TD03. Enhancing Manufacturing Performance Through Scalable Manufacturing Execution Systems ( MES) Aditya Chaudhary Information Solutions Business

Transcription

1 TD03 Enhancing Manufacturing Performance Through Scalable Manufacturing Execution Systems ( MES) Aditya Chaudhary Information Solutions Business PUBLIC

2 Single Loop vs Double Loop!"#$%&'()$*'+,'()-$./'0/'1$23)(45))$650(57$

3 Agenda W H Y M E S? H O W D O E S M E S H E L P? O U R A P P R O A C H S C A L A B L E M E S A U G M E N T E D R E A L I T Y A N D M E S T O G E T H E R 3

4 Metrics of concern to manufacturers Credit: Capgemini

5 0% 20% 0% 20% 0% 20% 0% 20% FINANCIAL 8.6% INVENTORY 15.0% INNOVATION 7.8% RESPONSIVENES S 7.8% Average Manufacturing PERFORMANCE IMPROVEMENTS 0% 20% 0% 20% 0% 20% 0% 20% EFFICIENCY 17.0% QUALITY 13.7% MAINTENANCE 14.9% COMPLIANCE 18.5% SOURCE: LNS, MESA INTERNATIONAL 5

6 Agenda W H Y M E S? H O W D O E S M E S H E L P? O U R A P P R O A C H S C A L A B L E M E S A U G M E N T E D R E A L I T Y A N D M E S T O G E T H E R 7

7 What is MES?- MES capabilities Chemical Food & Beverage Life Sciences Electronics Automotive Metals Hardware More Level 4 & 5 Vertical and Horizonzal Integration ERP PLM LIMS DMS... Product Tracing & Genealogy Resource Status & Allocation Process Management & Workflows Analytics Level 3 Labor Management Inventory & Logisitcs Quality Management Dispatching!!! Data Collection / Aquisition Level 2, 1 & 0 Based on MESA model 8

8 MES Functional Areas Automatic WIP Tracking Components Finite Capacity Scheduling Material & Genealogy Production Parameters Machine Status Power & Energy Management Quality Testing & Grading Workflow Management 10

9 Connecting the Enterprise MESSolution Closing the Information Loop from Execution through Data Management 11

10 Loss of Intellectual Property MESSolution Models manufacturing process & drive out variablility Setup on machines comes automatically with the order download Work instructions for quick learning per operations/ per station Quality processes integrated into operator actions 12

11 Meeting Regulatory Requirements MESSolution Compliance requirements come in many forms! Authentic Counterfeit STEP 1 STEP 2 STEP 3 Track-and-Trace Genealogy Counterfeit Prevention Record Keeping, Process Enforcement & EBR 13

12 Continuous Improvement Initiatives MESSolution Plants require new ways to ensure quality QUALITY PROCESSES become integral to production activities 14

13 Data Visibility Improve Asset Utilization Responsiveness To Demand Strategies for Success MES BENEFITS Improved Employee Productivity Embrace New Technology Reduce Cost & Time To Commercialization 6

14 Agenda W H Y M E S? H O W D O E S M E S H E L P? O U R A P P R O A C H S C A L A B L E M E S A U G M E N T E D R E A L I T Y A N D M E S T O G E T H E R PUBLIC 2018 Automation Fair Event #AutoFair18 Copyright 2018 Rockwell Automation, Inc. All Rights Reserved. 15

15 Scalable Execution Marketecture FT Analytics ERP PLM Other High fidelity analytics allow descriptive, predictive and prescriptive insights. EIHub Customer or System Integrator can build own application Industry Suite Customer or SI built application PharmaSuite More Industry Suites Quality Management Production Performance Warehouse Management Management Management (discrete) Fit for Purpose Applications More to come Customer Fit for purpose apps provide solutions OOB, configuration only. Extension concept allow to address future challenges Framework that allows building any MES application. SDK Modular Framework SDK Framework that allows building any MES application. Fundamental services for common objects, DBs, security. ProductionCentre EIHub Message-oriented middleware with a rule-based routing and mediation engine ERP PLM LIMS DCS Scalable Role based UIs Extensible by SDK Data Integrity Cloud ready Evergreen Agility Secure 16

