
with leaders in the
manufacturing industry.
To connect, simply
scan the QR code
below or visit
go.csc.com/
meet-the-expert
and submit the form.
Of course, instead of technologies like the assembly line and
the steam engine, we’re now talking about game-changers like
automation, the Internet of Things (IoT) and real-time data
analytics. The conversation has shifted from using machines to
making machines smarter, more efficient and more productive.
This age is really about making use of data. It’s about
integrating islands of information into one single source of
truth; leveraging real-time data and advanced analytics to
drive business strategy; and using simulations and digital twin
models to predict outcomes.
I’m eager to talk with you about the transformation we’re
seeing in the industry, and we’re making it easy to set up that
meeting of the minds. To get in touch, scan the QR code or
follow the link at left, then complete the form that comes up.
We will take it from there.
In the meantime, please enjoy this special publication, which
presents CSC’s best thought leadership on these important
topics. Read about how open-source software can put IoT in
reach, connected cars can drive business value, and emerging
technology can change the workplace.
The digital transformation in manufacturing is here. It’s
happening now. As chief technology officer for the global
manufacturing industry at CSC, I’ve been lucky to witness
up close history in the making. I can’t wait to see where
we go next!
Thank you,
CHRIS FANGMANN
CTO, GLOBAL MANUFACTURING INDUSTRIES, CSC
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Table of Contents
2 PUTTING IOT WITHIN REACH
4 FIVE TECHNOLOGIES THAT WILL
CHANGE WORK FOREVER
6 CONNECTED CARS DRIVE VALUE
9 Q&A: UNDER THE HOOD WITH FORD
10 THE DIGITAL TWIN
13 ABOUT CSC
2
6
4
10
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1

PUTTING I T
WITHIN REACH
Open source and shared platform
bring IoT benefits to more companies
by Lucy Nolan
An unprecedented amount of data — “actionable data” that
can be processed quickly to make operational decisions — is
coming in daily through connected machines. But until now,
many manufacturers have been reluctant to make major
investments in Internet of Things (IoT) systems and realize
the full potential of this data.
The IoT consists of the machines, devices and other physical
objects connected to a network. Sensors attached to all of
those items can provide a steady stream of data to a central
IoT platform. With custom dashboards, each department in a
manufacturing organization could work with the data in the way
it sees fit. Even the IoT platform itself could act on the data.
“IoT systems are intelligent enough to tune management
solutions automatically,” says Chris Fangmann, CTO for global
manufacturing at CSC. “Now let’s add a capability to simulate
a change in a production line before a part is physically
executed. That will save companies millions of dollars.”
The potential benefits of setting up an IoT platform are huge —
the ability to intelligently track and trace materials, parts,
and equipment and ensure that they’re delivered to the right
product at precisely the right time, or perhaps to predict
deviations and react accordingly. That same intelligence can
optimize production schedules and improve machine uptime
or react quickly to last-minute customer changes.
Other applications can help manufacturers harness vast
amounts of data streaming in from connected products.
Major automotive firms not only see these connections as
a way to take the driver’s experience to the next level with
predictive services, but they are also looking
at ways to harness the data for thirdparty
partners such as insurance
companies.
“Today, fast computing is
accessible to everybody.
It doesn’t matter if an
organization has 10
people or 10,000. Open
source technologies are
bringing costs down to
a commodity level.”
— Chris Fangmann,
CTO for global
manufacturing at CSC
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“This is not just automating the process of how a
truck gets from Point A to Point B. This is going
to have a pervasive effect on how we live our
lives in the future.”
— Rick Tomredle, IoT engineering and delivery
manager for CSC
Not being tied to a specific vendor also solves the matter of
portability. “With open standards, you’re not locked into a
specific platform or technology,” Doble explains. “So if one
vendor becomes too expensive, you can move to another.”
Fangmann also points out that open source helps to
ensure a DevOps environment, where the system can
be continually updated.
Equipment manufacturers are also looking at ways they can
utilize this data to provide better services to their customers.
While commercial IoT platforms are available from a variety
of vendors, manufacturers have been slow to adopt these
systems, which often require a major upfront investment.
