How digital technology is making manufacturing smarter

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How digital technology is making manufacturing smarter

Bicky Bhangu

President - South East Asia, Pacific and South Korea
Rolls-Royce

IoT and smart manufacturing are changing the way organisations operate. Bicky Bhangu, Rolls-Royce, President for South East Asia, Pacific and South Korea, highlights why digital methodologies are deeply embedded in the DNA of Rolls-Royce, and how they are transforming the business and other industries

When it comes to unlocking the next level of manufacturing, digital connectivity is the catalyst. Advancements in Internet of Things (IoT) and digital technologies have opened up possibilities for new ways of manufacturing. The potential is enormous. By tapping the power of data, automation and connected devices, organisations can dramatically boost productivity, efficiency and value in processes across multiple sectors—such as aerospace, electronics and healthcare.

In demanding industries with high workloads like aerospace and marine, these capabilities are extremely critical. As a result, countries like Singapore, which rely on these economic drivers, are pioneering digital economy initiatives to raise productivity while making the most out of limited resources. Successful digital programmes can cut down operational costs while maximising output, leading to better customer service and business growth. In line with this vision, companies like Rolls-Royce are exploring new digital capabilities in a coordinated global digital strategy. Here are some of the ways we are using digital to drive smarter manufacturing:

Pushing the limits of IoT sensors

The power of IoT lies in the ability to leverage connected devices to provide valuable insights about things we’ve never been able to measure before. And with IoT spending in South East Asia projected to hit US$7.53 billion by 2020, the capacity for innovation is enormous. One of the greatest challenges we face at Rolls-Royce is the difficult conditions that our sensors must operate in. This includes extreme heat, freezing temperatures, high altitudes and other challenging environments. By developing cost effective and sufficiently miniaturised sensors that are robust enough to operate effectively in these harsh environments, we can deploy them throughout the value chain—from factories to engines operating in the air.

Unlocking more value throughout the entire manufacturing chain

The raw power of digital lies in its ability to surpass certain physical limitations, hence, digital thinking and design must also be incorporated into the process of manufacturing. At Rolls-Royce, this principle has been deeply embedded in our people, processes and technologies for over 20 years. Currently, we are undertaking joint projects, with research partners like Agency for Science, Technology and Research (A*STAR) and academic institutions like Nanyang Technological University (NTU). Together we are making significant investments into advanced capabilities that will boost manufacturing and re-manufacturing methods. The end goal is to set up a “virtuous cycle” of manufacturing that constantly improves efficiency, productivity, quality and yield.

The solutions include intelligent automation of processes, for example module assembly, testing and inspection, advanced repair and remanufacturing methods, including laser metal deposition, adaptive technology for smart inspection, and factory simulation capabilities to optimise manufacturing.  Repetitive, manual or high-risk processes will be automated to reduce errors, increase employee safety and improve right-first-time rates. At the same time, digital systems will collect data and help identify ways to intellectually refine processes continually.

Performing high-stress tests with high-performance computing

We are using high-performance computing to accelerate engine design, testing and verification with digital visualisation and simulation. The complexity of our engines and the harsh environment they have to operate in means that traditional testing methods are time-consuming, complex and costly.

The rate of data capture and analysis is going to grow exponentially and by tapping into the growing amount of data, sensor technology and advanced algorithms, we can support physical tests with digital twins. This creates “lighter”, safer and customisable environments that can stress-test engine conditions. Engine simulations can be conducted in 3D environments, giving engineers the insights they need to make modifications before investing in full scale implementation.  These advancements could potentially cut away entire tests and shorten new engine development by up to a year.

Delivering great customer experiences

Apart from giving a boost to internal processes, the potential of digital technologies can be extended to services for customers. Technologies like cloud computing, advanced analytics and IoT can be utilised to fundamentally transform engine-related operations and services. In the case of airline customers, they can aggregate data from disparate sources across the world to gain a better understanding of fleet performance, flight routes and fuel usage.

Customers can get a full view of their assets to drive more performance and better operations. Data can be processed by advanced analytics solutions including artificial intelligence to discover new ways of operating. Fleets can be optimised by selecting the best flight routes and improving on-time performances. At the same time, fuel consumption can be reduced. Sensors can also enable predictive maintenance by tracking the health of engines in flight and notifying in advance on-ground support teams of any repair or maintenance requirements.

As the world becomes more interconnected by digital platforms and connected devices, industries like aerospace must continue to do the same. In light of this, we will continue to drive our digital streams through collaborative projects. Our explorations into new IoT and smart manufacturing horizons will yield more possibilities for our business and other players across Singapore’s digital ecosystem.

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Rolls-Royce develops and delivers complex power and propulsion solutions for safety-critical applications in the air, at sea and on land.









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