Your SlideShare is downloading. ×
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Rev 5058-CO900DUsing Manufacturing IntelligenceProvide Info...
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Agenda4. Rockwell’s Differentiated Approach3. Customers Val...
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.MotivationManaging costManaging costSustainabilitySustainab...
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Decision Making and Corporate Strategies4Business pressures...
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.The Connected EnterpriseSupply ChainDistribution CenterCust...
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Agenda4. Rockwell’s Differentiated Approach3. Customers Val...
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Manufacturing Intelligence Defined7Manufacturing
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Manufacturing Intelligence Defined8IntelligenceEnergy• Incr...
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Manufacturing Intelligence DefinedProduction dataProduction...
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Addressing Critical Business IssuesWhat is my equipment uti...
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Example case - QualityAlarmsHistorianControl SystemBatchWhi...
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Example case - PerformanceAlarmsHistorianControl SystemPerf...
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Example case - EnergyHistorianPerformanceControl SystemEner...
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.MachineAreaProductionPlantQuality & Operations MaintenanceP...
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Agenda4. Rockwell’s Differentiated Approach3. Customers Val...
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Value Statements for our Customers Performance Improvement...
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Performance Improvements18 Monitor and manage KPIs, OEE an...
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Production Improvements19 Real-time batch comparisons and ...
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Energy cost savings Correlating event and process data hel...
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Quality and Regulatory Compliance Eliminated manual data t...
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Agenda4. Rockwell’s Differentiated Approach3. Customers Val...
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.How Do You Access Information Today ?Reports/VisibilityEnte...
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.The “Information” Integration ChallengeControl SystemsHMIsM...
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Manufacturing Information SystemRole basedspecific informat...
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Integration …more than just connectivity!Role basedspecific...
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.One Common Production Model
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Why is a Model Important?Organize the model to fit your nee...
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Example Reports and Dashboards29
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Example Reports and Dashboards30
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Mobile Clients
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Agenda4. Rockwell’s Differentiated Approach3. Customers Val...
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Summary Actionable Information rather than just data Redu...
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.The Connected EnterpriseSupply ChainDistribution CenterCust...
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Learn More …Related Sessions35 FactoryTalk® VantagePoint E...
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Copyright © 2013 Rockwell Automation, Inc. All Rights Reser...
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Copyright © 2013 Rockwell Automation, Inc. All Rights Reser...
Upcoming SlideShare
Loading in...5
×

Using Manufacturing Intelligence to Provide Information for Better Business Decisions

173

Published on

Published in: Business, Technology
0 Comments
0 Likes
Statistics
Notes
  • Be the first to comment

  • Be the first to like this

No Downloads
Views
Total Views
173
On Slideshare
0
From Embeds
0
Number of Embeds
0
Actions
Shares
0
Downloads
0
Comments
0
Likes
0
Embeds 0
No embeds

No notes for slide

Transcript of "Using Manufacturing Intelligence to Provide Information for Better Business Decisions"

