Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
PUBLIC INFORMATION
Innovations in Industrial Mobility
Tech...
Innovations in Industrial Mobility Technology
JIM HILTON | MANUFACTURING
WW PRINCIPAL
Finished
Goods
Manufacture
& Assembly DeliveryPacking ShippingReceiving SCADA
Quality
Control Service
PROCESS
Food & Bever...
40%
of annual profits can
be lost due to
unplanned downtime
54%
of US manufacturers say
they lack a unified view of
their ...
5
ENHANCE OPERATOR EXPERIENCE
ENABLE MOBILITY
Motorola ET1
- Client -
PanelView™ Plus 6
- Server -
VNC
Pocket
Cloud
 Unit...
6
ENHANCE OPERATOR EXPERIENCE
ENABLE MOBILITY
Motorola ET1
PanelView™ Plus 6
FactoryTalk® View SE
VNC Pocket Cloud
Vmware ...
FactoryTalk View SE
For the Operators
 Monitoring process to keep production running
 Identifying relationships to optimize the process
Oper...
MOBILE OPERATOR
“It has been unbelievable! The
concept is fabulous. Operators
take this with them and are
immediately awar...
PACKAGINGWORLD
www.Packworld.com
January 2014 Issue
WIP (using RFID)
TDM is able to use RFID to report vehicle receipt,
production progress and shipping updates back to Ford ...
MOBILE MAINTENANCE IMPACT
“The ET1/Mobile HMI is an excellent
complement to our existing use of fixed local
and networked ...
DRIVING EFFICIENCY on the Shop Floor
Business Need (Line Side Inventory)
1. Large Elimination of paper based procedures
2....
Driving Traceability in Produce
Project: To trace tomatoes and other
produce using RFID. Tags will be
placed on produce bo...
Track & Trace (Traceability)
Asset Tracking (RFID Tray Tracking)
Using trays with embedded RFID
Chips and retro-fitting old trays
with RFID Chips
• Ins...
WARNING Line 6!
E-stop Pressed
Marquee Manager Gateway for:
• OPC
• ODBC
• RSLinx
• FactoryTalk View SE
• RSView32
• First...
OPTIMIZING ACROSS THE ENTERPRISE
Real Time Alerts
Enterprise Wide Improvements
Service, Productivity, Efficiency, Inventor...
77%
correlation between
profitability and
inventory turns
10%
of the inventory value
is the typical cost of
carrying inven...
NEW INNOVATIONS
More capable devices and networks…
Smaller: New categories of mobile devices are
now possible to connect e...
PAGE 21
UPGRADE INBOUND
HANDLING OPERATIONS
• Speed up the flow
• De-skill the workforce
• Execute perfectly
• Drive out w...
EFFIENCY in Yard and Infrastructure
Business Need (Trailer Tracking)
1. Large production facility with many trailers, yard...
50-70%
of potential service revenue is
lost because of poor record
keeping and management
$1BAverage revenue lost each yea...
OUR SOLUTIONS ARE BUILT ON A
DEEP UNDERSTANDING OF THE
CHALLENGES YOU FACE IN YOUR
FIELD OPERATIONS.
FIELD SERVICE
DIRECT ...
1. OPTIMIZING SALES, DELIVERY, MERCHANDISING
Signature Capture
Personal Area Network
“PAN”
Image / Video
Utilization
Gaine...
“Turn right onto
East Avenue…”
Route Optimization
• Bread Crumbing
• Geo-Fencing
Asset Tracking
• Geo-Coding
• Goods local...
3. OPTIMIZING PRODUCTIVITY AND REVENUE RECOVERY
Voice Recognition
Gained Productivity
Hands Free
Capture
PCI Compliant Pla...
OPTIMIZING ACROSS THE ENTERPRISE
Real Time Alerts
Enterprise Wide Improvements
Service, Productivity, Efficiency, Inventor...
Tools
Rockwell Microsite: http://www.motorolasolutions.com/rockwellautomation
www.plantcalculator.motorolasolutions.com
CALCULATING THE ROI FOR A
MOBILITY PROJECT
Safety & Environmental
• Soft and Hard Costs
Time Savings
• Hard Costs – Downti...
BEST PRACTICES FOR REALIZING
YOUR CALCULATED ROI
Envision, Document, and Execute a Mobile Strategy
• Engage Cross Function...
BUILDING A CUSTOM TCO
MODEL
https://partnercentral.motorolasolutions.com/TCO
Motorola MFG Resources
• Industry Week Webinar: http://bit.ly/plantmobility
• MSI MFG Page: http://www.motorola.com/Busine...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
We care what you think!
 On the mobile app:
1. Locate ses...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
PUBLIC INFORMATION
Thank you for participating!
Please rem...
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Motorola: Innovations in Industrial Mobility Technology

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Overview session on selecting and implementing three critical technologies: Industrial Voice and Data Networks supporting mobile devices and radios; High Frequency RFID for tracking materials, products and assets; and Mobile HMI technologies supporting PanelView Plus 6 and FactoryTalk View SE.

