Vision and Roadmap for Company X

Transformational Project

Meeting Objectives

• Obtain consensus on Automation/Business information standards (the Roadmap)

• Show Benefits and Cost Savings of the LSI Project methodology as applied to HB Fuller global manufacturing

Benefits of the LSI Approach

There will be the foundation in place for a world class manufacturing operation if the methodologies presented are adopted

Ability to proactively analyze and correct production delays and quality issues though standard reporting tools and KPI’s

Scalable solutions to fit both the individual plant needs and the needs of the entire enterprise

Up to 50% less time and money spent on commissioning and having new/upgraded systems in full production in 70% less time

Vision

ERP

MES

Common Data Platform and Reporting (OEE,

Trending, Batch Reports, etc.)

PLC or DCS

Field Devices, Field Busses, etc.

Automation and Business Information System Roadmap

Assessment Tool

ScalableFlexibleCost Effective

LSI Project Methodology

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World Class Manufacturing

Global Standards

Summary of Benefits of the LSI Approach

Up to 50% less time spent on commissioning and the plant is in full production in less time. Startup support is currently estimated at $2-4MM for HB Fuller transformational project. Roadmap adoption will result in savings of $1-2MM

Startup to full production in 70% less time 30% less hardware required for spares for individual plants 50% less control software development time and

implementation Up to a 40% reduction in MES and SCADA level software

development and deployment costs Common “language” for talking production performance and

KPI’s Foundation in place for a world class manufacturing operation

Reference slides…

Site Assessment – Page 1

Site Assessment – Page 2

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Engineering Process

Scope and Specifications clearly defined and written: Business requirements defined and agreed upon Functional and Operational requirements defined and

agreed upon Hardware and Software Design and implementation built

around the agreed upon requirements Appropriate simulation techniques used based on agreed

upon requirements Factory acceptance testing completed based on agreed upon

requirements

Benefit: Faster, smoother startups. “Eliminate the white knuckle ride of startups” – Up to 50% less time spent on commissioning and the plant is in full production in less time.

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User Requirement Specification Table of Contents

Process Control Specification

Unit Control Specification Table of Contents

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Standard PLC Hardware Platforms and Tools

Limited number of select hardware vendors and select products chosen within product vendor’s portfolios for automation projects Common hardware platform reduces spare parts requirements

across the enterprise Common software tools can be used to reduce software

development costs Appropriate vendors chosen by region based on support models

and available spare parts and product support (i.e. Siemens strong in Europe, Rockwell Automation in North America). LSI is a solution partner for both companies

Vendors will be standardized at each facility for both process and packaging

Benefit: 30% less hardware required for spares for individual plants, 50% less software control development and implementation time Back

Common SCADA/MES Software Platform

Common software and data platform to reduce development and deployments costs Object based data structures (i.e. mixers, reactors, etc.) for HMI

and for reporting MES functionality such as OEE, Process Historians,

Production reporting, etc. Ability to give plant wide and enterprise wide views via a web

interface Ability to give and “Executive” view and a “Plant view” as

required Software objects are built independent of the hardware platform

and simply “tied to” objects in the appropriate control system Worldwide acceptance and support LSI is a solution provider for Wonderware and for Intellution

Benefit: Up to a 40% reduction in SCADA and MES software development and deployment costs

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Reporting Capabilities

The common set of reporting tools will allow HB Fuller to speak a “common language” across all plants (i.e. OEE to track reporting in packaging, batch reports like the one below, etc.)

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What is OEE?

OEE (Overall Equipment Effectiveness) = Availability x Performance x Quality

Where:

1. Availability = Available Time / Scheduled Time

2. Performance = (Parts Produced * Ideal Cycle Time) / Available Time

3. Quality = Good Units / Units Started

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Common Objects for PLC and HMI

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Standard Packaging Vendors and MES/OEE Strategy

Where new packaging machines will be installed, the following will be recommended by region: Common PLC vendors Common motion control vendors Common field device vendors Common reporting interface specified by LSI through a standard set

of tags: Running/Stopped, Automatic/Manual, Package Count, Faults (where they can be automatically detected), etc.

Where packaging equipment will be retained and vendors will not be changed, the common reporting interface as detailed above will be developed

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