16 FT Production Management Control of manufacturing processes V A L U E P R O P O S I T I O N C A P A B I L I T I E S T E C H N O L O G Y "! Right first time - Enforcement of proper assembly routes "! Provides step by step instructions for discrete processes to enforce right first time "! "! HTML5 clients Support mobile scanner "! Execution client guides the operator "! Widgets provide detailed process steps "! Single source of truth - data aquisition direct from equipment "! Gapless documentation of each process step "! Improve yield lower inventory "! Workflows combine widgets for complete work instructions "! Routes define the overall manufacturing flow "! 80 out of the box widgets / panel widgets "! Order management with BOM "! Responsive design "! Integration by EIHub! Receiving Inspection Assembly Testing Rework Inspection RMA / Repair Shipping 17

17 FT Quality Management Ensure quality goals V A L U E P R O P O S I T I O N C A P A B I L I T I E S "! Control your process and product quality "! Version controlled Quality Recipe "! Ensure execution of quality gates "! Recipe Items with a wide range of data inputs "! Gapless documentation "! Sample forms by configuration "! " Immediate SPC evaluation "! Quality Recipe Plan defines conditions for execution and notifications "! Sample plan initiation based on trigger "! Workflow enforcement w/ instructions "! Integration to Automation T E C H N O L O G Y "! HTML5 clients "! Support mobile scanner "! Integration by EIHub Plant Model Sample plan Resources triggers Sample plan 18

18 C A P A B I L I T I E S "! Material, Batch, SL tracking "! Goods Receipt / Goods Issue / Movement "! Logistic unit Merge / Spilt "! Inventory stocks "! Transaction log "! Storage condition "! Configuration of workflows " GS1, S95 FT Warehouse Management I N V E N T O R Y C O N T R O L "! Visibility in inventory / warehouse "! Process enforcement "! No data redundancy due to ERP integration "! Warehouse operator efficiency T E C H N O L O G Y "! HTML5 clients "! Responsive design "! Support mobile scanner "! Integration by EIHub Goods receipt Storage Provision Transport Order Storage Picking Goods issue 19

19 A N A L Y Z E P E R F O R M A N C E "! Out-of-the-box reports facilitate a wide range of analysis "! Actual vs. target detail by day for OEE and its three components "! Production totals, including Target value and Reject count "! Aggregation to the line level FT Performance Management C A P A B I L I T I E S "! Plant model "! Line configuration "! Performance criteria per material "! Definition OEE targets "! Tag browsing "! Manual reason codes T E C H N O L O G Y "! HTML5 clients "! Responsive design "! Support mobile scanner "! Integration by EIHub Plant Model Line: Equipment 1 Equipment 2 Equipment 3... Dashboards 20

20 FT Enterprise Integration Hub V A L U E P R O P O S I T I O N C A P A B I L I T I E S "! Real Time Synchronization between all Domains "! Supports Enterprise Integration Patterns "! Visibility & Transparency across Domains "! High Availability & Scalability "! Single source of truth "! Ease of Configuration, Deployment and "! Lower integration cost by prebuild integration scenarios Management "! ERP MES DMS PLM AM DCS "! Configurable integration workflows "! Premier integration with RASuites, Applications and Automation "! Pre-Packaged Connectors using Industry Standard Protocols T E C H N O L O G Y "! Apache Camel "! Components: "! AMQP, Cassandra, EJB, File, FTP, HTTP, JDBC, JMX, Kafka, LDAP, Log, MQTT, Rest, SQL,... Many more "! Routing engine MES ERP PLM QMS EIHub MA DCS LIMS DMS 21

21 Customer Success Story

22 Agenda W H Y M E S? H O W D O E S M E S H E L P? O U R A P P R O A C H S C A L A B L E M E S A U G M E N T E D R E A L I T Y A N D M E S T O G E T H E R PUBLIC 2018 Automation Fair Event #AutoFair18 Copyright 2018 Rockwell Automation, Inc. All Rights Reserved. 22

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