Achieving Manufacturing Excellence - SME · • Achieving Manufacturing Excellence: Case Study ......
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sme.org/smartmfgseries Achieving Manufacturing Excellence Ramesh Subramanian, Practice Head - Connected Enterprise IT Tata Technologies
Transcript of Achieving Manufacturing Excellence - SME · • Achieving Manufacturing Excellence: Case Study ......
sme.org/smartmfgseries
Achieving Manufacturing ExcellenceRamesh Subramanian, Practice Head - Connected Enterprise ITTata Technologies
sme.org/smartmfgseries
• Tata Technologies - At a Glance• Global Operations• Connected Enterprise IT• Connecting Top Floor to Shop Floor• SCADA, MOM, MES Competencies
• The Future of Manufacturing• Industry 4.0• Five Types of Enablers• Platforms and Industrials• Benefits of IoT• Key Technology Trends
• Achieving Manufacturing Excellence: Case Study• Manufacturing & Supply Chain, OEM Strategy & Goals
Agenda
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Tata TechnologiesGlobal Operations
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Enterprise Resource
Planning (ERP)
Dealer Management
Systems (DMS/CRM)
Telematics & Mobility
Business Analytics (BA)
iPromis (Parts Catalog)
Application Management
Services
Supplier Relationship Management
Manufacturing Execution Systems
System Integration &
Testing
Core CompetenciesBusiness Outcomes
• Enabling smart connected factories
• Delivering global solutions for digital manufacturing
• Extending the digital lifecycle into effective manufacturing through consulting and implementation complemented by world-class AMS
Connected Enterprise IT
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Business Analytics
CRM
ERP
Integration Support
MES
SCADA
PLC
Connecting Top Floor to Shop FloorTraditional Manufacturing vs. Industrial IoT
Data LakeHadoop
Sensor/Smart ComputerAutomotive Aerospace Industrial Heavy Machinery Medical Devices
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SCADA, MOM/MES Competencies
• OSI PI – OPC, Tag browser, ProcessBook, Graphics, DataLink, ControlMonitor, Profile,Batch, managed PI(SMT)
• Honeywell – Experion, Process graphic, Uniformance, Matrikon - ECM, TAIJI PID,Alarm Manager
• Siemens - Win CC. PLC’s - S7, S5 • Rockwell – FT View ME/SE, RS View 32. PLC’s – ControlLogix, GuardPLC• GE – Proficy Cimplicty, iFix. PLC’s – 90/30, Versamax• Schneider – WonderWare InTouch. PLC’s – Modicon 984, 384, Quantum
SCADA-HMI/MMI/PLCs
• GE – Proficy for Manufacturing Discrete suite, Proficy Plant Applications• Siemens – SIMATIC IT Intelligence, Production and R&D suite• OSI - PI servers • Rockwell – Factory Talk Production Center
MOM/MES
• PI Data Historian • Aspentech Historian, Desktop Historian • SIMATIC IT Historian, Data Integrator, Line Monitoring • Factory Talk Historian, Vantage point, FTTM• Proficy Historian, Proficy SPC
MI,MESComponents
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Focus• Digital manufacturing plants• Digitized processes• Internet of things• Industrial Internet of things• Mobile-enabled technologies• End-to-end visibility• Supply chain integration – vertical & horizontal
Industry 4.0
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A
• Low power consuming sensors
• Cheap processing ability• Ubiquitous connectivity/
low-cost mesh connectivity
• Further reduction in cost of cloud storage and computing
Hardware technology
Source:Digital & IoT: A Tale of the Haves and Have-Mores, McKinsey & Company, December 2015 http://www.mckinsey.com/industries/high-tech/our-insights/digital-america-a-tale-of-the-haves-and-have-mores
• Evolution of predictive analytics and algorithms
• Confidence in security across entire IoT ecosystem
• Standardization of the stack and interoperability
Software technologyB
• Establish trust with consumers on sharing data
• Collaboration across companies and verticals
• Horizontal data aggregators
Data ownershipC
• Industry structure e.g., organized labor, third party servicing
• Committing to upfront investment based on clear business case
• HW-focused companies expanding core competency to SW
Business Org and cultureD
• Regulation for autonomous control
• Government and payor subsidy of healthcare IoT
• Agreement on fair data sharing practices
Public policyE
Five Types of Enablerswill drive IoT potential impact
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Platforms and Industrials
Applications for managing
communications between devices,
middleware, storage, and
data analytics.
