Global Manufacturing Trends

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    Global Manufacturing Trends - Presentation Transcript

    1. Global Manufacturing Trends Keith D. Nosbusch Chairman and CEO Automation Fair - 2009 Copyright © 2009 Rockwell Automation, Inc. All rights reserved.
    2. Today’s Agenda • Rockwell Automation Business Update • Global Economic Outlook • Manufacturing and Technology Trends • Next Cycle Growth Accelerators • Summary Copyright © 2009 Rockwell Automation, Inc. All rights reserved. 2
    3. Rockwell Automation Today • Fiscal 2009 Sales: ~$4.3B – ~50% outside the US • Two Operating Segments – Architecture & Software Leading global provider of Leading global provider of – Control Products & Solutions industrial power, control industrial power, control • Employees: ~19,000 and information solutions and information solutions • Serving customers in 80+ countries • Trading Symbol: ROK Copyright © 2009 Rockwell Automation, Inc. All rights reserved. 3
    4. Segments Architecture & Software ~ 40% of total revenues Logix Family Visualization and Industrial Motion Sensing Safety Information Software Networks Products Control Products & Solutions ~ 60% of total revenues Industrial Smart Motor Variable Motor Control Drive System Control Controllers Frequency Services Centers Systems Integration Products Drives Products Solutions & Services Customer-driven, comprehensive portfolio of products, solutions & services Copyright © 2009 Rockwell Automation, Inc. All rights reserved. 4
    5. Long-Term Growth and Performance Strategy Revenue Sustained secular, organic growth Sustained secular, organic growth -- Expanded served market Expanded served market -- Target highest growth markets Target highest growth markets -- Acquisitions as catalysts Acquisitions as catalysts Generate 3-4% annual cost Generate 3-4% annual cost Deploy human and financial Deploy human and financial productivity & maintain operating productivity & maintain operating resources to highest-ROIC resources to highest-ROIC leverage leverage opportunities opportunities Reinvestment Intellectual Capital Continued investment in technology leadership & market expansion Copyright © 2009 Rockwell Automation, Inc. All rights reserved. 5
    6. Macroeconomic Drivers and Outlook Real GDP Industrial Production Y/Y Change (%) Y/Y Change (%) Source: Global Insight (October 2009) Source: Global Insight (October 2009) Nominal Cap Ex - Mfg Global Manufacturing PMI Index Y/Y Change (%) >50 Expansion <50 Contraction 2005 2006 2007 2008 2009F Note: Regional aggregates compiled by Rockwell Automation based on Global Insight data. Note: Regional aggregates compiled by Rockwell Automation. Source: Global Insight (August 2009) Source: JPMorgan Chase (World); Global Insight Worst global recession since WWII, shape of recovery uncertain Copyright © 2009 Rockwell Automation, Inc. All rights reserved. 6
    7. Trend: Optimized Plant & Supply Network Enterprise Plant-Wide Business Optimization Systems Sustainable Agile Supply Chain Production Factory Distribution Center OEMs Customer Transformation of IT-connected manufacturing to optimized plant and supply network Copyright © 2009 Rockwell Automation, Inc. All rights reserved. 7
    8. Optimized Plant & Supply Network: Agile Supply Chain Agility - Speed / flexibility to meet global demand - Information flow - Customized products Inventory Management - From “push” to “pull” - Continuous flow of raw material and products Integration of real-time demand & supply information with manufacturing processes is a key enabler to agile supply chain optimization Copyright © 2009 Rockwell Automation, Inc. All rights reserved. 8
    9. Optimized Plant & Supply Network: Plant-Wide Optimization Design & Commission - Product & process design - Time to market Operate - IT integration - Cost and productivity - Flexibility - Quality - Business risk management Maintain & Improve - Asset lifecycle cost - Visibility and KPIs Plant-wide optimization yields highest asset utilization & productivity at best cost Copyright © 2009 Rockwell Automation, Inc. All rights reserved. 9
    10. Optimized Plant & Supply Network: Sustainable Production Safety - Worker, machine & product safety - Standards compliance Environment - Waste recycling - Materials content tracking - Carbon footprint - Sustainability scorecard by product Energy - Active management of energy - Smart Grid readiness Sustainable production is becoming an imperative Copyright © 2009 Rockwell Automation, Inc. All rights reserved. 10
    11. Sustainable Production: Industrial Energy Management Generation Transmission Distribution Utilization Residential/Commercial Substation Conventional: Coal, Nuclear, Oil / Gas, Hydro Smart Grid • Econometric models • Low-cost “embedded” energy sensors • Communications Renewable: Solar, Wind • Integrated control & • Machine / process level energy energy mgmt. sensing, measurement, analysis, optimization, control • Standards for process Industrial equipment energy Transform factories from passive to active energy management Copyright © 2009 Rockwell Automation, Inc. All rights reserved. 11
