The Digital Factory in Can-making using MES · MES is all we do… We build MES solutions that are...

The Digital Factory in Can-making using MESMartyn Gill – Business Development Director, EMEA

Agenda

Who is Lighthouse?

The Journey to the Digital Factory with MES using the S95 standard

The significance of Connected Processes

Digital Transformation

Shopfloor-Online (the heart of the Digital Factory)

MES is all we do…We build MES solutions that are fully integrated with the customer business processes and systems

Our Product is called Shopfloor-Online

It is running in hundreds of factories

We take along term partnership approach with our customers

We have 30 years experience of IT in manufacturing

We build MES solutions for the manufacturing industry

Shopfloor-

Online

Product

Integration

Services

MES

Solution+ =

Sales

14%

Implementation &

Support

52%

Admin

16%

Development

18%

People Resources

Our Organisation

Lighthouse Systems

LSL (EUR)

Sales

Implementation & Support

Admin

Development LSF (France)

Sales


LSN (Nordic)

Sales


LSCE (Central Europe)

Sales

LSG (Germany)

Sales

LSI (USA)

Sales


Admin

LSA (Asia)

Sales


Our Worldwide Network

Nordic

Sweden

Middle

East

Dubai

France

Paris

Central

Europe

Poland

UK

Crawley

USA

New York

Canada

South

Africa

PE

Israel

Ireland

Cork

Belgium

Aalter

Nether

-lands

Veghal

Thailand

Asia

Singapore

Germany

Koblenz

• SI Partners

• Regional

• Or Industry Specialists

• LZ Lifescience

• Stolle Machinery

• Partner Capabilities

• Have relevant experience in MES

• Complementary solutions (automation)

• Have dedicated Shopfloor-Online resources

• Have been extensively trained

• Can build and support their own solutions

Italy

Genoa

Brazil

Sao

Paolo

BLUE: LH Offices

ORANGE: Partners

Our End Users in the Can and Ends Industry, Worldwide

Shopfloor-Online MES: The heart of the Digital Factory

2 Piece Can

3 Piece Can

Ends

Aerosol / Bottle

160+ Can and End Manufacturing Plants globally using Lighthouse’s Shopfloor-Online MES Software suite!

Today’s manufacturing typically has low levels of Integration between IT and OT

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Today’s manufacturing typically has low levels of Integration between IT and OT

Convergence of IT and OT will allow decision makers to drive

inefficiencies out of the manufacturing operations.

Information Technology (IT)

Office Information Technology

Operations Technology (OT)

Automation Systems on the factory floor

MES provides the method of convergence

10

Plant Equipment

(Automation & PLCs)

Layers 0,1,2

Finance, Inventory and Core

business functions

Operators, Supervisors,

Process Engineers and

Continuous Improvement &

Operations Managers

Manufacturing in real-time

Production Counts, Detect

Counts, Downtime, Process

Parameters, Quality, Gauging

and Vision Systems

ERP

Layer 4Days, Months,

Quarters & Years

Machines, Logic, Lines,

Sensors

Plant Operations

Layer 3 – MES

Days, Shifts, Hours, Minutes, Seconds

Purchasing and Supply

Chain, Customers,

Sales Order

Management

What is S95 and where does MES fit?

11

Plant Equipment

(Automation & PLCs)

Layers 0,1,2

ERP


Quarters & Years

Plant Operations

Layer 3 – MES


What is S95?

12

Plant Equipment

(Automation & PLCs)

Layers 0,1,2

ERP


Quarters & Years

Plant Operations

Layer 3 – MES


• ERP is the BUSINESS system

• It has the BIG picture

• Used by OFFICE workers

• MES is the MANUFACTURING system

• It has DETAILED manufacturing

information

• Used by FACTORY workers

• User friendly, fast, with much automation

What is S95?

Where does Shopfloor-Online MES fit within S95?

13

Plant Equipment

(Automation & PLCs)

Layers 0,1,2

ERP


Quarters & Years

Plant Operations

Layer 3 – MES


Production

Operations

Maintenance

Operations

Inventory

Operations

Quality

Operations

Shopfloor-Online: Functional Modules

Inventory Operations

Inventory

Label Printing

Traceability –Consumption

Build Traceability

Warehousing/ Logistics

Quality Operations

Quality Checks

SPC

Process Monitoring

Links to Documents

Concerns/CAPA

Supplier Complaints

Customer Complaints

Maintenance Operations

Asset Register

Maintenance Management

Repairs

Tool Management

Energy

Production Operations

Scheduling

Job Tracking

Downtime

Production Counting

Waste

Line Log Book

OEE

Labour

The Significance of the ‘Connected’ factory

Manufacturing Operations

Inven

tory

Pro

du

ctio

nQ

uality

Main

ten

an

ce/

En

gin

eeri

ng

InboundDeliveries

WarehouseMove

InventoryConsumeInventory

LocalStorage

IsolationsCreate

InventoryScrap

Print LabelMove

InventoryWarehouse

OutboundShipping

PlannedProduction

Orders

SetupInstructions /

Docs /Recipes

ManpowerPlan

ManpowerTracking

Execution

ProductionsCounts

Waste

DowntimeEvents

Inbound QC

ProcessParameters

In-Line QC

Lab Checks

Concerns/CAPA

MaintenancePlan

PlannedMaintenance

Activity

ToolManagement

UnplannedMaintenance

Activity(Repairs)