  1. 1. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Rev 5058-CO900DUsing Manufacturing IntelligenceProvide Information for Better Business DecisionsKai BergemannProduct Manager Software – EMEA Region
  2. 2. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Agenda4. Rockwell’s Differentiated Approach3. Customers Value Statements2. Manufacturing Intelligence Defined1. Motivation5. Summary
  3. 3. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.MotivationManaging costManaging costSustainabilitySustainabilityVisibility ofinefficienciesVisibility ofinefficienciesSatisfy customerand regulatorydemandsSatisfy customerand regulatorydemandsDrive product andprocess innovationDrive product andprocess innovation
  4. 4. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Decision Making and Corporate Strategies4Business pressures drive need for Manufacturing Intelligence
  5. 5. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.The Connected EnterpriseSupply ChainDistribution CenterCustomersModern, global factories will beintegrated with the supply chain,distribution, customers, andbusiness systemsSustainabilitySustainabilityAgilityAgilityProductivityProductivityEnterpriseSmart Grid
  6. 6. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Agenda4. Rockwell’s Differentiated Approach3. Customers Value Statements2. Manufacturing Intelligence Defined1. Motivation5. Summary
  7. 7. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Manufacturing Intelligence Defined7Manufacturing
  8. 8. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Manufacturing Intelligence Defined8IntelligenceEnergy• Increase Energy Efficiency• Lower Energy costQuality• Stable quality level / Minimize scrap• Fast reactions on recallsPerformance• Increase machine + line performance• Optimal use of resourcesMaintenance• Preventive maintenance• Increase availabilityProduction• Increase throughput• Decisions based on real informationManufacturing
  9. 9. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Manufacturing Intelligence DefinedProduction dataProductionContext InformationSoftwareIMPROVEDDecisionMakingDecisionPeopleAgree!
  10. 10. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Addressing Critical Business IssuesWhat is my equipment utilization?What are the energyintensive processes?What are the majordowntime causes?What is my first pass quality?How are we performingagainst plan?Where are the bottlenecks?Is our manuallycalculated OEE correct?
  11. 11. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Example case - QualityAlarmsHistorianControl SystemBatchWhich batches andmachines are impacted?Batch A01 - B03+ Machine C03Quality issues in last shift – what happened?What are the related Alarms?High Temp. Alarm …What happened whilethe batch was running?Detailed machine data showsoperators changed set pointsWhat are thecurrent set points?Target temp = 175°CWhat has been changedin the last several days?Set points have been changed!Maintenance changed set pointsOperators were not informed aboutthis change and adjusted set pointsmanuallyMissing communicationcaused the quality issuesMaintenanceInformation Portal
  12. 12. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Example case - PerformanceAlarmsHistorianControl SystemPerformanceHow was performance onLine 1 compared to Line 2?Performance was 7% lowerWhy is Line 1 OEE 5% lower than Line 2 OEE?What are the related Alarms?Several Alarms fromcutting machineWhat happenedduring the last shift?Detailed machine datashows speed variancesWhat are thecurrent set points?Set points correct!What are the root causesof the speed variances?Material problems!Material on Line 1 from new vendorcaused problems on cutting machineNew Material specification andquality need to be validated againInformation Portal
  13. 13. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Example case - EnergyHistorianPerformanceControl SystemEnergyWhich machinescaused overspend?Air compressors demandhigher than expectedWhy is the electrical powerconsumption 15% above plan?What are the reasons?Compressors runningduring non production periodsOther reasons for overspend?10% above plan while in productionWhat can be changedto avoid overspend?Pressure can be reducedfrom 7,4 to 6,8 barHas performance beeneffected by this change?No negative effect on OEE!• Utilized compressor built in timer toshutoff during non production periods• Reduced operating distributionpressure from 7.4 bar to 6.8 barConsumption reducedand stays within base line!Information Portal
  14. 14. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.MachineAreaProductionPlantQuality & Operations MaintenancePlant Manager Document effects ofimprovement activitiesProductionFinanceSales / CustomersEmployeesBalanced ScorecardEngineer OperatorProduction ManagerDifferent Users, Different NeedsLine Define Corporate objectives & observe actively Costs, production output, overall efficiency Financial indicators, capacity Production output, achieving targets Efficiency of production Ways to improve production and yield Minimize scrap & rework Monitor process, ensure compliance Reducing downtime Preventive maintenance Monitoring process to keep production running Identifying problems in real time Improvement activities Keeping plant running Predictive maintenance Optimize asset availability
  15. 15. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Agenda4. Rockwell’s Differentiated Approach3. Customers Value Statements2. Manufacturing Intelligence Defined1. Motivation5. Summary
  16. 16. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Value Statements for our Customers Performance Improvements Production Improvements Energy cost saving Quality and Regulatory Compliance
  17. 17. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Performance Improvements18 Monitor and manage KPIs, OEE and downtime causes inreal-time to find root causes of inefficiencies Customize reporting to give management a clear pictureof plant floor operations Eliminated the time associated with manual paperwork Time in state reporting is in place to identify processdelays Real-time information helped operators set correct linebalance, identify bottlenecks and machine constraints,and reduce product rejectsPerformance70% OEE (from60%) after justfour monthsOEE +5%throughimprovedequipmentutilizationProductivity+20% withexisting plantfloor staffMinimized lineshutdowns forsavings of morethan$120,000/yearUncovered anOEE rate of65% - 20% lessthan what wasassumed
