EY Smart Factory - Boussias Conferences · EY Smart Factory Framework: Advanced technology,...
Transcript of EY Smart Factory - Boussias Conferences · EY Smart Factory Framework: Advanced technology,...
EY Smart Factory:
The leading digital solution to achieve
break-through and sustainable
Manufacturing Excellence results
Athens, 12th February 2019
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OEE 55% 70% 80% >85%
Unplanned
Downtime
<12% <8% <6% <2%
Unplanned MTBF
(Stops/day)
24 10 4 Unattended
Product Quality
Defects reduction
>50% >80% >95% ~0 defects
Process Failures
Reduction
>50% >80% >95% ~0 defects
SHE TIR ≤1.5 ≤1 ≤0.5 ≤0.2
Base Stable Progressive Leading
Companies are struggling to make a sustainable breakthrough in performance using traditional manufacturing excellence approaches
Sample Metrics
$200-300m savingsPhase 1
Phase 2
Phase 3
Phase 4
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http://www.newdesignfile.com/postpic/2012/05/information-technology-
icon_90996.png
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Make smarter decisions and drive smarter
actions
Intelligent applications and processesHarnessing disruptive technology to deliver value
Digital coachEmpowered leaders to build capability and empower people
Make the people
smarter……
……Make the equipment smarter
Smart Maintenance
Smart Quality
Smart Energy
Smart Materials
EY Smart Factory Framework:Advanced technology, supported by standard ways of working, empowers a capable
workforce to deliver value
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Accelerator
Digital strategy and transformation management
4Production systemIntegrated standard way of working for sustainable operational excellence
Shopfloor execution applicationDigital standard work processes driving execution excellence
AND/OR
CLIENT
OpEx system
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http://www.newdesignfile.com/postpic/2012/05/information-technology-
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Make smarter decisions and drive smarter
actions
Intelligent applications and processesHarnessing disruptive technology to deliver value
Digital coachEmpowered leaders to build capability and empower people
Make the people
smarter……
……Make the equipment smarter
Smart Maintenance
Smart Quality
Smart Energy
Smart Materials
EY Smart Factory Framework:Advanced technology, supported by standard ways of working, empowers a capable
workforce to deliver value
1
Accelerator
Digital strategy and transformation management
4Production systemIntegrated standard way of working for sustainable operational excellence
Shopfloor execution applicationDigital standard work processes driving execution excellence
AND/OR
CLIENT
OpEx system
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Fully integrated work system
Fundamental shift to Operator technical
mastery and equipment ownership
Based on an uptime and Run-to-Target
approach
Extensive use of reliability engineering
analytics
Daily Management Systems at its core
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2
3
4
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• Integrated manufacturing system – incorporates all TPM,
Lean, Six Sigma, TPS, Reliability Engineering and other
learnings
• Database of over 3500 integrated manufacturing capabilities
across 5 maturity Phases
Catalyst contains a full manufacturing Integrated Work System which
integrates all leading practices in a format that improves adoption
Manufacturing Excellence Pillars
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http://www.newdesignfile.com/postpic/2012/05/information-technology-
icon_90996.png
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Make smarter decisions and drive smarter
actions
Intelligent applications and processesHarnessing disruptive technology to deliver value
Digital coachEmpowered leaders to build capability and empower people
Make the people
smarter……
……Make the equipment smarter
Smart Maintenance
Smart Quality
Smart Energy
Smart Materials
EY Smart Factory Framework:Advanced technology, supported by standard ways of working, empowers a capable
workforce to deliver value
1
Accelerator
Digital strategy and transformation management
4Production systemIntegrated standard way of working for sustainable operational excellence
Shopfloor execution applicationDigital standard work processes driving execution excellence
AND/OR
CLIENT
OpEx system
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Assess, plan, learn, execute and
monitor
Catalyst OpEx
Platform
EY Catalyst’s supporting maturity phase progression
Virtual Manufacturing Excellence
Coach
OEE 55% 70% 80% >85%
Unplanned
Downtime
<12% <8% <6% <2%
Unplanned MTBF
(Stops/day)
24 10 4 Unattended
Product Quality
Defects reduction
>50% >80% >95% ~0 defects
Process Failures
Reduction
>50% >80% >95% ~0 defects
SHE TIR ≤1.5 ≤1 ≤0.5 ≤0.2
Base Stable Progressive Leading
Phase 1
Phase 2
Phase 3
Phase 4
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Assess, plan, learn, execute and
monitor
Catalyst OpEx
Platform
Catalyst Online Learning
Modules -
Uses advanced Adult learning
training techniques to improve
capability build
Catalyst Community For
Knowledge Sharing -
Ability to create different communities
across factories and the organisation
on similar Equipment, OpEx Pillars,
other topics. Share best practices.
