Equipment management and sustainability
One area that Castrip has been working on for the last two years is increasing the use of machine intelligence to increase process efficiency in the yield. “This is quite affected by the skill of the operator, which sets the points for automation, so we are using reinforcement learning-based neural networks to increase the precision of that setting to create a self-driving casting machine. This is certainly going to create more energy-efficiency gains—nothing like the earlier big-step changes, but they’re still measurable.”
Reuse, recycle, remanufacture: design for circular manufacturing
Growth in the use of digital technologies to automate machinery and monitor and analyze manufacturing processes—a suite of capabilities commonly referred to as Industry 4.0—is primarily driven by needs to increase efficiency and reduce waste. Firms are extending the productive capabilities of tools and machinery in manufacturing processes through the use of monitoring and management technologies that can assess performance and proactively predict optimum repair and refurbishment cycles. Such operational strategy, known as condition-based maintenance, can extend the lifespan of manufacturing assets and reduce failure and downtime, all of which not only creates greater operational efficiency, but also directly improves energy-efficiency and optimizes material usage, which helps decrease a production facility’s carbon footprint.
The use of such tools can also set a firm on the first steps of a journey toward a business defined by “circular economy” principles, whereby a firm not only produces goods in a carbon-neutral fashion, but relies on refurbished or recycled inputs to manufacture them. Circularity is a progressive journey of many steps. Each step requires a viable long-term business plan for managing materials and energy in the short term, and “design-for-sustainability” manufacturing in the future.
IoT monitoring and measurement sensors deployed on manufacturing assets, and in production and assembly lines, represent a critical element of a firm’s efforts to implement circularity. Through condition-based maintenance initiatives, a company is able to reduce its energy expenditure and increase the lifespan and efficiency of its machinery and other production assets. “Performance and condition data gathered by IoT sensors and analyzed by management systems provides a ‘next level’ of real-time, factory-floor insight, which allows much greater precision in maintenance assessments and condition-refurbishment schedules,” notes Pierre Sagrafena, circularity program leader at Schneider Electric’s energy management business.
Global food manufacturer Nestle is undergoing digital transformation through its Connected Worker initiative, which focuses on improving operations by increasing paperless information flow to facilitate better decision-making. José Luis Buela Salazar, Nestle’s Eurozone maintenance manager, oversees an effort to increase process-control capabilities and maintenance performance for the company’s 120 factories in Europe.
“Condition monitoring is a long journey,” he says. “We used to rely on a lengthy ‘Level One’ process: knowledge experts on the shop floor reviewing performance and writing reports to establish alarm system settings and maintenance schedules. We are now coming onto a ‘4.0’ process, where data sensors are online and our maintenance scheduling processes are predictive, using artificial intelligence to predict failures based on historical data that is gathered from hundreds of sensors often on an hourly basis.” About 80% of Nestle’s global facilities use advanced condition and process-parameter monitoring, which Buela Salazar estimates has cut maintenance costs by 5% and raised equipment performance by 5% to 7%.
Buela Salazar says much of this improvement is due to an increasingly dense array of IoT-based sensors (each factory has between 150 and 300), “which collect more and more reliable data, allowing us to detect even slight deteriorations at early stages, giving us more time to react, and reducing our need for external maintenance solutions.” Currently, Buela Salazar explains, the carbon-reduction benefits of condition-based maintenance are implicit, but this is fast changing.
“We have a major energy-intensive equipment initiative to install IoT sensors for all such machines in 500 facilities globally to monitor water, gas, and energy consumption for each, and make correlations with its respective process performance data,” he says. This will help Nestle lower manufacturing energy consumption by 5% in 2023. In the future, such correlation analysis will help Nestle conduct “big data analysis to carbon-optimize production-line configurations at an integrated level” by combining insights on material usage measurements, energy efficiency of machines, rotation schedules for motors and gearboxes, and as many as 100 other parameters in a complex food-production facility, adds Buela Salazar. “Integrating all this data with IoT and machine learning will allow us to see what we have not been able to see to date.”
The Download: sleeping in VR, and promising clean energy projects
People are gathering in virtual spaces to relax, and even sleep, with their headsets on. VR sleep rooms are becoming popular among people who suffer from insomnia or loneliness, offering cozy enclaves where strangers can safely find relaxation and company—most of the time.
Each VR sleep room is created to induce calm. Some imitate beaches and campsites with bonfires, while others re-create hotel rooms or cabins. Soundtracks vary from relaxing beats to nature sounds to absolute silence, while lighting can range from neon disco balls to pitch-black darkness.
