PSImetals FutureLab – the continuous innovation platform · 10 PSI - Software Excellence in...

PSImetals FutureLab – the continuous innovation platform PSImetals Industry 4.0 conference Heiko Wolf

Industry 4.0

PSI - Software Excellence in Metals 2

A Powerful Marketing Slogan to

Push the Revitalization of Industrial Production

in the Western World

2017-05-11

Industry 4.0 in a Nutshell


Identification and usage of any kind of networking possibilities within and

between factories and towards customers and suppliers.

SOURCE: MICHAEL F. ZÄH, PROF. DR.-ING. IWB MUNICH

2017-05-11

Data Driven Production – What Else?


© tatasteeleurope.com

Already today metals industry is highly automated and without integrated IT systems quality production with a complex order book is impossible.

2017-05-11

5 Essential Fields of Industry 4.0


Business Model

Business Organization

Information

IT Architecture

Worker of the Future

home game

2017-05-11

Field #1: Worker of the Future


Access from Everywhere at Any Time – in a Human Way

Wearables

Global Access

Multiple Data

Sources

A To global effects of local decisions

Training A Access

Simpli-fication

2017-05-11

Field #2: IT Architecture


Pay-per-Use Software is a Service Why pay for a service that is not used? Apps are following the Pay-per-Use principle.

Control a Complex Organisation with Lean IT

Shipping

Order Dressing

Transport Management

Planning

Scheduling

CLOUDSOLUTION

Protect Your Lead Security by Design Respecting all needs of secure software architecture, PSI provides a secure platform based on latest standards and technologies.

Open To Use “Best Products In Town” A platform provides open connectors to plug in apps and solutions from other vendors.

Opex

Control

2017-05-11

Established Business Models are Under Pressure

PSImetals supports your strategies by „KPI Driven Supply Chain“ and „Business Flow Configurator“

Field #3: Business Model


Lead Times

Quality in Time

Market Volume

Producer Consolidation

Product Lifecycle

Product Diversity

? Focus on low cost value driven products – „Commodity Strategy“

Focus on quality products – „Premium Strategy“

New ways for your business – „Innovators Strategy“

2017-05-11

Field #4: Information


Connected Production Assets, New Networking Technologies

Data from complete Production Process enriched semantically - including supplier and customer

Accessible in realtime via latest 3rd party tools

Cheap and powerful sensors

2017-05-11

Field #5: Business Organization


It’s all about the Flow – Inbound & Outbound

Global Supply Chains Track and Route your materials and products across the whole globe.

Just-In-Time Fulfill customer due dates in a global supply chain by total control of all movements and process steps.

Fully Automated Material Position Tracking. Keep a global Eye on your products.

Outbound Logistics. Organize all transports within and outside your plant(s) by one tool.

Supply Chain Modelling. Virtual supply chain support to make sure everything will be handled smoothly.

60 % PLATFORM SALES

40 % DIRECT SALES

10 2017-05-11

Some Call It…


We call it PSImetals

2017-05-11

PSImetals is proud of its culture of innovation

2017-05-11 PSI - Software Excellence in Metals 12

Melt Shop Solution - 2005 Heat Scheduling - 2008 3D Yard Management - 2012

PSI Gui Click Design - 2015 Mobile Solution - 2016

PSImetals FutureLab – the continuous innovation platform


Changing market circumstances create new challenges for our customers. Whole business models are under pressure. PSImetals FutureLab is the new approach for developing solutions for today’s and future challenges by supporting our customers to overcome them.

Industry 4.0 PSI Java Framework Customers & Partners

PSImetals FutureLab – 6 research paths


Adaptive best practices for metals Easy implementation & non-disruptive upgrades

Realtime responsiveness & optimization

Quality and reliability Data analysis & predictive services Multi-site solutions & data centers

PSImetals FutureLab – Path 1: Adaptive Best Practices for Metals

11/05/17 PSI - Software for Utilities and Industry 15

Adaptiveness Respect uniqueness and avoid unnecessary process change costs.

Business Process Support The goal is to reach a trade-off between standardized best practice processes and the respect for customer specific ways of production.

Flexibility and Adaptiveness Respect Unique Production Processes Best Practices as Benchmark

It’s the excellence of the people and the flexibility of the tools they work with that determines the success of metals production.

