Copyright © 2014 Rockwell Automation, Inc. All Rights ... · Copyright © 2014 Rockwell...
Transcript of Copyright © 2014 Rockwell Automation, Inc. All Rights ... · Copyright © 2014 Rockwell...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Agenda
2
Factory Talk Production Centre (Demo)
Manufacturing Execution System Overview
Project Management /Connected Enterprise Journey
Our Complex Environment
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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
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Complex Environment
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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
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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.
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Two data rich system that are disconnected…
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ERP
Plant
Floor
Enterprise System Existing Control Systems
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Manufacturing Execution System Connects IT and OT
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ERP
Plant
Floor
ERP
Plant
Floor
MES
Enterprise System Existing Control Systems
Centralize MES Strategy
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Data Utilization to Knowledge
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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
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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
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What is MES? Data Collection/Information Provider (Level 3)
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What is MES? Coalesces Information and Operations Technologies
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What is MES? Rockwell Automation Manufacturing Systems
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ERP Integration Gateway
Production Management
Performance Management
Quality Management
TECHNOLOGY
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ERP Integrated Gateway
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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
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Factory Talk Production Centre Features
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• 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
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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
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Graphical User Interface - Automation
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• Automation • Logix • Panel Views • Bar Code Scanners
• Enterprise Information • Work Orders • Serial Numbers • Part Numbers • Start Dates
• Operator • Status • Notification • Information
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Printed Circuit Board Assembly Cell Activity
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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
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Cell Performance Display (Score Board)
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Performance Management
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Process Readiness Process Characteristics
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Performance Management
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Graphical User Interface – Manual Assembly (Integrated Interoperability)
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Quality Management
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• Equipment Integration (using API) • Guided Manufacturing Processes • Process Enforcement • Automated and Manual Data Collection • Training and Certification Tracking • Documented Work Instructions • Workmanship Instructions
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Defect Data Entry Check Lists
Quality Management
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Quality Management – Report Generation
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MES Deployment Map
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Project Management Connected Enterprise Journey
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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)
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Project Management Connected Enterprise Journey
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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
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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
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Factory Talk Production Centre Demonstration