Efficiency, control, asset monitoring. Productivity,
through monitoring the factory floor.
Technology Convergence• Sensors• Bandwidth• Processing• Smartphones• Ubiquitous wireless coverage• Big data• RFIP• GPS• Wearables• IPv6• Machines & robots• Humans & robots
Source:Digital & IoT: A Tale of the Haves and Have-Mores, McKinsey & Company, December 2015 http://www.mckinsey.com/industries/high-tech/our-insights/digital-america-a-tale-of-the-haves-and-have-mores
Platforms Industrials
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Specifically, we expect IoT to impact three main verticals within industrials in the short term:
1. Automation2. Manufacturing3. Resources
Any smart connected device can be intuitive.
Benefits of IoT Next-generation operational intelligence Unified key
performance indicators
Connected operations
& paperlessshop floor
Supplierquality
Assettracking
Predictive analytics
Real-timeasset health monitoring
Open collaborative
design
Teachablerobots
Mass customization
Real-time inbound & outbound logistics
Products asa service
Machinelearning
Optimize Outcomes
Flexible Connectivity Composer Codeless
MashupDynamic
Collaboration Administration
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Year
Expe
ctat
ion
/ Tec
hnol
ogy
Tren
ds
Short Term i.e.• Wearable Tech• Connected Supply Chain• Mobile Technologies• Supply Chain Visibility• Track and Trace Serialization• Integrated plant floor system
Medium Term i.e. • 3D Printing in Supply Chain• BIG Data in Supply Chain • Industrial IOT, Industrie 4.0• Smart Digital Factories• Electrical Architecture• Connected Car• Fuel Cells & batteries
Long Term i.e. • Autonomous Car• New Production Materials• Cooperative Robotics• Ubiquitous Independent Logistics Grid• In memory computing• 4G,5G Pervasive bandwidth• Kinematics, Image recognition
1-2 4-6 8-10
3 to 4 years 5 years plus
RFID
NFC
QR
Key Technology Trends
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Manufacturing & Supply ChainOEM business strategy and goals
Capacity and
flexibility
Vertical integration
Global business
expansion
NPI, innovation
and technologies
Operational excellence
People and environment
Quality and customer delivery
precision
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1. Increase number of cars sold by 2.5 times between 2013 and 2022
2. Set up state of the art smart plants
3. Modular solutions deployment across plants
1. Transformation of legacy plant
2. Global business expansion 3. Centralised plant IT
systems 4. Standardization of local
manufacturing practices
Strategic objectives
Business considerations
Target State Architecture (TSA)
Mapping of business capabilities into ISA 95 model
Translation of business goals into business
capabilitiesBusiness goals and objectives
• Order management• MES• Operations management• Performance monitoring• Maintenance operation• Quality • New Product Introduction• Plant inventory • Spares and equipments• Order tracking • Inter-plant processing• Engineering change mgt• Plant capacity optimization• Quality and lean improvement• Part verification • Master vehicle records
Production process L0
L1
L2
L3
L4
Batch control
Conti-nuouscontrol
Discreet control
MOM/MES
BP & L
1. End-to-end linkages of systems and strategies
2. Alignment between PLM, ERP vendors and service providers
• Nearly 100 man years worth of efforts (mapping and business validation)
• Live document, constant refresh
47
44Business capabilities from Supply Chain domain
Business capabilities from manufacturing domain
• Identifying dependency between business
• Modular MES Generic MES module
• Assess• Design • Development • Deployment
• Core• Common• Unique 1.Detail mapping, documentation and
functional blueprint2.Reusability and enhancement
of baseline solution
• Standards used: MESA, ISA 95 • Benefit from retained knowledge
across the organization
• MES/MOM data
Global MOM template
Development approach
Capability definition and relationship
Data categorization
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Key Contacts
Ramesh Subramanian Practice Head – Connected Enterprise IT (EU & NA) [email protected]
Raja Ganguly VP Connected Enterprise IT (EU & NA) [email protected]
Sandeep Bhandari Head Delivery Connected Enterprise IT (NA) [email protected]
Ashish Thakur Presales Consultant – Connected Enterprise IT [email protected]
Pratim Banerjee Business Development Manager [email protected]
@TataTech_News
linkedin.com/company/tata-technologies
www.tatatechnologies.com
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