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Stupp corporation improved control and gained insight with mes
- 1. Improved Control and Insight with MES Stupp Corporation Systems Upgrades June 11, 2018
- 3. • Chief Information Officer • 40 years IT experience • 10 years USAF Intro www.stuppcorp.com | the energy-filled company 3 • Client Executive • 20 years real-time systems experience
- 4. People, Process & Technology www.stuppcorp.com | the energy-filled company 4 Technology PeopleProcess Sweet Spot People and Technology Without Process Automated chaos and confusion Poor customer service Automated Chaos People and Process Without Technology Frustration and inefficiency High cost of operation Frustration Process and Technology Without People Alienation and turnover Underutilized systems Alienation The Art and Science of Change Management Adapted from "Lean Enterprise Systems, Using IT for Continuous Improvement," www.steadyimprovement.com
- 5. The Problem www.stuppcorp.com | the energy-filled company 5
- 6. Where do we start? www.stuppcorp.com | the energy-filled company 6
- 7. The Projects www.stuppcorp.com | the energy-filled company 7
- 8. FactoryTalk® ProductionCentre MES Implementation www.stuppcorp.com | the energy-filled company 8 QUALITY MANAGEMENT MATERIALS MANAGEMENT PERFORMANCE MANAGEMENT RECIPE MANAGEMENT LOT-TRACKING GENEALOGY 2 Plants ORDER MANAGEMENT VANTAGE POINT & HISTORIAN ERP & Controls Integration Make to order 1400 pipes/day Deciding Factor: proved business value for MES
- 9. FactoryTalk® ProductionCentre MES Video www.stuppcorp.com | the energy-filled company 9
- 10. Business Systems Update www.stuppcorp.com | the energy-filled company 10
- 11. Data Analytics www.stuppcorp.com | the energy-filled company 11
- 12. SAWH Video www.stuppcorp.com | the energy-filled company 12
- 13. Benefits www.stuppcorp.com | the energy-filled company 13
- 14. Questions www.stuppcorp.com | the energy-filled company 14 ?
- 15. 15Copyright © 2018 Rockwell Automation, Inc. All Rights Reserved. 2018 Rockwell Automation TechED™ Event #ROKTechEDPUBLIC Share your Feedback Please complete a session survey on the mobile app Download the Rockwell Automation Events App Select Rockwell Automation TechED and login Click on Session Surveys or Schedule in the main menu Select the session you are attending Click on the survey tab Complete the survey and submit
- 16. www.rockwellautomation.com PUBLICPUBLIC Copyright © 2018 Rockwell Automation, Inc. All Rights Reserved. 2018 Rockwell Automation TechED™ Event #ROKTechED #ROKTechED Thank you!
Editor's Notes
- Holding company Briefly discuss entities
- The foundation of everything we do Has an impact on everything People tend to be the hardest most variables
- Disparate controls Islands of automation Difficult to troubleshoot problems Run to fail mentality Ownership issues Home grown software Not many options in the 90s Grew from Access applications Eventually evolved to .Net Lack of visibility into our manufacturing processes isolated systems made it hard to get info Silos of information Not just system silos People silos developed over time Data silos No productive way to tie it together Protective processes Shadow IT Staffing issues Maintaining engineers to support Maintaining developers to code
- How do you eat an elephant? Culture change Run to fail mentality created the best firefighters Culture initiative started from the holding company Requires leadership and executive presence Governance Implemented enterprise wide Oversight Steering Project PMO How do we know we have successful projects if we don’t measure them? Varying structure in projects across all operations Brock taught us how to deliver real project management Aligns with governance Better visibility into project progression Improved communication with the board Prioritization Reduce whiplash Set expectations within organization Reduce firefighting
- Defined systems as level 0 through 4 Controls streamline standardize data concentrator Manufacturing systems Business systems Name Description Example Responsibility Level 0 Sensor Level (Measuring Devices): Pressure, Temperature, Speed, Accelerometer, Force, Position, Shape, Thickness, etc. Sensors Mill Maintenance Level 1 Controller Level (Feed-back Closed Loop Control): Speed Regulator, Tension Regulator, Sequence Control, Position Control, Temperature Control, SCADA, etc. PLCs Mill Controls Group Level 2 Machine Level (Set-up Models): HMIs, Mill Set-Up Control, Coil Tracking, etc. Recipes Mill Controls Group Level 3 Plant Level MES, MRP: Scheduling, Material Flow, Manufacturing Execution System (MES), etc. Dashboards, etc. Mill Controls Group / Information Systems Level 4 Corporate Level CRM, CMMS, LMS, ERP: Order Process, Enterprise Resource Planning (ERP), etc. AX, CRM, CMMS, LMS, etc. Information Systems
- Deploy state-of-the-art manufacturing system Brock worked with team to develop business requirements and functional spec Used to determine if project should move forward Helped scope the project Entire Stupp team engaged Challenges We’ve always done it this way Don’t have time to plan Difficult to have vision Benefits Improved access to data Supportable system Yield improvement through cut optimization Change control Must be driven by senior leadership Brock managed us through the process Leveraged relationship with Rockwell Provides sustainment services
- Greg to provide walkthrough
- ERP implementation Process standardization Expected benefits Real-time access to data Streamlined processes Documented system Change control Must be driven by senior leadership
- The real reason we did all of this Fusion of operational and cost data Ability to make better decisions Next-gen tools to automate data analytics
- Saved money through yield improvements Improved processes Gained better access to data World-class manufacturing execution system