ATS Industry 4€¦ · Smart Automation, Quality and IT Excellence Solutions •Double digit growth...
Transcript of ATS Industry 4€¦ · Smart Automation, Quality and IT Excellence Solutions •Double digit growth...
The Independent Solution Provider for Smart Digital Transformation
Good, Bad & Ugly of Industry 4.0Understanding what is possible with Industry 4.0, today, tomorrow and in the future
ATS Global Headquarter
Hofmanweg 5A, 2031 BH
Haarlem, Netherlands
Michele Sciuto
Chief Commercial Officer
www.ats-global.com
ATS North America
1055 East South Boulevard
Rochester Hills, MI 48307, USA
The Independent Solution Provider for Smart Digital Transformation
ATS Global Business
• 30 Years leadership in Smart Automation, Quality and IT Excellence Solutions
• Double digit growth year on year
• 900+ people (>75% Consultants + Technical)
• 4000+ customers worldwide
• Selected by Gartner as Global MES/MOM consulting provider with system integration services
(2018 Gartner Market Guide for MES/MOM Implementation)
ATS Canada
ATS USA
ATS Australia
ATS UK
ATS Spain
ATS Belgium
ATS GermanyATS Netherlands
ATS Austria
ATS Czech Republic
ATS Mexico
ATS South Africa
ATS Singapore
ATS Turkey
ATS Italy
ATS IrelandATS China
ATS Hong-Kong
ATS India
ATS Indonesia
ATS Macedonia
Automation & IT MES / MOM PLM Quality ManagementSupply Chain
Management
Smart Manufacturing
Industry 4.0
The Independent Solution Provider for Smart Digital Transformation
Agenda
Practical steps to implement
an I4.0 strategy
An outlook on the factory of
near future
How do we see Industry 4.0?
Good, Bad and Ugly of it
The Independent Solution Provider for Smart Digital Transformation
Industry 4.0: Strategy to Raise Maturity
Computerization Connectivity Visibility Transparency
Predictive
Capacity Adaptability
Digitalization Industry 4.0
Valu
e
Seeing
Understanding
Being Prepared
Self-Optimizing
FIR e. V. at RWTH Aachen University: Stages in the industrie 4.0 development path
What happened
What is
happening?
What will
happen?
How can an autonomous
response be achieved?
The Independent Solution Provider for Smart Digital Transformation
The Good
It is a Strategy, delivering strong financial benefit
Triggers innovation and looking for new business opportunities
Generate competition in the manufacturing market
Industrial Standards are still very much valid (e.g. ISA-95, 88, 99)
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The Bad
A lot of Buzz-wording
Technology for technology?
What’s the risk not to take that road?
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The Ugly
Business Case can be extremely challenging
New Technologies are still under finalization
Need to complete the digitalization phase first
It is a long journey…
The Independent Solution Provider for Smart Digital Transformation
Need a Solid Strategy
Digital transformation is about business transformation
De
fin
e t
he A
mb
itio
n
Strategy Raising the Maturity Level Industry 4.0
Exce
llen
ce
Ad-H
oc
Pla
nnin
g &
Contr
ol
Sta
ndard
ized
Pro
cesses
Pre
dic
table
Perf
orm
ance
Continuous Im
pro
vem
ent
Business
Benefit
Processes
Structure
Technology
People
New Business Models
Internet of Services
Virtual to Physical
World
Individualization of
Mass Production
Self-Organized Smart
Factories
Cyber Physical
Systems
„Most people overestimate what they can do in one year and underestimate what they can do in ten years.“
Business
Benefit
Business
Benefit
Business
Benefit
The Independent Solution Provider for Smart Digital Transformation
Manufacturing Technology Landscape
Reduce Total Cost of
Ownership
Break data silos
Effectively collect data from
OT and IT systems
Enable and foster innovation
Enable collaboration among
the different systems
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Bridging the IT/OT Gap
ERP
MESPLM
01001001001010100010
Leverage on IT and OT investments already in
place
Enable machine to machine and business to
machine collaboration
Acquire all the relevant data to create digital
product and process representations – Digital
Threads
Create a secure environment for data exchange
Break data silos and unleash untapped potential
The Independent Solution Provider for Smart Digital Transformation
Process VisibilityCollect, Calculate and Visualize KPIs
Use the ISO 22400 KPIs to find opportunities for
improvement in manufacturing operations
Process real time data stream to take decision
when process or product deviations happen
Make critical factory information accessible from
anywhere and any devices
Compare KPIs across multiple plants and find
what make a certain plant successful
Build and configure reports and dashboards to
