Next‑generation, mission‑critical, automotive manufacturing IT environment with HP and abat+Solution brochure

your automotive production towards the next‑generation factory with greater agility, efficiency, and competitive edge.

Guide

Can collaboration revolutionize your shop floor?It is only recently that the automotive industry has begun to view IT as a strategic tool that would increase competitive advantage, promote sustainability, and yield greater control over processes. Though automotive manufacturers are rushing to integrate IT tightly into their business, there are several challenges. Globalization demands that businesses operate from any geography; there is also the simultaneous need to extend supply chains across the world. With distributed operations arises the need to integrate new technology and processes. Also important are environmental and regulatory compliance that spur demand for sustainable innovations and efficient use of resources. It is a tough task for the automotive industry that is already dealing with heightening competitive pressures and economy dynamics. Primarily implemented to automate disparate processes, IT is now being adopted on an enterprise‑wide scale. Advances in IT methodologies and architectures, such as service‑oriented architecture (SOA), enable manufacturers to model IT functions into services in an effort to increase agility and reduce time to market. Another enabler is converged infrastructure. In a globalized economy, it is no surprise that convergence—of communications, control systems, power, and information technologies—is spilling on to the shop floor in the shape of manufacturing execution systems (MES). But these innovations are not enough. That is why we need to look towards the next‑generation, mission‑critical, automotive manufacturing IT environment.

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Teaming with the right technology partnerThe right partner can be instrumental in revitalizing your production system. When considering a partner, one must not neglect to consider the extent of the partnership, the future availability of the proposed products, and the roadmap. HP and abat+ team together to offer you a comprehensive service offering, which combines the technology leadership and end‑to‑end services expertise of HP with the domain know‑how of abat+ (an automotive technology partner of HP) in an effort to help you meet your business objectives of mission‑critical business continuity. With this one‑stop solution, HP helps to draw up roadmaps for your products, including the necessary migration strategies in the event of a transition to new technologies.

HP Converged Infrastructure solutions help mobilize IT for the new order—improving enterprise agility by simplifying deployment and speeding IT delivery. Designed to be a key element in an Instant‑On Enterprise, these offerings are designed in coordination to help reduce IT sprawl and turn technology assets into interoperable, shared pools of resources with a common management platform. With our next‑generation, mission‑critical, automotive

manufacturing IT systems, you can leave the shop floor technology in the hands of experts at HP and abat+, while you focus completely on business outcomes.

Achieve synergistic intelligence for manufacturing processesWe offer a new mission‑critical solution for efficient production control. It packages the MES standard software PLUS from abat+, the HP Integrity NonStop platform, and end‑to‑end services by HP. Particularly effective in supporting the automotive enterprise’s demanding manufacturing operations, the solution delivers improved visibility into manufacturing operations and performance, makes assembly lines trimmer, and restores mission‑critical availability across the manufacturing lifecycle. The solution from HP and abat+ enables enterprises to achieve and exceed benchmarks in quality, efficiency, and cost savings with relative ease, while offering the capability to accept and implement customer change requirements, anytime from order through delivery. In addition, HP has innovated a concept called Factory IT as a Service (FaaS). With FaaS, HP undertakes the complete IT of your manufacturing plant and enables measurement of business results.

Challenges for automotive manufacturing

1. Establishing mission‑critical availability and operational excellence (such as factory templates) with agility to meet global economic and social dynamics

2. Eliminating disparate inflexible IT systems and processes to gain better business insights

3. Managing a global manufacturing network across brands

4. Integrating manufacturing service providers—an increasingly important MES requirement

5. Achieving desired throughput, continuous improvement, and customer demand satisfaction through rigorous, productive, and mission‑critical systems

6. Providing manufacturing agility to adapt instantly to shifting demands

7. Integrating critical business processes better, particularly development, ERP, and spare part management

Figure 1Delivery and support model for HP and abat+ MES solution

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Powered by PLUS solution from abat+Based on a service‑oriented structure, PLUS is the MES solution central to FaaS and controls production from body shop to handing over final product to sales or the customer. The advantages of the PLUS SOA include:1. Technological advantages