“That is one of the biggest barriers to implementing an IoT
platform,” Fangmann says. “Companies are either not willing
to make the large upfront investment to stand up their own
environment, or they’re concerned that they don’t have enough
knowledge to do so. The costs — and time involved for valuable
IT staff — would quickly become prohibitive.”
“Any company can now take advantage of the most
modern system available without having to worry about
upfront investments, ongoing maintenance fees or looming
obsolescence,” Fangmann says. “By using an as-a-service model,
any manufacturer should be able to find an IoT platform to
support the specific use case it needs.”
LUCY NOLAN is a content editor with CSC’s global
content team.
Learn more at csc.com/manufacturing.
Open source opens the way
Using open source technologies is one approach to keeping costs
down, and a commitment to open source was a guiding principle
in the development of CSC’s new industrial connectivity and data
exchange platform, which connects and harmonizes data flow
among all types of machines. The CSC environment is based on
Hadoop Apache Storm, an open source framework for storing
and processing large streams of data.
“We wanted to have as many open standards as we possibly
could,” says Andrew Doble, an enterprise architect at CSC.
“We’re very familiar with open source products — and they’re
quickly becoming standard for streaming analytics.”
Nico Krebs, mobility consultant with CSC, also believes in the
power of using open source. Shop floors often use proprietary
vendor protocols, making machine-to-machine connectivity
difficult. These challenges, Krebs explains, can be overcome
with protocols based on open standards.
“We believe in open IoT standards such as MQTT [a machine-tomachine
IoT productivity protocol],” he said. ”It’s free to use, and
I think we will see many libraries for this protocol in the future.
We think open protocols will dominate the market in a few years.”
Share the burden
An individual manufacturer might have difficulty dedicating the
resources necessary to build out a Hadoop IoT/big data system,
but CSC built its platform so that it can be offered to multiple
companies on a pay-per-usage basis.
“Offering a shared platform produces cost savings for us, which
we can pass along to our clients,” Doble explains. “And we further
reduce our costs by not being tied to a large licensing fee —
something manufacturers should consider as well.”
IoT Around the World
By connecting machines to each other and to business
operations, the Internet of Things gives companies the ability
to analyze data to make better-informed decisions. Here are
two successful uses of CSC’s IoT platform, OmniLocation ® ,
built entirely from open source tools.
1. Pharmaceutical manufacturer simplifies supply chain.
A large pharmaceutical manufacturer uses IoT to better
manage its assets, operations and supply chain. Data from
public and private sources, including suppliers around
the world, is aggregated and analyzed to keep track of
operations and recognize problems and disruptions. The
system alerts the necessary workers of supply chain issues.
“We are continuously updating, through automated
notification via text message and email… exactly what’s
going on across the company, across the supplier network,
so they can make real-time adjustments that allow their
operations to keep moving smoothly,” says Dan Munyan,
Internet of Things product manager at CSC.
2. Industrial site overcomes environmental challenges.
CSC overcame a number of challenges to install an IoT
at a large surface mine. The industrial site did not have
available cell coverage or power. In fact, Rick Tomredle,
IoT Engineering and Delivery Manager for CSC, described
the environment as resembling “the surface of Mars.”
To reliably generate IoT data in this environment, CSC
engineered an extensive “extrastructure,” says Tomredle,
complete with radio towers and power. The company
can now pull important data from the site to improve
business operations.
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3

Here are five technologies that are about to make a huge
impact on work as we know it, according to Stuart Downes,
CSC workplace offerings lead, and Gary Beckett, CSC global
director for workplace and enterprise systems management
(ESM) services.
1. Wireless connectivity
You walk into a meeting room to make a
presentation, and everything is wireless —
truly wireless.
Your laptop automatically syncs with the big-screen
monitor at the front of the room and with the screenshare set up for
remote audiences. Wireless chargers power up all devices in range.
The WiFi network detects the number of devices and increases
bandwidth to that part of the building.
Sound like a dream?
“This isn’t technology that’s years away,” Downes says. “It’s
technology that’s here, but most enterprises tend to be a bit
slower on the adoption curve of these things.”