Energy Usage

ERP PLCs

The ‘Disconnected’ factory

Manufacturing Operations

Inven

tory

Pro

du

ctio

nQ

uality

Main

ten

an

ce/

En

gin

eeri

ng

InboundDeliveries

WarehouseMove

InventoryConsumeInventory

LocalStorage

IsolationsCreate

InventoryScrap

Print LabelMove

InventoryWarehouse

OutboundShipping

PlannedProduction

Orders

SetupInstructions /

Docs /Recipes

ManpowerPlan

ManpowerTracking

Execution

ProductionsCounts

Waste

DowntimeEvents

Inbound QC

ProcessParameters

In-Line QC

Lab Checks

Concerns/CAPA

MaintenancePlan

PlannedMaintenance

Activity

ToolManagement

UnplannedMaintenance

Activity(Repairs)

Energy Usage

ERP PLCs

The Significance of the Connected Factory using a single MES Solution

The Digital Factory has all the measurement systems, line sensors and computer systems joined up in a completely seamless manner…

The data from the measurement systems, sensors and computer systems would be available to each other… and talk to each other!

Predictive Analysis could determine when tool changes or maintenance is really required

These technologies & capabilities could dramatically change manufacturing operations

Spoilage rates could be cut, HFI could be eliminated, Line Availability

(Uptime) could be increased, non value-added manpower could be a thing

of the past

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The Digital Transformation – Quality Data

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ManufacturingExecution System

Dome Depth

Rim Varnish

Film Weights

Decoration Defects

Top WallMid WallBottom Wall

Lacquer Weights

Axial Load

Dome Reversal

Pin Holes

Trim HeightColour

Flange Diameter

Lube Weight

Oven Temps

pHFlouride

Dome Reversal

The Digital Transformation – Production Data

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Cupper Counts

Bodymaker Counts

pH

Oven zone temperatures

Label Changes

Pressure

Downtime

Cupper Sprayer NeckerBodymaker DecoratorWasher Oven

ManufacturingExecution System

Short Cans

Trimmer FaultsDowntime

Downtime

Inks

Varnish

Energy Downtime

ProductionCounts

Downtime

Lacquer

Tooling

Fluoride

ProductionCounts

The Digital Transformation – Inventory and Asset Data

Press Tools

Pallets of Bright CansRaw Materials

Complex Tool PacksCoil Changes

Tool Assignments

Tool Repairs

Maintenance Schedules

Punches

Rings

Pallets of Finished GoodsPallet Labels

HFI

Manufacturing Execution System

Shopfloor-Online MES: The heart of the Digital Factory

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ArchitectureOne database = one system

Browser based

No Client Installation

For UsersAccess from anywhere

Easy to use

Easy for training

For ITCloud or On-Premise

Scalable (single factory / multi factories)

Easy deployment

Standard IT infrastructure

Classic Can-Making Process Dashboard

Floor 1

Real-time visualisation – Screen Configurability

Shopfloor-Online: Production Scheduling

Shopfloor-Online: Plant Overview Dashboard

Operator User Interface

Quality Control – Real-time monitoring

Mobile Data Collection

MES – The ‘Real’ Benefits

All factory (Operations Technology) data will go into one place

All users will be able to access it from wherever they are

No data will be recorded on paper

No reports manipulated in Excel

Information will be immediate, live, accurate, correct

Data will be transformed into actionable items

Performance, status, problems will be instantly visible to all

Users will be alerted to problems (SMS, email)

Users will be guided through business processes

MES – The ‘Added Value’ Testimonial

• Less time spent entering data

manually

• Downtime now automatic

• Label Changes

• Data Entry page configuration

• Quality data improvement and

alignment

• Standardised Part Variants between

European and all American sites

• Potential to utilise cross-functionality

• Local System

• Saving on hosting costs

• System will suffer less delay from local

servers

• No dependency on a wide area network

• Data accuracy

• Interfaces mitigate human error

• Allow better business decisions

• HTML5: Latest web-browser

technology

• Faster updates

• Less error prone

• No restriction on IE

• Browser independent

• Ergonomic User Interface

• Searchable content

• Favourites

• Visual appeal feeds in to user buy in

• More control by super users

The Journey to Digital Transformation

Smart Manufacturing…. It’s a journey

It might be a long journey!

It’s a journey that can only be made with incremental steps

You don’t have to get travel sickness!

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Start with a DIGITAL TRANSFORMATION strategy

Connect your measurement systems and Quality Data to a centralised MES

Connect your machines, sensors and PLC’s to a centralised MES

Tag your critical Assets and track their use in a centralised MES

All plants can be Smarter even with existing systems…

Start your Digital Transformation journey nowwww.LighthouseSystems.com

The Digital Factory in Can-making using MES · MES is all we do… We build MES solutions that are...

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