IOT: EXPOSING THE HIDDEN FACTORY - Easyfairs · 1 WEEK SPRINTS Shipped Product 1 week sprint 24-48...
Transcript of IOT: EXPOSING THE HIDDEN FACTORY - Easyfairs · 1 WEEK SPRINTS Shipped Product 1 week sprint 24-48...
IOT: EXPOSING THE HIDDEN FACTORY
Advanced Engineering 201812:45 UK, 13:05 CET
Wednesday 31th October, 2018
2© 2018 PTC and InVMA All Rights Reserved
INTRODUCTION
Rob Dinsmore
Solutions Sales Manager
InVMA
▪ Digital Innovation Partner
▪ End to End Capability
▪ Industrial Heritage
▪ Partner Ecosystem
Transform
Consult
Design
Develop
Supply
Integrate
Support
4© 2018 PTC and InVMA All Rights Reserved
5
THE HIDDEN FACTORY
WHAT IS THE HIDDEN FACTORY?
“Activities that reduce the quality or efficiency of a manufacturing operation or
business process, but are not initially known to managers or others seeking to
improve the process.”
Six Sigma and similar initiatives focus on identifying "hidden factory" activities in
order to eliminate sources of waste and error.
WHAT PROBLEMS AND OPPORTUNITIES? - FACTORY
OEE Scrap Energy
RFT Yield Waste
WIP Re-WorkMaintenanceNon Compliance
WHAT PROBLEMS AND OPPORTUNITIES? - EXTERNAL
Big Data
Social
Environmental
Economic
Supplier
Supply Chain
Out Bound
Deliveries
Knowledge
Best Practice
Performance
Reliability
Vendor Analysis
• Execute the plan with small steps in a controlled way
• Study the results
• Plan ahead for change
• Take action to standardise or improve the process
Act Plan
DoCheck
TO IMPROVE YOU NEED TO EXPOSE WHAT’S HIDDEN
TeamsData
Culture
THE CORE ARCHITECTURE AND ISA95 MODEL IS A CAUSE
Traditional System Landscape
Logistics SuppliersExternal
Business Systems
(ERP, CAD, PLM)
Level
4
Operational Control
(MES, MOM)
Level
3
Process Monitoring
(HMI, SCADA, Test Stands)
Level
2
Control Level & Data Acquisition
(PLC, CNC, Autoclave)
Level
1,0
Production Quality Inventory Mainten. EnergyQuality
Plant
Manager
Maintenance
Operator Process & Quality
Planners
Vendor Support
DISPARATE SYSTEMS ACROSS SITES ARE A CAUSE
12
TECHNOLOGIES
13
PHYSICALWORLD
DIGITALWORLD
PRODUCTS ARE CHANGINGSmart Connected Products
OPERATIONS ARE BECOMING MORE EFFICIENTSmart Operations |System of Systems
SERVICE IS TRANSFORMINGRemote Service | Product as a Service (PAAS)
HOW WE INTERACT WITH THINGS IS CHANGINGAUGMENTED REALITY | VIRTUAL REALITY
18
UNDERSTANDING INDUSTRIAL DIGITAL INNOVATION
“Smart, connected productsraise a new set of strategicchoices about how value
is created and captured, and how companies secure
competitive advantage as the new capabilities reshape industry
boundaries.”
“Smart connected products are not only redefining competition
but how we run companies across the value chain. New kinds of
cross functional integration and
coordination are necessary, and whole new organizational units are
being created.”
“There is a fundamental disconnect between the
wealth of digital data available to us and the physical world in
which we apply it. AR solves this
problem by putting information directly into the context in which
we’ll apply it.”
November 2014 October 2015 November 2017
Digital
World
Human
Physical
Experience
Human
Digital
Experience
Physical
World
1101
0101
WE EXPERIENCE PHYSICAL AND DIGITAL SEPARATELY
COPYRIGHT 2017 © MICHAEL E. PORTER AND JIM HEPPELMANN
20
PHYSICALThing
DIGITALTwin
AR IOT
IOT AND AR – UNLOCK THE VALUE OF INDUSTRIE 4.0
1101
0101
Digital
World
Human
Converged
Experience
Physical
World
Converged View of Physical / Digital World
CONVERGED EXPERIENCES ENABLE FASTER DECISIONS
COPYRIGHT 2017 © MICHAEL E. PORTER AND JIM HEPPELMANN
22
Connect the Physical World
OT IT
Understand the Context
Orchestrate the Response
Engage People using Digital on Physical
Analyze the Digital Data
UNITING DIGITAL AND PHYSICAL KEY CONCEPTS
PHYSICALWORLD
DIGITALWORLD
Traditional System Landscape
Logistics SuppliersExternal
Production Quality Inventory
Business Systems
(ERP, CAD, PLM)
Level
4
Operational Control
(MES, MOM)
Level
3
Process Monitoring
(HMI, SCADA, Test Stands)
Level
2
Control Level & Data Acquisition
(PLC, CNC, Autoclave)
Level
1,0
An Industrial Innovation Platform
complements and brings
• Unified visibility across systems,
assets, devices and people
• Wrap and extend existing systems
• Actionable and comprehensive
operational intelligence
• Real-time, social, mobile
• Rapid application developmentMainten. Energy
USE NEW TECHNOLOGY TO WRAP AND EXTEND
SOURCE CONTEXTUALIZE SYNTHESIZE ORCHESTRATE ENGAGE
AN INDUSTRIAL INNOVATION PLATFORM
25
THE EXPERIENCE OF OTHERS
© Howden Group 2018
Howden Data Driven Advantage
Uptime
© Howden Group 2018 27
This is what we do:
Howden Digital TransformationData Driven Advantage
© Howden Group 2018 28
Why are we discussing Digital Transformation?