The opportunity to sleep in groups can be particularly appealing to isolated or lonely people who want to feel less alone, and safe enough to fall asleep. The trouble is, what if the experience doesn’t make you feel that way? Read the full story.
Inside the conference where researchers are solving the clean-energy puzzle
There are plenty of tried-and-true solutions that can begin to address climate change right now: wind and solar power are being deployed at massive scales, electric vehicles are coming to the mainstream, and new technologies are helping companies make even fossil-fuel production less polluting.
But as we knock out the easy climate wins, we’ll also need to get creative to tackle harder-to-solve sectors and reach net-zero emissions.
Inside the conference where researchers are solving the clean-energy puzzle
The Advanced Research Projects Agency for Energy (ARPA-E) funds high-risk, high-reward energy research projects, and each year the agency hosts a summit where funding recipients and other researchers and companies in energy can gather to talk about what’s new in the field.
As I listened to presentations, met with researchers, and—especially—wandered around the showcase, I often had a vague feeling of whiplash. Standing at one booth trying to wrap my head around how we might measure carbon stored by plants, I would look over and see another group focused on making nuclear fusion a more practical way to power the world.
There are plenty of tried-and-true solutions that can begin to address climate change right now: wind and solar power are being deployed at massive scales, electric vehicles are coming to the mainstream, and new technologies are helping companies make even fossil-fuel production less polluting. But as we knock out the easy wins, we’ll also need to get creative to tackle harder-to-solve sectors and reach net-zero emissions. Here are a few intriguing projects from the ARPA-E showcase that caught my eye.
“I heard you have rocks here!” I exclaimed as I approached the Quaise Energy station.
Quaise’s booth featured a screen flashing through some fast facts and demonstration videos. And sure enough, laid out on the table were two slabs of rock. They looked a bit worse for wear, each sporting a hole about the size of a quarter in the middle, singed around the edges.
These rocks earned their scorch marks in service of a big goal: making geothermal power possible anywhere. Today, the high temperatures needed to generate electricity using heat from the Earth are only accessible close to the surface in certain places on the planet, like Iceland or the western US.
Geothermal power could in theory be deployed anywhere, if we could drill deep enough. Getting there won’t be easy, though, and could require drilling 20 kilometers (12 miles) beneath the surface. That’s deeper than any oil and gas drilling done today.
Rather than grinding through layers of granite with conventional drilling technology, Quaise plans to get through the more obstinate parts of the Earth’s crust by using high-powered millimeter waves to vaporize rock. (It’s sort of like lasers, but not quite.)
The emergent industrial metaverse
Annika Hauptvogel, head of technology and innovation management at Siemens, describes the industrial metaverse as “immersive, making users feel as if they’re in a real environment; collaborative in real time; open enough for different applications to seamlessly interact; and trusted by the individuals and businesses that participate”—far more than simply a digital world.
The industrial metaverse will revolutionize the way work is done, but it will also unlock significant new value for business and societies. By allowing businesses to model, prototype, and test dozens, hundreds, or millions of design iterations in real time and in an immersive, physics-based environment before committing physical and human resources to a project, industrial metaverse tools will usher in a new era of solving real-world problems digitally.
“The real world is very messy, noisy, and sometimes hard to really understand,” says Danny Lange, senior vice president of artificial intelligence at Unity Technologies, a leading platform for creating and growing real-time 3-D content. “The idea of the industrial metaverse is to create a cleaner connection between the real world and the virtual world, because the virtual world is so much easier and cheaper to work with.”
While real-life applications of the consumer metaverse are still developing, industrial metaverse use cases are purpose-driven, well aligned with real-world problems and business imperatives. The resource efficiencies enabled by industrial metaverse solutions may increase business competitiveness while also continually driving progress toward the sustainability, resilience, decarbonization, and dematerialization goals that are essential to human flourishing.
This report explores what it will take to create the industrial metaverse, its potential impacts on business and society, the challenges ahead, and innovative use cases that will shape the future. Its key findings are as follows:
• The industrial metaverse will bring together the digital and real worlds. It will enable a constant exchange of information, data, and decisions and empower industries to solve extraordinarily complex real-world problems digitally, changing how organizations operate and unlocking significant societal benefits.
• The digital twin is a core metaverse building block. These virtual models simulate real-world objects in detail. The next generation of digital twins will be photorealistic, physics-based, AI-enabled, and linked in metaverse ecosystems.
• The industrial metaverse will transform every industry. Currently existing digital twins illustrate the power and potential of the industrial metaverse to revolutionize design and engineering, testing, operations, and training.