Catalyst Reader —
Ability to take relevant
leading practice
content and read off
line to increase
understanding and
skills
Knowledge share
Reader
Online Learning
EY Catalyst’s cloud-based operational excellence (OpEx)
platform, accessible to all and centrally controlled
Leading Practice Shop Floor
Execution
Shop floor execution application -
Leading practice work processes
that are covered in Catalyst training
and executed through this
application to ensure quality of
execution e.g. CIL, CL, Defect
Handling, Breakdown elimination,
etc
“Virtual Manufacturing Excellence Coach”
Manufacturing Excellence
leading practices,
assessments methods,
training and tools:
Linked to 4 Phase maturity
progression with automatically
generated 90 day work plans
based on continuous
performance and capability
assessment
Assessment &
Content Management
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http://www.newdesignfile.com/postpic/2012/05/information-technology-
icon_90996.png
2 3
Make smarter decisions and drive smarter
actions
Intelligent applications and processesHarnessing disruptive technology to deliver value
Digital coachEmpowered leaders to build capability and empower people
Make the people
smarter……
……Make the equipment smarter
Smart Maintenance
Smart Quality
Smart Energy
Smart Materials
EY Smart Factory Framework:Advanced technology, supported by standard ways of working, empowers a capable
workforce to deliver value
1
Accelerator
Digital strategy and transformation management
4Production systemIntegrated standard way of working for sustainable operational excellence
Shopfloor execution applicationDigital standard work processes driving execution excellence
AND/OR
CLIENT
OpEx system
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We have an opportunity to make a significant improvement in the
execution of OpEx leading practices
Changeover Efficiency
application
Breakdown Elimination
application
Safety & Quality Incident
Elimination
6 Daily Management Systems
• Centerlining
• Clean, Inspect, Lubricate
• Defect Handling
• Breakdown Elimination
• Safety & Quality Incidents
elimination
• Rapid Changeover
Daily Direction Setting
Manufacturing Excellence Pillar
Shopfloor performance
improvement application
Shopfloor meetings
application
Defect logging
applicationClean Inspect and
Lubricate application
Centerlining application
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EY’s Smart Factory applications are intended to compliment other digital
factory applications
EY Applications
Although we have developed a suite of Smart Factory applications, the goal is to operate within an open system of multiple vendor applications – companies will choose different vendors for different areas
Other Vendor Digital Applications
My Tasks
EY Edge
Device
Client manufacturing systems – data depending on Smart Factory application
(Historian, MES, ERP, Maintenance Mgt, others)
Quality,
Energy, etc
My Tasks could manage actions & alerts across applications
Ability to share dataEY Edge device is pre-configured with data contextualisation to enable rapid set up of EY applications
Select the EY applications that are appropriate
Note
• Application interface
approach recognises
Plants typically have data
and systems issues
• EY Catalyst & Standard
Work Applications (No.2 &
No. 3) can be operating
within 4-5 weeks
• No. 4 IoT Predictive
Analytics Applications can
require more time to
ensure senor and data
calibration
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http://www.newdesignfile.com/postpic/2012/05/information-technology-
icon_90996.png
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Make smarter decisions and drive smarter
actions
Intelligent applications and processesHarnessing disruptive technology to deliver value
Digital coachEmpowered leaders to build capability and empower people
Make the people
smarter……
……Make the equipment smarter
Smart Maintenance
Smart Quality
Smart Energy
Smart Materials
EY Smart Factory Framework:Advanced technology, supported by standard ways of working, empowers a capable workforce to deliver value
1
Accelerator
Digital strategy and transformation management
4Production systemIntegrated standard way of working for sustainable operational excellence
Shopfloor execution applicationDigital standard work processes driving execution excellence
AND/OR
CLIENT
OpEx system
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EY Smart Factory – Smart Maintenance Application;CBPM (Condition Based Predictive Maintenance)
EY Smart Factory
Application of Artificial Neural Networks to create digital twin of the equipment makes a process of constructing of a model of normal behavior easier and more reliable.