TECHNOLOGIES
THAT WILL CHANGE WORK
FOREVER
by Christine Neff
Employees have already seen massive
changes in their workplace. With
modern tools, they can access their
work on nearly any device, anytime
and anywhere, making it easier than
ever before to collaborate, innovate
and be productive. But that is only
the beginning.
The advent of ubiquitous connectivity opens up huge
opportunities for the workplace in the form of Internet of Things
and collaborative digital tools — and upcoming 5G cellular
technology will only magnify that trend. For instance, Beckett
predicts that live-streaming of video will become “matter-offact,”
making it easier for colleagues and partners at remote
locations to collaborate. “Those things start to open up and
expand people’s ability to innovate,” he says.
5G mobile subscriptions to hit
150 million by 2021
— Ericsson Mobility Report, Mobile World
Congress Edition, February 2016
2. Smart machines
As systems gain the intelligence to perform
tasks and make decisions that formerly
required human input, employees — even
highly educated knowledge workers — will
be affected. In fact, a widely cited Oxford
University study predicts that 17% of American knowledge
workers will lose their jobs to machines.
Already, artificial intelligence has crept into the service sector to
“staff” help desks for workplace IT departments and consumer
applications. The technology may expand in the near future to
respond to proposals, write legal documents and reports, act as
a personal assistant, perform supervisory roles, make staffing
decisions and do any number of tasks that currently require a
living, breathing, knowledge-based employee.
“The smart machine will be very disruptive in the next 5-plus
years,” Downes predicts.
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3. VR/AR
With Facebook’s Mark Zuckerberg now fully
invested in virtual reality (VR), and major
tech and media companies joining the craze
every day, the technology seems to be on the
cusp of finally becoming a, well, reality.
Some industries have embraced the potential as early
adopters. For instance, the International Space Station now
has augmented reality (AR) headsets that enable expert remote
support to work more efficiently with astronauts to rehearse for
procedures in space. Manufacturers, surgeons and others have
used VR (tools such as Oculus Rift and Google Cardboard)
or AR (such as Microsoft’s HoloLens) to better visualize and
complete complex tasks.
More than 24 million VR/AR devices
will be sold in 2018
— CCS Insight’s Augmented and Virtual Reality
Device Forecast, 2015 – 2019
“Today, I don’t see it as a general work habit, but I do see it
becoming a requirement for specific use cases with reality
rooms appearing in more facilities,” Downes says.
While it’s not a stretch to imagine using a VR headset to brainstorm
with remote colleagues in a virtual office space, Downes
doesn’t see this becoming mainstream in the near future. “For
the next 2 to 3 years, AR and VR will be limited, with the
consumer market driving enterprise adoption,” he says.
4. Wearables
One of the hottest segments in consumer tech,
wearables — gadgets that measure the user’s
physical activity, such as the Apple Watch and
Fitbit — are starting to make their way to the
workplace, and the trend is expected to grow.
Employers can find big value in encouraging employees to use
wearables to maintain healthy levels of activity throughout
the day. “The whole focus is on: ‘How do we prevent people
from entering chronic or acute care systems?’ Companies can
distribute sensors and get people to sign up and report back
on their activity,” Beckett says.
Wearables can also lead to the reimagining of the physical work
space. As sensors track how employees move and congregate
throughout the day, the office space can be designed to meet
their different needs. Rather than a traditional desk setup, for
instance, the office can support different styles of work, such as
social, research-driven and concentrated tasks, Downes says.
5. Data analytics
Big data provides new opportunities
and challenges for enterprises, and the
technology is about to take another
leap forward.
Enterprises can now access reams of data about systems,
processes and performance that can be analyzed to create
more productive workplaces and tools. “We’re seeing a
point where data is more accessible, and data scientists
are beginning to drive real value from new analytics
techniques,” Downes says.
Data can be used to design more functional spaces,
understand the characteristics of high-performing individuals
and teams, make better-informed hires and more, all with
the goal of establishing a “highly intelligent workplace
experience,” Downes says.
At an individual level, employees have become “data
managers” of their personal data at work. This task requires
a set of user-friendly tools to keep track of HR and benefits
records, training logs, contact information, evaluations
and more.