Unique Processes Best Practice

Innovative A flexible platform facilitates process innovations in an ever-changing business environment.

Reality: Adaptive Like Your Business - Flow Configurator


Configurable Business Flows Used for business process customization during standard delivery and on site with the customer Drag & drop work flow editor to design business work flows from standard bricks Configuration vs Development

PSImetals FutureLab – Path 2: Easy Implementation & Non-disruptive Upgrades


Fast and Agile Delivery Limited impact on running production to become independent from planned downtimes.

Easy Implementation Non-disruptive Upgrades System Availability

Only a stable and reliable product with a broad installation base is able to meet current and future industry requirements.

Time to Market A new solution or an upgrade must be productive as fast as possible to shorten return of investment time.

Unified View A global rollout strategy needs standardized and reproducible implementation methods. This promotes a reduction in maintenance and training costs.

Reality: Benefits of Using a Product

Benefits of Standard Approach

Sustainability Scalability Extensibility Reduced Total Cost of Ownership (TCO) IT Security Configurability Tested Standard Roll-Out Capability


Grown Up Product Needs New

Project Thinking

vs. Releasability

Product Driven

Methodology

PreProject Project Maintenance

Solution Grows with Your Requirements

Flexibility

2017-05-11

Maintenance

Product-based Project Methodology

Project Pre-Project

Come Together Meetings – Learn to know each other Project Methodology Next Steps

Prime Analysis Checklists Project Schedule <-> Release Plan

Proposal Scope of Supply Commercial Figures Timeline Terms & Conditions

+

Early Trainings On PSImetals Standard System

Detailed Analysis

Workshops Use Cases Fit-Gap-Analysis

Specification

Reduced Risks Shorter Project Duration Reduced TCO

Faster ROI Robust System Highly Configurable

Upgrades On PSImetals Release

Basic Configuration

PSImetals FutureLab – Path 3: Realtime Responsiveness & Optimization


Assistance At every step of production the best possible decision or alternatives must be provided – in real time.

Responsive User Interface The way of interaction must be collaborative and supportive instead of obstructive.

Optimization Real time Responsiveness Manage the Unpredictable

Manage process exceptions by having the right choice available – in real time. Smart assistance systems will guide operation experts through the uncertainties of production.

2015 2023

Exchange Information – Any time System access 24/7 all around the year from every spot on this planet.

Selective Information To decide fast, the right information needs to be available at the right time - context drives content.

Reality: Freedom to the User with PSI Click Design

Modern GUI with graphical elements Easy to Configure by PSI Click-Design Metals-Oriented Usability • Process-driven navigation • High user acceptance • Rapid reactivity Highly Secured Release Upgrades

PSI - Software Excellence in Metals 21 2017-05-11

Reality: Fast Accessibilty With Mobile Devices in PSImetals

Services

Barcode scanner Camera integration Small screens, touch screens Web based solution

Supported Business Processes

Material Information Bundling Transport Management: Stock Yard PDA – Data acquisition KPI visualization


http://www.google.it/url?sa=i&rct=j&q=&esrc=s&frm=1&source=images&cd=&docid=FW_Hj0WE0oJE5M&tbnid=6QWO959qiE1x1M:&ved=0CAUQjRw&url=http://www.virtualrealityguide.com/vr1&ei=OoiQU5KMO6OP7AbnoIHoCQ&bvm=bv.68235269,d.ZGU&psig=AFQjCNF9PrNUqBye9vQ_yLCFXa7p9oE2nA&ust=1402066686104697

PSImetals FutureLab – Path 4: Data Analysis & Predictive Services


Cyber Physical Systems A seamless data exchange with production equipment and its sensors is the necessary foundation to finally realize the vision of a smart factory.

Intelligent Production The concept of machine learning enables the hidden patterns already present in mass data to be identified and utilized.

Machine Learning Big Data Domain Know-how

The availability of new mass data technologies provides a golden opportunity to maximise the potential of every producer’s IT environment.

Expertise Pure IT concepts are worthless without the domain experts able to fine tune algorithms and procedures.