• Global uptake of the digitization trend
• More about the service than about the product
– Every type of commodity today is moving
towards a “as a service” model
What is our Data Driven Advantage strategy?
• Howden is not a Big Data organisation
• We are committed to leveraging the data around our operations and equipment to
– Enhance the customer value through the service around our equipment
– Optimize our operations
– Create a new business model
Howden Digital Transformation
Product
Service
Data Driven Advantage
© Howden Group 2018 29
Howden Data Driven AdvantageUptime
Uptime
Unique digital solution building on
• Howden digital twins
• Artificial Intelligence (AI)
• Machine Learning
• Augmented Reality
• Our expert guidance to realise full
customer value
Our foundational block
Highly differentiated Digital Twin approach,
first of its kind in most air and gas handling
applications
Our technology stack is completed by our
strategic partners, Microsoft and PTC
Over 160 years experience in designing and
manufacturing rotating equipment
The Howden Digital Twin
Our design data is used to model theoretical performance and
compared with actual in-field data from the sensors
Connected machines
We work with all industrial connectivity protocols, we can integrate
with existing control logics or operate completely remotely, our
connectivity block is completely customizable to our customers’
needs
Data storage solution: Microsoft Azure
Integrated solution that lives in the cloud
We take our customers' data very seriously and with Azure we have
further fortified our approach to security and data protection
ThingWorx: purpose-built industrial innovation platform
to streamline our approach
Combine the industrial experience of ThingWorx - world leading IIoT
platform - with OEM differentiated analytics to deliver predictive/
prescriptive maintenance and performance optimization on demand
Full customer solution
Ai powered Machine Learning
Smart analytics powered by the Howden Digital Twin
Complete AR experiences and HoloLens integration
24/7 support and direct access to Howden AFM
© Howden Group 2018 30
UptimeThe service around the customer’s equipment
OEM differentiated digital solution that delivers optimized equipment and plant performance
Current state
• Complex customer need
• Unplanned downtime around critical assets
• Howden equipment operating away from best efficiency point
Future state
• Predictive maintenance as a service to avoid the unplanned downtime of critical assets
• Performance Optimization on Demand around our customers’ equipment/process
• Direct link to Howden service and support
© Howden Group 2018
Thank you
Understanding Machine Health
& Their DNA
Important FactTypically it is often stated that the profit generated by:-
Sustainable long term savings are key, not short term
savings.
World Class OEE – 90% and a 2010 Aberdeen Study
suggested the best in class was 89%.
Typically most US & West European companies operate at
50%!!!
A 10% saving
in maintenance
costs
A 40% increase
in sales &
turnover
Machinery DNA
Each machine / asset has it’s own unique DNA / finger
print. The variables associated with this unique DNA are
numerous:-
• Temperature
• Vibration (velocity, acceleration, time waveform, etc)
• Ultrasound (dB(A), distress, etc)
• Oil Condition & Oil Temperature
• Motor Load
Applications monitored include:-
Fans Compressors Conveyors Pumps Mixers
Classifiers Gearboxes Extruders Vibratory Screens
Crushers Motors Blowers Turbines
Continuous Monitoring Systems
2005
• MachineGuard
• Wireless Comms & Stand Alone Software
2011
• MachineGuard II
• iMATS Web Portal Software & Alerts
2017
• MachineGuard III
• Asset Minder Web Platform
2018
• MachineGuard Blue Tooth Sensors
• Asset Minder II Web Platform
Web Portal
Continuous Monitoring SystemsNew spiral bevel pinion
fitted on Friday /
Saturday. On Sunday
they ran up the system
and it was apparently
very noisy. A set of
readings were taken
and as you can see
from the vibration
spectra, a problem was
identified. We
diagnosed that the
spiral bevel gears were
not mating correctly
(620Hz – 25T @ input
speed).