Companies not up to par may find themselves losing talent to
competitors, warns Beckett. “In 5 years, the digital workplace
strategy in major corporations will be the realm of HR. As the
battle for talent becomes ever more difficult, the differentiator
will be not just in the kind of work, but also in the strategy
deployed by the business,” he says.
CHRISTINE NEFF is a content editor with CSC’s global
content team.
Making Work, Work
CSC offerings and services are designed to deliver a
modern workplace experience for current and future
generations of business workers.
CSC MyWorkStyle provides a framework for supporting
the growing variety of cloud-based applications and
services. We enable existing applications to operate with
an expanding universe of devices that includes tablets
and smartphones. CSC MyWorkStyle provides a common
platform for access and authentication, allowing users to
operate onsite and at remote locations in an equal fashion.
CSC MyWorkStyle is designed to take advantage of
continual improvements and enhancements with few or
no service interruptions. As additional capabilities and
functions emerge in the industry, the updates are made
readily available to employees.
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5

Connected Cars
DRIVE VALUE
by Dale Coyner
Using telematics
data to deliver
benefits throughout
the automotive
value chain
Learn more about CSC’s
connected car solutions at
csc.com/connectedcar.
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Autonomous driving and electric cars may dominate
headlines about the future of the automobile, but the era of
the connected car has already arrived. Fueled by demands
from an always-connected mobile society, millions of cars
equipped with built-in connectivity are driving off dealership
lots every year.
Connected vehicles enable a host of innovations that add
convenience, comfort and safety, says Chris Fangmann, CTO,
global manufacturing industry at CSC.
“Connectivity enhances safety features such as parking
assistance, adaptive cruise control, blind spot assistance,
collision avoidance and improved night vision, to name just a
few,” he says. “While those features are important to attract
new buyers, the value of connected cars to automotive and
other industries, such as insurance, extends much further.”
Let’s stay in touch
Data generated by connected vehicles has inherent value,
whether it’s used to study the reliability and service life of a
power window relay, analyze and automatically optimize engine
performance in a wide range of environments, understand
driver habits, communicate with other vehicles, predict failures,
report an accident, or track and predict any of a vast range of
specific vehicle metrics.
Ford Motor Company will be using the data to customize
maintenance and services, improve safety and enhance the
driving experience.
“With connected vehicles, we can create a custom
maintenance schedule for the customer,” says Roopak Verma,
Ford’s CIO for Europe, the Middle East and Africa. “Today, we
might tell a customer to change the oil every 10,000 miles,
but in reality the schedule should be based on the customer’s
driving habits. With connected capabilities, you can know it’s
OK to wait until 11,500 miles, and the same applies to every
component in the car.”
Connectivity also enables Ford vehicles to automatically
reconfigure driving characteristics based on weather and
road conditions.
In a pilot project in London, Fords are even tapping into data
from parking lots. “You enter an address into the GPS, and you
can see in real time where the parking spaces are — and in
London, that’s a big deal,” Verma says.
Ford is conducting pilot projects for car sharing, which is
made easier with connected cars. Rather than exchanging
keys, drivers can simply send a code to unlock the vehicle
over a mobile phone. Settings for the seat, radio, rearview
mirror and more can be activated with the touch of a
button on a smartphone.
“I believe the biggest impact is going to be to the fleet business,
because you can really optimize your costs,” Verma says.
Larry Stolle, global automotive marketing director at SAP,
says advancements like these are changing the fundamental
makeup of cars. “I like the contrast Dr. Lawrence Burns from
the University of Michigan makes: When you look at the old
DNA of the industry, the automobile was fossil-fuel powered,
mechanical, owned and operated by a person, and built to
suit many purposes,” Stolle says. “The DNA of the car is
changing — self-driving, shareable and more types built
for specific uses. That future is here, now.”
The power of data
The collected data has great potential value beyond
manufacturers, for example to third-party service providers
such as auto insurance companies. Vehicle information can
help insurers adjust rates based on driver performance,
leading to more efficient risk-pricing models, lower claims and
faster claims processing. Marketers would pay for that data,
too, because they would have yet another channel to reach
customers. Plus, new services could be offered based on the
data — imagine drivers entering a route into their GPS and
receiving a proposal for trip-dedicated roadside assistance due
to road and weather conditions.