• Monitors in real-time the equipment’s performance against critical parameters using IoT, sensors and
• Machine learning (AI) algorithms determine behavior of the equipment under different external & internal conditions; learns optimal running parameters.
• Automatically alerts Operators and Maintenance when equipment runs outside desired targets to enable early intervention
• Predicts failure by recalculating failure times based on how the equipment is being run and its current condition.
• Better scheduling of Planned Maintenance based on actual equipment condition; extending Planned Maintenance periods
Condition Based Maintainers concept is focused on improving reliability and OEE while decreasing life-cycle cost by optimizing the planned stops and cost of maintenance.
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EY Smart Factory – Smart Maintenance Application;Intelligent Maintenance (Digital Skill Augmentation using AR)
EY Smart Factory
► Operators use tablets / glasses to automatically identify the equipment & get the relevant technical info
► A combination of augmented reality and sensors on the equipment enable the Operator to visualize the
breakdown of the equipment and refer to standards to understand equipment issues
► It also helps eliminate errors in workflows such as CILs, Centerlines, Maintenance tasks, etc.
► Work instructions for service or
maintenance virtually available on the
wearable device
► Paperless, secure process enabling
higher efficiency
Virtual Manuals for service and repair functions
► Deviations from target machine
parameters are visualized on a tablet,
smartphone, smartglasses or
smartwatches
► Rapid identification of assets to be
targeted to maintenance activity
Cutting force error
► Real-time capturing of
maintenance order information
► Maintenance work is immediately
registered after completion and
confirmation by technician
► Spare part ordering
► Spare parts can be directly ordered
locally at the machine by looking at
the defective part
Visualization of asset conditions
Maintenance & Remote Service
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EY Smart Factory - Smart Quality Application;
IPO (Intelligent Process Optimisation)
EY Smart Factory
• Effective production process control is hindered by the inability to directly
observe or estimate industrial process parameters, including external factors,
equipment condition, temperature, raw material conditions, etc.
• Product laboratory tests are expensive, lengthy, infrequently performed, only
allowing a small number of samples to be tested.
Results depend directly on laboratory equipment, human factors, and sample
quality. Uncertainty and product quality fluctuations are increased.
Corrective actions cannot be taken during the actual process, not real time data
The solution lies in IPO, which are statistical / machine learning (AI) models based
on information from easily measured process variables delivered by IoT sensors
and provide on-line estimates of unobservable ones.
Objective: to improve quality and yields in chemical processing and reduce variation in raw material
inputs in industries such as Food, Pharma, Home & Personal Care, and Chemicals
IPO is monitoring the processing in real time and predicting yield and quality issues before the process completes.
Operators are alerted during processing and can make immediate adjustments to improve the output,
or equipment can be self correcting.
Manipulated Variable e.g., Feed Rate Advanced Control
(APC system)
Optimum
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video
Smart Factoryhttps://players.brightcove.net/5076297001001/r19F4B3Mx_default/index.html?videoId=5768851631001
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Better outcomes
3 Performance culture create value
Help empower and 2 engage people
Standard ways of 1 working
321
End-to-end digital ecosystem
Integrated andcontextualized data
Problem centric application of technology
Smarter people
Smarter equipment
Data
Insight
Decision
Action
Manufacturing transformation in the digital age:Transforming each element of the information value chain enables breakthrough performance improvement and competitive advantage
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Significant cost and process
improvements facilitated: 7 to 10 times
return on investment
Average 10% to 25% OEE and
productivity improvements.
Focus on value provided
One of the leadingmanufacturing consultingfirms in the world
Unique alliance with P&G and
Microsoft provides access to a
proven ‘off the shelf’ manufacturing
excellence solution. Strategic
alliances with key technology
providers.
Strategic alliances
EY teams have deployed IWS and Smart Apps at hundreds of plants across the world of Consumer products, Life
Sciences, Diversified Industrial products, Chemicals and O&G industries
EY has been ranked by industry and
technology analysts as one of the
leading manufacturing consulting
firms in the world based on depth
and breadth of consulting services –
EY teams have over 3.000 SC&O
professional across 150 countries.
EY Smart Factory journey: Delivery and impact achieved over the last five years
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George Panagiotopoulos
EY Director, Advisory Supply Chain &
Operations
+30 6937 321096
For further information, pls contact:
Robert Dziedzic
EY Assistant Partner, European Advisory
Center, Manufacturing
+48 508 018 332