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Using SCADA for Production MonitoringThe Manufacturing Lesson<br />Rick Caldwell<br />President, SCADAware<br />
Me and Dick“The Day We Failed”SUCCESS STORY<br />
SCADA For Manufacturing<br />Data Acquisition Only<br />
SCADA For Manufacturing<br /><ul><li>Great Visualizations
Need Better Reporting</li></li></ul><li>Largest Project Ever<br /><ul><li>Customer has large install of SCADA system for <...
Customer asks for flexible reporting system including </li></ul>OEE (Overall Equipment Effectiveness) for corporation wide...
There was not widespread acceptance of this software as the solution.
Development continued until all features were added and the product was completed and ready for a release to the customer ...
New System Being Introduced<br />Customers were invited to a showing of the new release.<br />One week before the software...
Day of Presentation<br />Friday, February 29, 2008<br />Everyone<br />arrives. <br />
Entertainment – Morley <br />
But we really brought him in for the…. <br />
Food – Chowder and Chili<br />
Presentation<br />The <br />Boring<br />Engineer<br />
Dick says, “Fire the boring engineer!”<br />Can’t see the screen<br />Boring Engineer<br />
Dick Says “Failure”<br />Guy on cell phone<br />Guys<br />talking during presentation<br />
Everyone Focuses on the Light<br />
Everyone Focuses on the Display<br />
Weekend Worry<br />
Monday Morning - Customer Calls<br />
Saw the Light<br />
“Do you have the light?”<br />
Wants to buy software/hardware combo<br />
“Do you have both?”<br />Hmmm….<br />
“Of Course!”<br />
Quickly Design Light and Controller<br />
Installations in three weeks<br />
The customer loves the solution<br />
We won the order - $20M USD Potential<br /><ul><li>Customer wants installations in 110 Factories</li></li></ul><li>Most Im...
Widespread acceptance in all areas of manufacturing</li></li></ul><li>Current Installations<br />3,428installations, in 62...
Lessons<br /><ul><li>What did we do wrong in the beginning?
We followed all the steps correctly with the design meetings and customer involvement.
How did we almost miss the opportunity to help our customer?
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“The Day We Failed” Success Story by Rick Caldwell,SCADAware

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Transcript of "“The Day We Failed” Success Story by Rick Caldwell,SCADAware"

  1. 1. Using SCADA for Production MonitoringThe Manufacturing Lesson<br />Rick Caldwell<br />President, SCADAware<br />
  2. 2. Me and Dick“The Day We Failed”SUCCESS STORY<br />
  3. 3. SCADA For Manufacturing<br />Data Acquisition Only<br />
  4. 4. SCADA For Manufacturing<br /><ul><li>Great Visualizations
  5. 5. Need Better Reporting</li></li></ul><li>Largest Project Ever<br /><ul><li>Customer has large install of SCADA system for </li></ul>monitoring production.<br /><ul><li>Target improvements have not been achieved.
  6. 6. Customer asks for flexible reporting system including </li></ul>OEE (Overall Equipment Effectiveness) for corporation wide SCADA<br /><ul><li>All custom development</li></li></ul><li>Years of Development<br /><ul><li>Software is developed as modules so early installations </li></ul>can be made with enhancements and features added over time.<br /><ul><li>Customer agrees to purchase early versions in small quantities as a test.</li></li></ul><li>Years of Development<br /><ul><li>Installations were showing good improvements on efficiencies, but only on the newer automated machine tools.
  7. 7. There was not widespread acceptance of this software as the solution.
  8. 8. Development continued until all features were added and the product was completed and ready for a release to the customer on a large scale.</li></li></ul><li>Invitation to Introduce New System<br />
  9. 9. New System Being Introduced<br />Customers were invited to a showing of the new release.<br />One week before the software showing I had an idea.<br />The customer needs a response light for the manual stations and assembly lines. <br />
  10. 10. Day of Presentation<br />Friday, February 29, 2008<br />Everyone<br />arrives. <br />
  11. 11. Entertainment – Morley <br />
  12. 12. But we really brought him in for the…. <br />
  13. 13. Food – Chowder and Chili<br />
  14. 14. Presentation<br />The <br />Boring<br />Engineer<br />
  15. 15. Dick says, “Fire the boring engineer!”<br />Can’t see the screen<br />Boring Engineer<br />
  16. 16. Dick Says “Failure”<br />Guy on cell phone<br />Guys<br />talking during presentation<br />
  17. 17. Everyone Focuses on the Light<br />
  18. 18. Everyone Focuses on the Display<br />
  19. 19. Weekend Worry<br />
  20. 20. Monday Morning - Customer Calls<br />
  21. 21. Saw the Light<br />
  22. 22. “Do you have the light?”<br />
  23. 23. Wants to buy software/hardware combo<br />
  24. 24. “Do you have both?”<br />Hmmm….<br />
  25. 25. “Of Course!”<br />
  26. 26. Quickly Design Light and Controller<br />
  27. 27. Installations in three weeks<br />
  28. 28. The customer loves the solution<br />
  29. 29. We won the order - $20M USD Potential<br /><ul><li>Customer wants installations in 110 Factories</li></li></ul><li>Most Important<br />Customer has success!<br /><ul><li>20% to 40% improvement in production efficiencies
  30. 30. Widespread acceptance in all areas of manufacturing</li></li></ul><li>Current Installations<br />3,428installations, in 62plants, in 9 countries<br />
  31. 31. Lessons<br /><ul><li>What did we do wrong in the beginning?
  32. 32. We followed all the steps correctly with the design meetings and customer involvement.
  33. 33. How did we almost miss the opportunity to help our customer?
  34. 34. The didn’t want a software reportingsystem. They wanted efficiency.
  35. 35. Take a step back.
  36. 36. Look at the big picture.
  37. 37. Be ready to think outside the box.
  38. 38. Don’t be afraid of your ideas.
  39. 39. Know your customer(internal and external)</li></li></ul><li>Thank you!<br />
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