© Tan Delta Systems Limited 2017
MachineGuard III – The Future!
View trends
View spectra
Blue Tooth
accelerometer
Gateway &
enclosure
Asset
39
Examples of outcoes achieved with PTC Digital Transformation Journeys
MANY COMPANIES ARE VERY SUCCESSFUL WITH PTC
53
A GLOBAL FOOD LEADER INCREASES PRODUCTIVITY
5 to 8% improvement in productivity
HEALTH
20105
Alarms
4,700/25,500 lbs/min
50,0000
WasteOEE
68%Fair
M T W FT
TOPWEEKLY
GOAL 77%complete
Operat or Keyser Ar ea 18 March 25, 2015
Keyser_SözeGE Proficy
Shift Events Start Time 05/25/2014 22:30:00 End Time 05/26/2014 06:30:00
22:30:00 23:30:00 24:30:00 1:30:00 2:30:00 3:30:00 4:30:00 5:30:00
Alarms
0301,500/1,000
lbs/min
3,5000
Waste
2,050 / 2,100 lbs/min
3,0000
Speed
6467 / 70,000 units
11%
Complet eOrder 2501879
RUNNING
05/25/2014 22:30:00 / 05/25/2014 22:27:00
05/26/2014 05:30:00 / PENDING
Start Time
End Time
Milk Chocolate Chips
14141414
Product
SKU#
Current Event Status
BreakStarted 24:41.00
Shift Events Detail
Not sure what to put...
Not sure what to put...
Not sure what to put...
Not sure what to put...
Not sure what to put...
Not sure what to put...
Not sure what to put...
Reason 3 Comments
1
3
4
6
8
5
Not sure what to put...
Not sure what to put...
Not sure what to put...
Not sure what to put...
Not sure what to put...
Not sure what to put...
Not sure what to put...
Reason 2
Not sure what to put...
Not sure what to put...
Not sure what to put...
Not sure what to put...
Not sure what to put...
Not sure what to put...
Not sure what to put...
Reason 1
0hr 15min
1hr 02minv
0hr 15min
0hr 2min
0hr 31min
1hr 20min
0hr 01min
Duration
05/25/2014 14:15:20
05/25/2014 17:47:00
05/25/2014 24:02:01
05/24/2014 01:56:09
05/24/2014 05:51:00
05/24/2014 04:34:02
05/24/2014 03:28:43
Stop
05/25/2014 14:00:23
05/25/2014 16:45:07
05/25/2014 23:47:24
05/24/2014 01:54:11
05/24/2014 05:21:10
05/24/2014 03:14:26
05/24/2014 03:27:49
StartEvent
BREAK
DOWNTIME
DOWNTIME
WASTE
BREAK
DOWNTIME
WASTE
69
Use Remote Service to monitor equipment performance.
Reduce on-site visits by 42%.
Save $2,000 for each on-site visit avoided.
73
React and respond to customer service needs 3X faster than competition.
Improve first-time fix rate from 88% to mid 90% (industry average 60%).
40© 2018 PTC and InVMA All Rights Reserved
BUILD A BACKLOG
Business Planning
SelectionDesign and
Product BacklogExecution of
Approved Sprints
Innovation, Ideas, Opportunities, Needs
Screening Process
Agile Project Management
1 2 3
Highest value
items prioritised
Low value items de-prioritised
New requirements prioritised and added to the stack
4
Hold a design and prioritisation session you to explore your detailed requirements and develop them in to a series of user stories which we will
prioritise into a “work stack”
41© 2018 PTC and InVMA All Rights Reserved
1 WEEK SPRINTS
Shipped Product
1 week
sprint
24-48 Hours
Regular Scrum MeetingProduct
Backlog
Sprint Backlog
1week sprints delivering value from the customers perspective
All managed through a shared portal
We will take the back-log and deliver elements of it in 1 week sprints.
As ThingWorx is extremely flexible with large pre-built elements this enables
you to focus on the parts that you value.
42© 2018 PTC and InVMA All Rights Reserved
USEABLE PRODUCT EARLY
Sprint 1 Sprint 2 Sprint 3 Sprint 4
ActualResource
Resource
Time
Value
Prioritise
Design
BuildTest
Deploy
Prioritise
Design
BuildTest
Deploy
Prioritise
Design
BuildTest
Deploy
Prioritise
Design
BuildTest
Deploy
Prioritise
Design
BuildTest
Deploy
Small dedicatedteams delivering
value early
The approach also enables you to decide what gets delivered first allowing for user
feedback before further investments are made
43© 2018 PTC and InVMA All Rights Reserved
THANK YOU
Rob Dinsmore
Sales solution Manager
InVMA
invma.co.uk
@InVMA_IoT
www.linkedin.com/company/invma-limited/
4
4