fit your business needsSolution powered by Microsoft PowerBI
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Process Transparency and Prediction
Reduce maintenance costs and improve asset
health and performance
Explore asset performance data to learn the
cause of failure
Provide optimized maintenance
recommendations to technicians
Calculate asset health scores and predict life
spans
match existing defect image and flag product
as defective
Solution powered by IBM Watson
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Dynamic Planning and Scheduling
Support major decisions of production capacity:
extend workforce, resource capacity and
factories
Predict effects of change in production and
react in real time to lack of resources
match existing defect image and flag product
as defective
Solution powered by Siemens Preactor
Import production orders from ERP and create
the optimal detailed schedule for the plant
The Independent Solution Provider for Smart Digital Transformation
Production Management
Show electronic work instructions to operators
Dispatch the jobs to the right work centers
Deliver part programs and recipes to shop-floor
machines
If any, plug your MES system into the
ecosystem
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Quality ManagementATS CM4D - Dimensional Quality (Discrete Manufacturing)
Validate accuracy of supplied parts
Create the Digital Twin and compare product to
Original Design
Predict Assembly Problems and avoid
production issues
The Independent Solution Provider for Smart Digital Transformation
Quality Management ATS Inspect, Visual Quality for Discrete Manufacturing
Improve Right First Time KPI and Prevent
Defective Products from Leaving the Plant
Create a dynamic inspection process with the
support of 3D models
Eliminate Paper Checklists
Minimize Costs of Rework and Scrap
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Quality Management Cognitive Visual Quality for the Discrete Manufacturing
Employ cognitive and human expertise to attain
the highest confidence levels of defect detection
Reduce Inspection cost and time while
improving throughput
Increase consistency of defect detection and
classification
Images captured
Defects compared
Real-time monitoring
existing defect image and flag product as defective
Store
Machine Learning system
Match
Solution powered by IBM Watson
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LIMS Laboratory Management for the Process Industry
Improved lab efficiency through reduced
administration, errors, scrap and rework
Automatic data capture and centralized data
consolidation for fast and easy quality data
retrieval and reporting
Full traceability of quality data resulting in
improved regulatory compliance
Improved lab efficiency through reduced
administration, errors, scrap and rework
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Realize the Factory of the Future
Predictive Maintenance
Planning and Scheduling
Cognitive QualityQuality Management
Manage Production
Process Visibility
Laboratory Management
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What to do then?
• Create a step-by-step business case reflected in your Digital Roadmap and focus on gradual measurable improvements
• Leverage on IT and OT investments already in place
• Complete the digitalization phase first, the 4th
Industrial Revolution can only come later
• Start as soon as possible, it will be a long learning journey…
The Independent Solution Provider for Smart Digital Transformation
Industry 4.0Let’s start the journey
Computerization Connectivity Visibility Transparency
Predictive
Capacity Adaptability
Digitalization Industry 4.0
Valu
e
Seeing
Understanding
Being Prepared
Self-Optimizing
FIR e. V. at RWTH Aachen University: Stages in the industrie 4.0 development path
What happened
What is
happening?
What will
happen?
How can an autonomous
response be achieved?
The Independent Solution Provider for Smart Digital Transformation
Thank You
ATS North America
1055 East South BoulevardRochester Hills, MI 48307, USA
Michele Sciuto
ATS Global CCO
http://www.ats-global.com
mobile: +31 6 46764766
email: [email protected]
ATS Global Headquarters
A. Hofmanweg 5a, 2031 BHHaarlem, The Netherlands
The Independent Solution Provider for Smart Digital Transformation
Thank You
Michele Sciuto
CCO
ATS Global B.V.A. Hofmanweg 5a
NL-2031 BH Haarlem
http://www.ats-global.com
mobile: +31 6 46764766
email: [email protected]
Discover more
The Independent Solution Provider for Smart Digital Transformation
TraditionalTraditional BronzeBronze SilverSilver
MaturityModel
Reactive...Reactive... Monitor...Monitor... Vision...Vision...Control...Control...