Governments have begun to grasp the significance of connected
vehicle data. Proposals by federal regulators in the United States,
the European Union and Brazil are targeted at either encouraging
or requiring manufacturers to include telematics to improve
safety, report crashes and reduce incidents of vehicle theft. The
U.S. National Transportation Safety Board is creating standards
to promote connected technologies, predicting that crashes may
be reduced by more than 75%. The European Union will require
eCall crash alert technology on all new models by 2018, which it
is estimated will save 2,500 lives annually. Governments, as well
as private companies, can also use data about road conditions to
focus their investments on road repairs or route planning.
Retailers are eager to tap into the personal data collected,
including location, but the challenge is finding services that
both benefit the customer and address privacy concerns,
Ford’s Verma says.
“We have so many legal constraints, data privacy constraints.
How do we ensure the user’s ownership of data is taken
into account?” Verma says. “That is slowing us down a
little because everybody wants to be extremely careful in
complying with the law.”
One solution is to give drivers the right incentives, according
to Fangmann. “Most people are willing to give up some data
privacy for a 5% to 10% better deal on services or products,”
he says.
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7

Staying connected in the aftermarket
Still, connected cars offer manufacturers an important avenue
for developing stronger, longer-lasting ties to customers.
“Manufacturers have a reasonable chance of generating
revenue from an owner during the duration of a vehicle’s full
warranty, a window of about 3 to 5 years. Once that period
ends, things change,” Fangmann says. Owners soon begin
making greater use of aftermarket service and independent
parts providers.
Compounding the problem is the fact that cars are staying on
the road longer, with the average age of vehicle registrations
creeping up to 11 years. An IHS Market study found that in 2016
the average age of light vehicles reached 11.6 years old, up from
9.6 years in 2002.
Connected cars alter that equation by offering manufacturers
an effective way to stay in touch with vehicle owners over a
vehicle’s entire life cycle. Manufacturers would have a much
greater chance of maintaining service revenue and a stronger
brand-building channel to drive repeat sales. And that
always-on connectivity can help automakers notify drivers
about recalls and address security threats more effectively
by issuing over-the-air software updates to critical systems.
Not too late for older models
The number of new vehicles shipping with telematics systems
accounts for only a small percentage of vehicles on the road
today. For vehicles that predate the connected car revolution,
CSC offers hardware, services and an online platform that can
collect and report performance data from a car’s controller
area network (CAN) bus port, used for diagnostics.
Data is displayed in a dashboard on a variety of mobile
devices for the driver, owner or fleet manager, as well as the
manufacturer. “Car makers, rental agencies and enterprise
fleet managers have the opportunity to bring millions of
vehicles online,” Fangmann says.
Despite the challenges in ramping up quickly, automakers
need to continue to push ahead with connected capabilities,
as competitors who already understand the value of large
data pools are nipping at their heels. A few well-known Silicon
Valley enterprises with large connected customer bases, such
as Google, have been experimenting with their own mobility
services and connection technologies.
“These companies are making rapid progress, and they’ve
already connected customers,” Fangmann says.
“This could allow them to become the
owners of the connected car space
before manufacturers realize
they’ve been overtaken.”
DALE COYNER is a writer with CSC’s
digital marketing team.
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Q&A
Under the Hood with Ford
Roopak Verma
— Ford CIO,
Europe, the Middle East
and Africa
Ford Motor Company was among the first in the industry
to offer connected car services through the driver’s
cell phone. Today, new models released by Ford have
a built-in modem for connectivity. For more on the key
considerations raised by connected cars, CSC recently
spoke with Roopak Verma, Ford’s CIO for the Europe,
Middle East and Africa region.
How is Ford helping to secure the connected car?
How can OEMs work together to address this threat?
Recent security demonstrations have really prompted
all of the OEMs to take a hard look at vehicle security.
We have the capability today to remotely unlock a vehicle,
and if someone can hack into it, that’s the first thing he or
she will do. If someone can control the functionality of the
vehicle remotely, that’s dangerous.