Targets Re-Adjustment of Production Management Clear cut: SAP Business/PSI Production Standard solution which is release-able Simplification of IT-landscape Simplification and standardization of interfaces Rule-based Production Control

Reality: Statistical Process Control @ thyssenkrupp Rasselstein (GER)

24

Production Management System

OI 2015/09

Quality Solution

Collect data from different sources (Standard L2 Interface, Test Results, Material Data, …) and store it into PAM archives Data can be Product (Material, e.g. width measurement) or Process (e.g. bath temperature each hour) related Data can be visualized by configurable standard PAM screens Data is used to feed configured Control Charts (Regelkarten). Control Charts are used to evaluate the SPC data, recognize trends and show alerts on deviations (predictive maintenance) On relevant situations, defined users will be informed In RAS there is an external system to visualize the Control Charts (ProDaSys, Prozess Daten System) which is requesting the need data by interface. So there is nothing foreseen in PSImetals yet.

+ Integration with SAP and L2 Automation

PSI Metals - Software Excellence in Metals

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© www.thyssenkrupp-rasselstein.com

2017-05-11

PSImetals FutureLab – Path 5: Quality & Reliability


From Formula to Statistics Methods like big data and SPC in combination with mass data from cheap sensors are a fundamental step for quality improvement.

Genealogy The history of each single material is important – not only for the final product – but also for the whole process and its improvement.

Traceability Zero Defect Strategy Knowledge Management

Reliable processes which are robust towards disruptions are the basis for high quality products. Therefore expert know-how and seamless process traceability must be reflected by the responsible IT system.

Experience Transferring the experience of experts into a knowledge base is the prerequisite for process stability.

CONNECTED


Reality: Digital Fingerprint of Your Material with Material Genealogy

2017-05-11

PSImetals FutureLab – Path 6: Multi-site Solutions and Data Centers


Protect Your Lead Security by Design respecting all needs of secure software architecture based on latest standards and technologies.

Open Platform A platform approach that is open to plug in apps and solutions from other vendors.

IT Security The Metals Cloud New Business Models

A stable and flexible IT infrastructure which follows the ever-changing demands of global production is the right backbone to realize the business of the future.

Complex Production with Lean IT IT must be able to focus on the core processes and must become a production factor like oil and gas.

Information Security Management System

ISO27k certified

xxxx

Use safe & up-to-date standard protocols

Use latest standard to secure sensible data

Reality: Security by Design with PSImetals


Authentification

Create Awareness

Encryption

Safe Data Transmission Updates & Recovery

Organization

2017-05-11

Reality: Metals Virtual Factory


Virtual Machine(s) in the cloud Definition of a logically isolated area within AWS by using a Virtual Private Cloud (VPC). Maintaining complete control of the environment. With few steps it is possible, to connect on-premise network with one or more AWS VPCs. Used for • PSImetals Academy • PSImetals Product Tests

2017-05-11

PSImetals FutureLab – Success through Collaboration PSI | Customers | Partners | Experts


Suddenly everything’s that simple.

2017-05-11

Copyright 2016 PSI AG.

No part of this publication may be reproduced or transmitted in any form or for any purpose without the express permission of PSI AG. The information contained herein may be changed without prior notice. PSImetals, PSIintegration and other PSI products and services mentioned herein as well as their respective logos are trademarks or registered trademarks of PSI AG and PSI Metals GmbH in Germany and in several other countries all over the world. All other product and service names mentioned and associated logos displayed are the trademarks of their respective companies. Data contained in this document serves informational purposes only. National product specifications may vary. The information in this document is proprietary to PSI. This document is not subject to your license agreement or any other agreement with PSI. This document contains only intended strategies, developments, and functionalities of the PSI product and is not intended to be binding upon PSI to any particular course of business, product strategy, and/or development. PSI assumes no responsibility for errors or omissions in this document. PSI does not warrant the accuracy or completeness of the information, text, graphics, links, or other items contained within this material. This document is provided without a warranty of any kind, either express or implied, including but not limited to the implied warranties of merchantability, fitness for a particular purpose, or non-infringement. PSI shall have no liability for damages of any kind including without limitation direct, special, indirect, or consequential damages that may result from the use of these materials. This limitation shall not apply in cases of intent or gross negligence. The statutory liability for personal injury and defective products is not affected. PSI has no control over the information that you may access through the use of hot links contained in these materials and does not endorse your use of third-party Web pages nor provide any warranty whatsoever relating to third-party Web pages. All Rights reserved.


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