  18. 18. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Production Improvements19 Real-time batch comparisons and the capability to makeinline corrections Access to integrated data provides improved diagnostics formore preventative and predictable maintenance Remote batch monitoring allows a single operator to serviceseveral processes Reports allow batch traceability and historical data to beavailable for trending and process analysis Integration with ERP system streamlined operations,increased reliability of recipe execution and decreasedprobability of operator errorProductionSaved morethan$250,000/yearby reducingbatch lossesThroughputincreased by60%+Reduced batchcycle time by upto 10% throughreal-timereportingGain onecleaning cycleper shiftReduced wastethroughincreasedvisibility andcontrol
  19. 19. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Energy cost savings Correlating event and process data helps speed up systemreadiness, reducing gas usage and steam pressure lossduring warm-up Monitoring of electricity, gas, steam, compressed air andwater at a line-level Find air leaks within minutes instead hours or days Actual vs. baseline comparison make losses immediatelyvisible Optimization of maintenance schedule according to energyefficiency needsEnergyEfficiencyDecreased theplant’sgreenhousegases by 442tons annuallyGovernmentinformationwhich reducedtaxes for thecompanySaved 30% oncost ofcompressed airgenerationReducedenergyconsumptionsaves$845,000/yearImprovedoperatingmargin by 3%
  20. 20. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Quality and Regulatory Compliance Eliminated manual data transcription process, reducing errors By tracking pressure variances, quality was increased whileless raw materials were consumed and waste was reduced Implemented end-to-end tracking and tracing system forfaster and more accurate response to product recalls Historian acts as a safe records repository to helpmanufacturer comply with the U.S. FDA’s rules Automatic report generation with data coming from multipledata sources reduced manual work and increased informationqualityQuality andComplianceValidationtimelinereduced fromtwo weeks toone or two days720 man-hourssaved annuallyin reportgenerationReducedwasted productby 10% due toequipmentstoppageReducedbudget whileremainingregulatorycompliantReducedvalidation costsby $2 million
  21. 21. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Agenda4. Rockwell’s Differentiated Approach3. Customers Value Statements2. Manufacturing Intelligence Defined1. Motivation5. Summary
  22. 22. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.How Do You Access Information Today ?Reports/VisibilityEnterpriseSystemsEnterpriseSystems
  23. 23. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.The “Information” Integration ChallengeControl SystemsHMIsManufacturingExecution SystemAlarms/EventsOther DatabasesystemsComputerized MaintenanceManagement SystemsPerformanceManagementQualitySystemsProductionHistoriansLaboratory InformationManagement Systems
  24. 24. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Manufacturing Information SystemRole basedspecific informationBusinessintegrationWeb accessand mobile clientsAvailableproduction dataOnecommon networkTrusteddata storageOne commonproduction modelMaintenancePerformanceEnergyProduction
  25. 25. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Integration …more than just connectivity!Role basedspecific informationBusinessintegrationWeb accessand mobile clientsRole basedspecific informationBusinessintegrationWeb accessand mobile clientsAvailableproduction dataOnecommon networkTrusteddata storageAvailableproduction dataOnecommon networkTrusteddata storageMaintenancePerformanceEnergyProduction
  26. 26. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.One Common Production Model
  27. 27. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Why is a Model Important?Organize the model to fit your needs Allows correlation of multiple pieces ofdata associated with a single logical unit Real-time values Historical values Asset / maintenance records Alarm / event based information Information is conveyed in userconsumable terms Pumps, compressors, mixers, etc. Plants, Lines, Work cells, etc. Products, Ingredients, Batches, etc. Single Version of the truth Data is access directly from the sourceControl SystemsHMIsManufacturingExecutionSystemAlarms/EventsOther DatabasesystemsComputerized MaintenanceManagement SystemsPerformanceManagementQualitySystemsProductionHistoriansLaboratoryInformationManagement Systems
  28. 28. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Example Reports and Dashboards29
  29. 29. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Example Reports and Dashboards30
  30. 30. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Mobile Clients
  31. 31. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Agenda4. Rockwell’s Differentiated Approach3. Customers Value Statements2. Manufacturing Intelligence Defined1. Motivation5. Summary
  32. 32. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Summary Actionable Information rather than just data Reduced production costs Increased productivity Improved quality and customer satisfaction Drive product and process innovationManufacturing Intelligence deliversthe information which drives productand production improvement
  33. 33. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.The Connected EnterpriseSupply ChainDistribution CenterCustomersModern, global factories will beintegrated with the supply chain,distribution, customers, andbusiness systemsSustainabilitySustainabilityAgilityAgilityProductivityProductivityEnterpriseSmart Grid
  34. 34. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Learn More …Related Sessions35 FactoryTalk® VantagePoint EMI MI02 - Architecting a Manufacturing Intelligence System MI03 - Manufacturing Intelligence in Action: Interactive Demo MI04 - Mobile Access to Production Information MI14 - Build an Information System on Your Integrated Architecture System (Lab) MI15 - FactoryTalk VantagePoint EMI Advanced Lab: Exploring the Possibilities(Lab) MI17 - FactoryTalk VantagePoint EMI: Advanced Reporting (Lab) MI18 - Reporting Best Practices for Production Information FactoryTalk® VantagePoint Energy PE08 - Energy Monitoring and Control with Rockwell Automation Energy Intelligence
  35. 35. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Rev 5058-CO900DQuestions?
  36. 36. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Rev 5058-CO900DThank you for participating!Please remember to tidy up your work area for the next session.We want your feedback! Please complete the session survey!

×