A Fusion Hybrid, for example, is generating 25 gigabytes
of data per hour. A hacker would love to get access to the
functionality of the car, your location data, your contact
data, even your credit card data. At Ford, we realize you
have to have the fundamental security architecture built
into the vehicle. The architecture that controls the vehicle
functionality needs to be isolated from the connected
vehicle architecture, and you need encryption between
every component.
Everybody’s facing a common challenge. A lot of the safety
features we expect are going to require vehicles to talk to
each other, so if a Ford car is not talking to a GM car, it’s not
going to know the car is stopped ahead just around a blind
curve. That type of connectivity is going to require us to work
together on the protocols and the security architecture.
What role is data analytics playing at Ford in supporting
automotive sales, production and services?
Data analytics and intelligence can give us a single, integrated
view of people who are researching a car on the Web, linking
them with the people who may come in and visit the dealer,
and linking them with the people who might actually buy a
car and then come back to Ford for the servicing. It can help
us change the whole marketing paradigm.
It’s also going to help us make a connection with the
customer to design the next-generation car. We won’t
need hundreds of hours of research to find out where
the next trends in car designs are going. We’ll be talking
to our customers.
Organizations are under constant pressure to step up their
rate of innovation. How are you nurturing innovation at Ford?
One of the things we’ve been doing in Europe is looking
for a way to really democratize innovation. What we used
to always see is that you could come up with a great idea,
it worked well, but there was always a challenge in the
implementation and getting the business value out of it.
So we started the Ford Innovation Challenge. The idea is
that anybody in Ford with an innovative idea can put it
forward. We opened it for 2 weeks and we had 415 ideas.
We had a semifinal event to select the top 12 ideas, and
now the business owns these ideas, and we are providing
them time, funding and resources to take them forward.
It’s exciting.
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9

THE
DIGITAL TWIN
With the rise of digital, manufacturers are finding themselves rich in data. Meanwhile,
computing has emerged as the cheapest, most abundant resource that we can deploy
against any problem.
The problem in manufacturing is not the lack of new ideas and products, but the ability
to design and build new products efficiently. An IDC Big Data user study found that
operations-related processes were the top priority for analytics investments.
This next wave of IT innovation, the rise of digital, is providing manufacturing with
the engine to improve efficiency. IT has become an integral part of a product. This
is because of cheap sensors and processors, cheap storage, purpose-built software,
purpose-built clouds enabling data storage and ubiquitous connectivity.
Simulating new innovations is the idea behind the digital twin in manufacturing. We can
use stochastic simulation to generate future “what-if” scenarios and use those scenarios
to avoid costly product quality issues, speed time to market, and increase throughput.
This may sound exotic, but it is really just a modern twist on a very old idea — the
scientific method. Build stochastic simulations, generate experiments, and use those
experiments to minimize risk and innovate in the process.
Tesla is an excellent example of this concept. Tesla has a digital twin of every VIN they
manufacture. Data is constantly being transmitted back and forth from the car to the
factory. If a driver has a rattle in a door, it can be fixed by downloading software to adjust
the hydraulics of that particular door. Tesla regularly downloads software updates to
their customers’ cars based on the data they are constantly receiving from each VIN.
Future What-If Scenarios
Real Manufacturing Innovation
New Materials
Product Design
Innovations
Process
Innovations
Manufacturing Process
101 1010101
Manufacturing Simulation
f (x)
Instrument the manufacturing
equipment and feed our
simulations streaming data
Flaws
Cost
Performance
Figure 1. Using the digital twin as a source of manufacturing insight
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Prescriptive data, and pipelines
Creating a digital twin starts with establishing new pipelines of manufacturing data.
We can automate the collection, for example, of materials and design data. When
integrated with historical operations performance data, we have the raw data
required to support the creation of a digital twin.
The next step is to take the manufacturing process and model it using rules. But
instead of using the more common retrospective models, digital twin simulation uses
prescriptive models. Retrospective models, like those commonly used in predictive
modeling, try to calculate the future based on past trends. Models like that have been
successful in some areas of manufacturing prediction, but they take us away from
breakthrough innovation and keep us stuck in optimizing. Instead, we need to build
stochastic simulations, or prescriptive models. We create rules for mapping from
design to performance and add randomness to simulate risk.