    12. Optimized Plant & Supply Network: Technology Trends Plant-Wide • Combined product-process design Enterprise Business Optimization • Advanced process control Systems • Flexible, modular automation Agile Supply Chain Sustainability • Modeling and simulation Factory • Integrated safety solutions • Secure Ethernet Distribution • Unified information between plant & enterprise • Smart devices with energy monitoring Center • Wireless • Production optimization to meet real-time • Waste & emissions optimization global customer demand OEMs Customer Evolution of Integrated Architecture & Logix addresses technology trends to provide greater value to more customer applications Copyright © 2009 Rockwell Automation, Inc. All rights reserved. 12
    13. Integrated Architecture (IA) & Logix – Investing to Address Technology Trends • Integration of multiple control disciplines – Discrete, Batch, Process, Motion, Motor Control, and Safety are core disciplines – Integrating energy as a core discipline – Expanding advanced process control, integrated Common Software safety, and applications • Deliver plant-wide optimization and machine design productivity – Improving scalability to serve more OEMs • Build upon converged, secure Ethernet Logix – Enterprise connectivity and unified information • Expand innovative products, services, solutions – Domain knowledge – Partners Intelligent Motor Control Copyright © 2009 Rockwell Automation, Inc. All rights reserved. 13
    14. Rockwell Automation Growth Accelerators Process: Expansion of DCS capabilities, migration of legacy DCS systems OEMs: Scalable and flexible for multiple machine types Sustainability: Energy, environment, safety Safety: Global regulations, productivity, personnel protection Information: Software for optimization and connectivity Emerging Markets: China, India, SE Asia, Latin America and emerging EMEA Integrated Architecture and Logix are the foundation Copyright © 2009 Rockwell Automation, Inc. All rights reserved. 14
    15. Significant Process Wins, FY2009 Consumer Goods Batch chemical process for oral care $2.0M Life Sciences Solvent recovery unit $3.0M Life Sciences Regulated environment control system $2.8M Pulp & Paper Pulp mill, high pressure boiler house $0.7M Metals Zinc refinery control $1.5M Chemical Greenfield chlorine / bleach plant $0.4M Mining Greenfield taconite plant $2.9M Mining Gold mine & processing plant $1.2M Power Utility Primary control for 2 x 680 MW units $2.1M Water Utility Water / waste treatment plant $1.0M Oil & Gas Gas compressor station $2.2M Oil & Gas Gas treatment plant $1.4M Ongoing success in hybrid and heavy industries, growing success in continuous applications Copyright © 2009 Rockwell Automation, Inc. All rights reserved. 15
    16. Process Success Story K2 Pure Solutions selects PlantPAx for implementing Safer Technology to manufacture bleach and related products – A multimillion dollar opportunity per site, with a number of sites planned over the coming years – Key market drivers for K2 Pure are: speed to market, maximizing uptime, and minimizing risk – Rockwell Automation differentiators that allow K2 Pure to address their goals were: platform scalability, plant-wide control, plant asset management , MES Integration, and the value of our channel network Demonstrates the value of PlantPAx combined with power and instrumentation integration Copyright © 2009 Rockwell Automation, Inc. All rights reserved. 16
    17. Delivering Solutions to OEMs Converting, Material Process Mfg. /Assembly Energy Packaging Print, Web Handling Resource-based Manufacturing Balance of Plant Case Packing Converting Conveyor Systems W/WW Metal Compressors Tray Forming Paper, Paperboard, Cranes Power Gen Rubber Skids Pack & Unpack Tissue AGV Oil & Gas Plastics Fans Closing & Sealing Film Extrusion Mining Mining, Aggregate, Pumps Sorting Systems Pulp & Paper Cement Fill, Form & Seal Printing Sorters Chemical Glass Blister, Skin, Vacuum Package & Commercial Storage Systems Consumer Facing Alternative Energy Labeling & Coding Carousels Food/Bev Assembly Solar Product Identification Web processing ASRS Systems Life Science Automotive Wind Misc Web Handling HPC Tire Geothermal Palletizing Airport & Postal Other Solar Biomass Feed, Orient, Place Textiles Systems Electronic Wrapping Natural & synthetic Sorters & Pushers General fiber Upstream (Make) Downstream (Convert and Package) Copyright © 2009 Rockwell Automation, Inc. All rights reserved. 17
    18. Sustainable Production • Energy – Optimize usage through process improvements and conservation – Assist with energy recovery – Renewable energy alternatives – Smart Grid readiness • Environment – Recovery and recycling – Raw material reduction and process optimization – Emissions monitoring and optimization – Responsible product and package design • Safety – Worker and machine safety – Community and process safety – Product and brand integrity Cleaner, safer, more energy efficient Copyright © 2009 Rockwell Automation, Inc. All rights reserved. 18
    19. Sustainable Production - Machine and Process Safety 2009 Machine Safety Market Leaders Vendor Market Share Rockwell Automation #1 OMRON #2 Siemens #3 SICK #4 Pilz #5 2008 Process Safety Market Leaders Vendor Market Share Invensys / Triconex #1 Rockwell Automation #2 Honeywell #3 ABB #4 Hima #5 * Source ARC Machine Safety (2009) & Process Safety (2008) Market Studies Rockwell Automation – The World Leader in the $3.5B Safety Market Copyright © 2009 Rockwell Automation, Inc. All rights reserved. 19
