Copyright © 2014 Rockwell Automation, Inc. All Rights ... · Copyright © 2014 Rockwell...


Agenda

2

Factory Talk Production Centre (Demo)

Manufacturing Execution System Overview

Project Management /Connected Enterprise Journey

Our Complex Environment


20 YEARS AVG PRODUCT LIFE

PRODUCT TYPES

• Stock + Configure to Order • Engineered to Order

387, 000 SKUS

200 SKUs AVG ORDER

20 PLANTS

The Connected Enterprise Implementation & Transformation


Complex Environment

4

Smart Motor Controllers

Variable Frequency Drives

Solutions Custom OEM Panels

LV Control Centers

Logix Family

Small Controllers

Control & Visualization Platforms

Performance & Visualization

MV Control Centers

Connection Devices

Push Button & Signaling Devices

Sensors & Switches

Components

Product Complexity & Lead Time


Complex Environment + Supply Chain Restructuring + Global Process Transformation (ERP Initiative)

We did not have clear visibility into every plant’s operation

Best practices or greatest difficulties were tough to compare or contrast since

they were defined by different sources of information or points in the process

Making confident decisions off of known good data was tough to do.


Two data rich system that are disconnected…

6

ERP

Plant

Floor

Enterprise System Existing Control Systems


Manufacturing Execution System Connects IT and OT

7

ERP

Plant

Floor

ERP

Plant

Floor

MES

Enterprise System Existing Control Systems

Centralize MES Strategy


Data Utilization to Knowledge

8

Data Actionable Information

Knowledge

The right information at the right time to manufacturing decision

makers on how the current conditions on the plant floor can be optimized

to improve production output


FTPC Enabled Lean Manufacturing Quality, Service, Cost, Sustainability

MES-Level

Process Control

Plant-Level

Process Control

Paper Process

Verification

Work Order Chasing

Sub-Optimized

Processes

Real-Time Global CTQ

Parameter Monitoring

Integrated Order

Management

Data Driven Process

Optimization

Quality

Service

Cost

Sustainability

FTPC

+

ERP

Machine Data Machine Information &

Intelligent Tools

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 10

What is MES? Data Collection/Information Provider (Level 3)


What is MES? Coalesces Information and Operations Technologies


What is MES? Rockwell Automation Manufacturing Systems


ERP Integration Gateway

Production Management

Performance Management

Quality Management

TECHNOLOGY


ERP Integrated Gateway

14

Production Order

ME

S

En

viro

nm

en

t

Production Orders

Component Scrap

Operation Confirmation

Master Data

ER

P

Manual Operation Confirmation

Material Master

BOM

Routing

Characteristics

Inventory Inventory Receipts During Day

Procurement Open PO & Stock Transport

Data Element Code Desc.

Warranty

Assembled Module Serial Number

Child/Parent Serial Number Linkage


Factory Talk Production Centre Features

15

• Single Operator Interface

• Work Order Management

• Quality Data Collection

• Embedded Checklists (Audits/Verifications)

• Operator Training & Certification

• Process Enforcement & Visibility

• View Work Instructions & Work Standards

• Performance Management Reporting

• Labor Tracking

• Downtime Tracking

• Alarms & Warnings

• Quality Analysis Tool

• Tester Integration

• Parent-Child Relationship

• Performs SAP Confirmations

• Assembly Verification

• Buffers Transactions for ERP

• Allows Productions during ERP Outages


Single, Consistent User Interface for Manufacturing

Consistency in use of terminology where appropriate and possible

If the user interface is used to inform or instruct the manufacturing associate (MA) then it should be presented in the native language

Screens available in Spanish, Mandarin, Polish and Portuguese

Simplify required interaction between MA and System

Minimize time duration of data input

No switching between applications

Minimize actions required to enter data

Barcode scanning

Function Keys

One or two pointing device (mouse) clicks

Touch screen


Graphical User Interface - Automation

17

• Automation • Logix • Panel Views • Bar Code Scanners

• Enterprise Information • Work Orders • Serial Numbers • Part Numbers • Start Dates

• Operator • Status • Notification • Information


Printed Circuit Board Assembly Cell Activity

18

Inputs

6,450 raw materials

300 W/Os released/day

1.3M placements/day

10,000 boards/day

64 changeovers/day

55,000 FTPC transactions

per day in PCBA cell


Cell Performance Display (Score Board)

19



20

Process Readiness Process Characteristics


Graphical User Interface – Manual Assembly (Integrated Interoperability)

22


Quality Management

23

• Equipment Integration (using API) • Guided Manufacturing Processes • Process Enforcement • Automated and Manual Data Collection • Training and Certification Tracking • Documented Work Instructions • Workmanship Instructions


Defect Data Entry Check Lists

Quality Management


Quality Management – Report Generation


MES Deployment Map


Project Management Connected Enterprise Journey

27

Detailed Schedule based on Global Process Transformation (GPT) ERP System deployment

New release every 6 months

New manufacturing plant(s) deployed

System enhancements & new feature sets

Detailed Factory Talk Production Centre (FTPC) Release Schedule

New release every 2 months

New manufacturing plant(s) based on GPT release schedule (Critical Path)

System enhancements, bug fixes & new feature sets

Each Plant Deployment utilized as Statement of Scope, Statement of Work and WBS

Review and Signoff was required by Key Plant Stakeholders

Follow-up (Hyper-care) meetings for support (action items, responsibilities, target dates, status)


Project Management Connected Enterprise Journey

28

Requested Enhancements

Prioritized (scored for criticality and overall impact)

Reviewed, Approved and Scheduled

Conduct User Group Meeting on a monthly basis

Share Best Process Practices

Review Scheduled Releases

Voice of the Customer (VOC)

Project Phase Gate Reviews

Project Management Office (PMO)

Financial Plan vs Actual

Schedule Review of identified projects with plan and customer feedback

Risk Identification, Risk Review and Mitigation Plans


PLANT BEHAVIOR

Inventory 120 days to 82 days

CapEx

30% per year in capital avoidance

Productivity ►4% to 5% per year

SUPPLY CHAIN / LEAD TIMES

Delivery Mid-80s to 96%

Lead Times Reduced 50%

CUSTOMER SERVICE

Time to Want 82% to 98%

Quality

50% reduction in PPM

Achievements

Copyright © 2014 Rockwell Automation, Inc. All Rights ... · Copyright © 2014 Rockwell...

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