The prescriptive data from the simulations tells us how new products will work. We
can detect design flaws early. We can predict and minimize cost. Because randomness
is inherent in our models, we can simulate the kinds of uncertainty we encounter in
the real world. Computer power is cheap — we can afford to run millions of scenarios.
We can anticipate an entire spectrum of possible outcomes rather than just a single
expected result.
Continuous insights through IoT and industrial machine learning
We can learn as much from the digital twin as we can from the real-world original.
Internet of Things (IoT) technology allows us to augment the manufacturing process
with sensors and automatically generate data about operations, performance and
maintenance. If we use industrial machine learning to build and deploy, we can turn the
streaming variant of the digital twin into a continuous source of manufacturing insight. 1
1
Access and Collect Data
Ingest and Clean
Agile Experimentation
10110
Scaled globally across the entire
manufactuing process
2 3
Map to standard
concepts and make
insights repeatable
Use experiments
to produce reliable,
measurable results
Transform Manufacturing
New Materials
Product Design
Innovations
Process
Innovations
Generate
Insights
4
Produce insights that
can be distributed
and used throughout
the entire manufacturing
process
Figure 2. When deployed according to CSC’s Industrial Machine Learning, the digital
twin becomes a continuous source of manufacturing insight
Digital twin really sits in the continuum of the IoT. If we agree that the foundation of
IoT is connectivity, sensors and analytics, predictive maintenance is an established
IoT application. Predictive maintenance is case-based reasoning enabled by data for
mitigation and repair. Digital twin incorporates product data from design to operation
and beyond, including maintenance history. Harnessing all the data to enable a complete
digital twin isn’t there yet. But examples and pilots showing the steps along the way
are certainly relevant.
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11

The digital twin comes to life
This idea is beginning to take hold in several major manufacturers. GE is piloting a
“digital wind farm” concept, which it uses to inform the configuration of each wind
turbine prior to procurement and construction. Once the farm is built, each virtual
turbine is fed data from its physical equivalent, and software enables optimization of
power production at the plant level by adjusting turbine-specific parameters, such
as torque of the generator or speed of the blades. The hope is to generate 20% gains
in efficiency.
PTC has developed a “Smart Connected PLM” software product called “Windchill.”
The Swiss solar panel manufacturing company Oerlikon uses Windchill to automatically
track system metrics and keep account managers apprised of the condition of their
customers’ systems. PTC describes it as a FRACAS process, a failure reporting, analysis
and corrective action system.
Dassault Systèmes has built an aerospace and defense-specific manufacturing operations
management product called “Build to Operate.” It provides the ability to monitor,
control and validate all aspects of manufacturing operations — ranging from replicable
processes and production sequences, to the flow of deliverables throughout their
supply chain — each on a global scale. Airbus Helicopter has deployed this system
for current and future helicopter manufacturing.
In every industry, we see the increase of data at both higher velocity and volume. This is
leading to the creation of more machine learning algorithms designed to learn incrementally
over new data. In manufacturing, these new algorithms will take the form of digital twins
capable of helping manufacturers design and build new products more efficiently.
What do you think? Are there any compelling manufacturing products or processes
that would benefit by creating a digital twin?
JC Brigham
CSC ResearchNetwork Analyst
Joan-Carol (JC) Brigham has been an
analyst within CSC’s ResearchNetwork
for 8 years. She has led strategy work
and managed much of the startup of
industry research within the
ResearchNetwork. Right now she is a
principal and business manager analyzing
the manufacturing industry. Prior to joining
CSC she worked in the services area at
Sun Microsystems, and before that, at a small
digital marketing company. She stumbled
into the high-tech market analysis profession
during her 15 years as an IDC analyst. JC
lives in the mountains of Colorado, loves the
outdoors and travels as much as she can.
Jerry Overton
CSC Distinguished Engineer
Jerry Overton is head of Advanced
Analytics Research in CSC’s
ResearchNetwork and the founder of
CSC’s FutureTense initiative, which
includes the Predictive Modeling
Research Group, the Advanced Analytics
Lab and the Predictive Modeling School.
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