− On‑the‑fly deployment of the latest software, hardware, and security standards − High flexibility, simplicity, scalability, and faster migration and deployment − Improved administration and real‑time processing while lowering hardware requirements

2. Quality and service advantages

− Clearly defined scope, responsibilities, and service‑level agreements (SLAs) − Proven high availability, fault tolerance, and data integrity with central data store − High level of skills and know‑how at the application service provider level − Operable at peak loads (product launch, model change) and fluctuations

3. Cost benefits

− Lower capital expenses, lower TCO resulting in higher liquidity − Improved cost control and planning accuracy due to transparent cost structures − Better use of resources and concentration on core competencies

4. Strategic advantages

− Fast and reliable support of process changes and business requirements − Standardization and harmonization of production processes − Low cost of access to domain‑specific IT and process skills − Variable deployment of hardware, power, and manpower resources for low fixed costs and manageable variable costs

How HP and abat+ can help re‑vitalize your automotive manufacturing processes

1. Reduced TCO, increased differentiation, and enhanced business continuity

2. Built‑in high availability, continuous enhancement, and quality assurance through infrastructure redundancy and electro‑mechanical security precautions

3. Unrivalled excellence in hardware and network infrastructure; designed for modular integrity

4. Well‑defined ITIL‑compliant process flows; increased quality control, versatility, and greater operational efficiency

5. Integrated software, service components, and processes for high performance and smooth operation

6. A standardized MES solution, PLUS from abat+ provides visibility, analysis, and evaluation across the production lifecycle

7. Greater and sweeping process control—customer change requests can be accommodated right until before delivery

Figure 2Service‑oriented architecture of PLUS

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The process range and features of PLUS are:•Electronic Command Control Center—displays on

dashboards the overview of the progress of all orders at all times, including quality metrics, stock for rework and scrap, thus promoting transparency in production.

•Shop floor data acquisition—facilitates product tracking and management in real‑time, increasing visibility and throughput, and reducing stocks. Complete overview of the supply chain, sales, and management that translates into timely delivery and logistics.

•End‑to‑end quality data acquisition and analysis—facilitates seamless administration of all processes, with high availability and almost no lost information. PLUS supports Inline Quality Management such as vehicle test, failure recording, rework control, and action management.

•Ease of use and built‑in worker guidance—offers enhanced operational efficiency. The PLUS solution is multilingual.

•Management of production processes—offers end‑to‑end control of product and material flow throughout the manufacturing assembly line. All relevant information for production management is available to the user directly from the PLUS system. PLUS is capable of implementing a closed loop production equipment integration by providing order

data to and collecting production data from devices, including:

− Mechanisms − Conveyor belt technology − EC‑screwdrivers − Bolts − Clearance equipment

•Management of tools and supplies—makes certain that at the start of a production order, the required components from the Bill of Materials (BOM) are transported to the workplace. PLUS manages work in progress inventory and also the supply and disposal of materials and tools at work stations. PLUS provides the worker with information about the vehicle and the part assembly, including vehicle dispatch card in paper and electronic format.

•Unrivaled application availability—is enforced via hardware and software infrastructure with built‑in automated failure handling, including redundant hardware and networking from HP with automatic self‑healing functions.

•Converged Infrastructure model—is supported as PLUS supplements its core functions by monitoring and managing support from mobile devices as well.

Figure 3Automotive manufacturing processes addressed by the PLUS solution

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Powered by HP Integrity NonStop systems To increase availability, general‑purpose servers and software require individual and sophisticated configuration to be deployed as a high‑availability cluster. This is typically time‑consuming, expensive, and error prone.

In contrast, HP Integrity NonStop systems are designed from the ground up to be “always available” and therefore, provide higher application availability out‑of‑the‑box, reducing the need for complex and costly configurations for high‑availability. Also, they achieve virtually unlimited, near‑linear scalability via the addition of logical processors, which are in fact standard server blades—without the need for additional wiring. Also, you can easily add these logical processors or disk capacity online as per your requirements. These special features enable HP to flexibly configure its NonStop servers to match your capacity requirements, even servicing plants with a production capacity of 50,000 cars up to 1 million cars per year, or even higher.