Inherited local operational rules base on local key performance
metrics
Making the hidden factory visible to enable informative
decisions
Taking control of manufacturing through standardisation
World class flexible and responsive manufacturing
operations
Us
Paper Based
Solution
Plant Scheduled
Weekly
LowEfficiencies Manual
Reliance
Push Philosophy
FirefightingMentality
WIPTracking
Production Scheduling
Manual Data Capture /
OEE
Electronic Work
Instructions
Visual Inspection
Standard Accurate Reporting
Quality Management
Auto Data Capture /
OEEChangeover
Management
Order Management Machine
Connectivity Resource Compliance
Advanced Production Scheduling
Supply Chain Management Predictive
Maintenance
Inventory Management
Product Lifecycle
ManagementIndustry 4.0
You GoldGold
ATS – Maturity Pathfinder
The Independent Solution Provider for Smart Digital Transformation
• Graphics from GKN presentation
The Independent Solution Provider for Smart Digital Transformation
Agenda
• What is Industry 4.0 about?• It is financial benefit / new business models
• Industry 4.0 VS digitalization
• Good• It is a Strategy
• It delivers Financial Benefit
• Triggers innovation and looking for new business opportunities
• Generate competition
• Industrial Standards are still valid (ISA-95)
• Bad:• Buzz Wording and confusions (Gartner hype
• Technology for technology
• What’s the risk not to take that road?
• Ugly:• Business Case extremely challenging
• New Technologies still under finalization
• Need to complete the digitalization phase first
• It is a long journey
• How do we approach it?• Need a strategy (VP slide)
• IT/OT convergence (Factory of Future)
• Next opportunities (Factory of the future)
• Food and Beverage and Pharma (Recipe Management and LIMS)
• SODA (innovation)
• 4:10 PM - 4:45 PM - Solution Spotlights
• Future Technologies & IoT
• Good, Bad & Ugly of Industry 4.0
• Understanding what is possible with Industry 4.0, today, tomorrow and in the future
• Michele Sciuto, Chief Commercial Officer, ATS Global
The Independent Solution Provider for Smart Digital Transformation
• How do we approach it?• Need a strategy (VP slide)• IT/OT convergence (Factory of Future)• Next opportunities (Factory of the future)• Food and Beverage and Pharma (Recipe Management and LIMS)• SODA (innovation)
• 3 Waves Process (???)1. Strategy2. Raise Maturity Level with gradual Benefit Realization 3. Implementations???
The Independent Solution Provider for Smart Digital Transformation
Success Stories
The Independent Solution Provider for Smart Digital Transformation
Automotive OEM Automated Self Correction Process
Problem
Need perfect robotic welding and painting processes with an automated self correction process
The Solution – ATS ADOS
Capture all the data generated, no matter the type or source
Automated validation for the quality of welding and painting processes
Enable manufacturing traceability for each component and validate vehicle variants at every gate
Business Case
2% improvement in overall quality of robotic operations
10% reduction in scrap rate due end-to-end traceability and root cause analysis
Checklist
Points
Automated Decision
OK NG
The Independent Solution Provider for Smart Digital Transformation
Automotive OEM Improve Product Quality and Reduce Warranty Claims
Problem
A carmaker knew that not all the defects found in the quality inspections made it to the reports due to
lost paper sheets and informal communication. They wanted to go paperless, provide KPI reporting to
the plant floor and send real-time alarms for critical issues to the production supervisors for immediate
containment to increase their FTR%.
The Solution – ATS Inspect
Business Case
Number of defects decreased 84% in 18 months at constant volume.
Paper removed from the plant
Real-Time Analysis
Inspection
Points
Rework
Points
Ship / No Ship Decision
Sites: 10 | Countries: 5 | Inspection Points: 100+ | Benefit: Quality Improvement | Savings: Millions
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Quality defects behaviour
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Problem
Easily integrate IT and OT layer
Send work order information between machines on shop floor and MES platform.
Track location of each part on the production line.
Collect all data through the production process
The Solution – ATS Bus
Business Case
Full process visibility and product traceability thanks to data contextualization
All data are securely transferred
Low TCO and ability to easily extend the architecture with new IT and OT components
Leading Aerospace OEM chooses ATS Global for Integrated Production Tracking and Order Handling
Representative
image
The Independent Solution Provider for Smart Digital Transformation
Problem
Simplified, system driven, Planning & Scheduling process
Ability to present various short-term schedule scenarios to the planning team(s)
Obtain medium-term forecasts to support internal forecasting requirements
The Solution – APS integrated in the application landscape
Business Case
25% reduction in customer complaints relating to deliveries.