    20. Alternative Energy Success Story Rockwell chosen to upgrade control system at one of the most complex integrated water and hydro-electric power facilities in the world – $12M order will allow the collection of real-time operational information and integration with existing systems, a critical aspect of the upgrade and purchase decision – Rockwell Automation control system collects operational data from the plant condition monitoring system, enabling the facility to increase efficiency by capturing unused capacity – Rockwell Automation control system seamlessly interfaces with SCADA system, allowing real-time decision making and control – All upgraded-to-date units are approaching “five nines” standard of control reliability, availability, and forced outage rates RA control system seamlessly integrates with existing I/O and SCADA system Copyright © 2009 Rockwell Automation, Inc. All rights reserved. 20
    21. Rockwell Automation View of Software Automation Software – Primarily configuration and visualization software Enterprise Systems – Sold with hardware Automotive Life Sciences CPG Biofuels CMM Chemical Information Software Operations & Manufacturing Intelligence Information Software – Software solutions for optimization, predictive control, production management and enterprise- wide intelligence Realtime Compliance & Sustainability – Vertical industry specific solutions to solve Model Control & Optimization business problems with proven ROI Services / Common Data Model Unique Customer Value – Logix is the data server Automation Software – Comprehensive suite of Operations Management capabilities – discrete, batch & continuous – Unique enablers – common data model, 3rd FactoryTalk services PARTIES – Industry experience and domain expertise – Global presence and infrastructure •Optimizing customer operations through better utilization of plant floor data Copyright © 2009 Rockwell Automation, Inc. All rights reserved. 21
    22. Information Success Story F. Hoffmann-La Roche selected FactoryTalk® Pharma Suite solution for material tracking at its chemical production sites – The software will provide comprehensive material tracking, tracing and pre-weighing, while also providing real-time visibility of the shop-floor inventory and production status – The Rockwell Automation industry specific approach and experience in the industry was key in Roche’s decision to use FT Pharma Suite – The software will interface with the existing shop floor systems, including SAP, OSI PI and warehouse management – The new system assists Roche in remaining at the forefront of the pharmaceutical manufacturing industry by being able to respond even more quickly to the changing global business environment Leading MES platform tailored to a specific industry Copyright © 2009 Rockwell Automation, Inc. All rights reserved. 22
    23. Globalization – Emerging Markets • Importance of emerging markets – Automation growth rates will be 50% higher than those of developed economies – Growing consumer economies will drive manufacturing investment – Energy utilization will drive sustainability investments • Why Rockwell is well-positioned – Maintained our investments in the downturn – Strengthened our position with OEM’s – Added delivery capability – Increased local manufacturing/engineering capability – Expanded channel competency Goal: 60% of revenue outside of U.S. by 2013 Copyright © 2009 Rockwell Automation, Inc. All rights reserved. 23
    24. Summary • Focused on Our Customers’ Success – Addressing major manufacturing trends: plant-wide optimization, agile supply chain, sustainable production – Expanding global footprint / presence and application expertise in emerging markets to support our customers Enterprise Business Plant-Wide Optimization Systems • Driving Technology Leadership and Innovation – Integrated Architecture & Logix Agile Supply Chain Sustainable Production – Intelligent Motor Control Factory Distribution Center – Industry domain knowledge, services and solutions OEMs Customer • Financial Strength – Capability and commitment to invest and innovate the best products, solutions, and services for industrial automation Well positioned to leverage manufacturing and technology trends and deliver superior value to our customers Copyright © 2009 Rockwell Automation, Inc. All rights reserved. 24
    25. 2009 Automation Fair Addresses Customer Drivers For Plant & Supply Network Optimization Smart, Safe, Sustainable Manufacturing Copyright © 2009 Rockwell Automation, Inc. All rights reserved. 25
    26. What’s New at Automation Fair 2009 • An industrial energy management “greenprint” that helps manufacturers take an “inside- out” approach to energy management • Portfolio of integrated motion solutions over EtherNet/IP • New series of servers and workstations for building a process automation system • Vertical industry approach to our information strategy and launch of FactoryTalk VantagePoint EMI and FactoryTalk Historian Machine Edition • Completed the integration of our safe-speed core technology into four product offerings • Dozens of additional new products including an extension to the safety light curtain line, a new safety controller for mid-range applications, a new managed switch, two new ControlLogix controllers, servo motors and drives and much more • Hundreds of offerings from the exhibitors within the Rockwell Automation PartnerNetwork • Hundreds of workshops, technical sessions, industry forums and hands-on labs Copyright © 2009 Rockwell Automation, Inc. All rights reserved. 26
    27. Enjoy the Show! Copyright © 2009 Rockwell Automation, Inc. All rights reserved.
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