PLUS is designed to leverage the unique features provided by the NonStop architecture and consequently enables highest possible application availability. This also includes the capability for introducing online upgrades of the application. HP Integrity NonStop systems are part of the HP Mission Critical Converged Infrastructure portfolio, designed to provide uncompromising resiliency and flexibility, increase infrastructure return on investment and availability, and reduce total cost of ownership. This approach is delivered through a common architectural framework, based on a standard set of components and management tools. With this technology, data centers are able to respond quickly in an agile business environment.

The proven NonStop architecture consistently delivers the world’s highest application availability.1

1 The Standish Group, 2010

HP ServicesHP Technology and Enterprise Services—consultants and support experts to solve your most complex infrastructure problems. We help keep your business running, no matter what. Boost availability and avoid downtime, trust our expertise to improve your HP solution.

Recommended Services

•HP Critical Service Solution provides comprehensive proactive and reactive support designed for businesses that run essential mission‑critical applications, where downtime is not an option.

•HP Proactive Service Solution provides improved stability, availability, and operational effectiveness with an integrated hardware and software support service that combines industry‑leading reactive technical assistance with proactive account services, giving your IT management support from a team of service specialists.

•HP Foundation Service Solution combines pre‑installation preparation, assessment, integration, installation and start‑up, hands‑on training, and HP Support Plus 24 service.

Related Services

•HP Deployment and Startup Services: These services provide installation and configuration services, including design services, availability checkup, site environmental services, hardware and software installation/initialization, custom integration, educational services, and transition to operation.

Trust the Services professionals at HP. For more information, contact your HP sales representative or HP‑authorized Channel Partner.

Visit: https://h10134.www1.hp.com/industries/automotive/

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Powered by HP Enterprise ServicesHP Enterprise Services provide an end‑to‑end business solution offering to the manufacturing IT clients around the world with a focus to increase business efficiencies and performance for an Instant‑On Enterprise. HP has decades of experience helping manufacturing clients transform their IT environment—from current state analysis to design/implementation/integration and support—to gain cross‑organization business efficiencies. Our solution portfolio includes infrastructure, applications, and business process capabilities such as ITIL‑compliant IT operations and Cloud Services with enterprise‑grade cloud solutions. Together, these help you become more agile, cost‑effective, and competitive. The service levels and configuration will be jointly defined and governed by you.

With FaaS, HP is providing not only a transformation from fixed to variable costs and a predictable agility of manufacturing IT, but we are also introducing a contract whereby HP is compensated directly based on the performance of the plant. Figure 4 above provides an overview on our HP Enterprise Services offerings.

About abat+abat+ is a leading service provider in the space of high‑availability IT solutions for production execution, scheduling, planning, and quality management. The

organization provides a portfolio of services that spans software development, maintenance, implementation, and rollout including all associated support levels. It offers comprehensive skills and know‑how in application management, maintenance, and outsourcing of high‑availability solutions. To learn more, visit: www.abatplus.com

HP Financial ServicesHP Financial Services provides innovative financing and financial asset management programs to help you cost‑effectively acquire, manage, and ultimately retire your HP solutions. For more information, visit www.hp.com/go/hpfinancialservices .

Global citizenship at HPAt HP, global citizenship is our commitment to hold ourselves to high standards of integrity, contribution, and accountability in balancing our business goals with our impact on society and the planet. To learn more, visit www.hp.com/hpinfo/globalcitizenship , and for information about the HP Eco Solutions program, go to www.hp.com/ecosolutions .

Align your production processes directly to business goals.

To achieve breakthrough performance across your automotive manufacturing value chain, visit www.hp.com/go/automotive.

Figure 4HP Enterprise Services—End‑to‑end offerings

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Get connectedwww.hp.com/go/getconnected

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© Copyright 2011 Hewlett‑Packard Development Company, L.P. The information contained herein is subject to change without notice. The only warranties for HP products and services are set forth in the express warranty statements accompanying such products and services. Nothing herein should be construed as constituting an additional warranty. HP shall not be liable for technical or editorial errors or omissions contained herein.

4AA3‑4523ENW, Created September 2011