>5% yield improvement through optimised scheduling
10% increase in on-time deliveries
Improved Forecasting Ability that enabled scenario planning
ATS Integrates Advanced Planning & Scheduling System at a Turbine Blade Manufacturer in the UK
The Independent Solution Provider for Smart Digital Transformation
Back Up
The Independent Solution Provider for Smart Digital Transformation
Electrical Vehicles OEM
Problem
Ensure production is in sequence, track vehicles and improve efficiency
The Solution – ATS Ignition Solution
• RFID tags are read at each work station and compared to the body sequence queue for vehicle tracking and process
instructions
• Vehicle body spec are communicated to the offline work cell operators, PLC, and robots thus insuring the offline
production is in sequence to the main line.
• Andon control: warnings or line stops are triggered if there is a quality problem (Pokayoke points). Automated conveyor is
controlled based on the production schedule
• OEE is calculated and displayed along the full assembly process
Business Case
Zero mistakes on production sequence, every vehicle is built according to the specs with no quality issues, world class OEE
The Independent Solution Provider for Smart Digital Transformation
Problem
Process innovation and built in quality with end-to-end traceability
Mind-set shift, introducing excellent process with robust gatekeeper and “zero outflow” management
The Solution – ATS ADOS (phase-wise rollout approach)
Phase 1 – Trim & Chassis and Vehicle Quality Assurance (VQA) – Using ATS Inspect and ATS Bus
Phase 2 to encompass all earlier manufacturing processes
Phase 3 to encompass all variable production data stored within ATS CM4D
Business Case
Unified European QMS
Major advances in data availability and process reporting
Reduction in re-work and production errors due to end-to-end traceability
Leading Car Manufacturer chooses ATS Global to improve Quality Assurance and Traceability
8Global plants where
solution is being used
The Independent Solution Provider for Smart Digital Transformation
The Digitalization Process
Digital transformation is about business transformation
De
fin
e t
he A
mb
itio
n
Strategy Raising the Maturity Level Industry 4.0
Exce
llen
ce
Ad-H
oc
Pla
nnin
g &
Contr
ol
Sta
ndard
ized
Pro
cesses
Pre
dic
table
Perf
orm
ance
Continuous Im
pro
vem
ent
Business
Benefit
Processes
Structure
Technology
People
New Business Models
Internet of Services
Virtual to Physical
World
Individualization of
Mass Production
Self-Organized Smart
Factories
Cyber Physical
Systems
„Most people overestimate what they can do in one year and underestimate what they can do in ten years.“
Business
Benefit
Business
Benefit
Business
Benefit
The Independent Solution Provider for Smart Digital Transformation
The Independent Solution Provider for Smart Digital Transformation
Step-by-Step Process to Manufacturing Excellence
The Independent Solution Provider for Smart Digital Transformation
Awareness and Strategy
Business Assessment
Business Case
Selection and Specification
Implementation and Integration
Support Packages
Benefits Realization and Consulting
WP1
WP2
WP3
WP4
WP5
WP6
WP7
A successfully proven process developed by ATS in
delivering Manufacturing IT and OT solutions to customers
Based on the ISA-95 standard model
It comes with a defined set of deliverables
It incorporates lessons learnt and best practices gained
from ATS and other implementations
It provides a guideline in implementing Manufacturing IT
and OT solutions but it can be tailored to our customer
needs
SUCCESSFULL
STANDARD
DEFINED
EXPERIENCED
FLEXIBLE
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On Time parts delivery
Minimize Inventory Level
Receiving Area
Trace delivery of external
suppliers
Quality of supplied parts
The Independent Solution Provider for Smart Digital Transformation
Ensure visibility of work in
Progress (WIP)
Fabrication Area
Improve efficiency and
equipment availability
Optimize production
schedule and allocation of
resources
Ensure quality of produced
parts
Dispatch the right job to the
right work center at the right
time
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Painting Area
Minimize setup and change
over times
Ensure quality of painted
part
Minimize consumption of
utilities
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Synchronize sub-assemblies
with the main line
Assembly Area
Support customizations
(MTO/CTO/ETO)
Timely dispatch EWIs and
recipes to the line
Be ready for quality audits
Trace direct and indirect
material consumption
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Feedback to engineering any
need of business
improvement
Shipping Area
Deliver a perfect product on
time
Minimize inventory of
finished goods
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Quality ManagementATS CM4D - Dimensional Quality
Validate accuracy of supplied parts
Create the Digital Twin and compare product to
Original Design
Predict Assembly Problems and avoid
production issues
The Independent Solution Provider for Smart Digital Transformation
The Good