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Motorola: Innovations in Industrial Mobility Technology

  1. 1. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. PUBLIC INFORMATION Innovations in Industrial Mobility Technology Motorola Solutions
  2. 2. Innovations in Industrial Mobility Technology JIM HILTON | MANUFACTURING WW PRINCIPAL
  3. 3. Finished Goods Manufacture & Assembly DeliveryPacking ShippingReceiving SCADA Quality Control Service PROCESS Food & Beverage CPG - Soft goods (i.e., Soaps) Pharmaceutical and medicine Paper, print, and publishing Chemical, plastics, and rubber Textiles and apparel DISCRETE Transportation equipment CPG - Hard goods (i.e...Toys) Industrial & electrical equipment Computer & electronic products Furniture & office equipment Medical equipment DEFINING THE MANUFACTURING ENTERPRISE
  4. 4. 40% of annual profits can be lost due to unplanned downtime 54% of US manufacturers say they lack a unified view of their plant floor information PLANT & FACTORY - “Manufacturing Transparency, Turning Visibility into Value,” Aberdeen Group - “The Hidden Cost of Downtime: A Strategy for Improving Return on Assets,” Maintenance Technology
  5. 5. 5 ENHANCE OPERATOR EXPERIENCE ENABLE MOBILITY Motorola ET1 - Client - PanelView™ Plus 6 - Server - VNC Pocket Cloud  Unit Counts  Receive, Act and Acknowledge Alarms  Review Historical Trends Free operators from stationary clients yet still provide quick information
  6. 6. 6 ENHANCE OPERATOR EXPERIENCE ENABLE MOBILITY Motorola ET1 PanelView™ Plus 6 FactoryTalk® View SE VNC Pocket Cloud Vmware View  Enable mobile operators to be proactive instead of reacting to alarms  Autonomous Maintenance  Retrieve Manuals, Drawing and Procedures from anywhere Free operators from stationary clients yet still provide quick information
  7. 7. FactoryTalk View SE
  8. 8. For the Operators  Monitoring process to keep production running  Identifying relationships to optimize the process Operator For the Production Manager  Schedule, track production activity  Way production is running, ways to improve Production For the Engineering / Maintenance Manager  Keeping plant running  Predictive maintenance, asset optimization Engineering For the Quality Manager  How product was made, ensure compliance  Ways to improve product and yield Quality For the Executive  Costs, schedules, production output  Financial indicators, sustainability Plant Mgmt. The Pressure to Improve Productivity What keeps manufacturers up at night ?
  9. 9. MOBILE OPERATOR “It has been unbelievable! The concept is fabulous. Operators take this with them and are immediately aware of alarms and can begin to investigate. What would have taken 2 operators now only takes one.” Major Cheese Manufacturer 10/2012 Mobile HMI Benefits # of Operators Per Shift # of Shifts Per Day # of Workdays Per Week Fully Burdened Cost Per FTE % of Operators Using Mobile HMI Hours Worked per FTE Hourly Labor Cost Annual Expansion/Relocation Savings # of New HMI Stations Planned for Next 5 Years $ Average Cost of New Fixed HMI Hardware & Installation # of HMI Station Moves Planned for Next 5 Years $ Average Cost of Relocating an HMI Station % of New HMI Stations Eliminated by Mobile HMI % of Relocated HMI Stations Eliminated by Mobile HMI $$ Saved Response Time Improvement - Downtime & Scrap # of Process Alarms Per Operator Per Shift # Avg Response Time Minutes without Mobile HMI # Response Time Minutes with Mobile HMI Downtime Savings % of Process Alarms Resulting in Downtime $ Downtime Cost Per Minute # of Downtime Minutes Per Alarm without Mobile HMI % of Downtime Saved with Faster Response $$ Saved Product Scrap Savings % of Alarms Resulting in Scrap Product $ Product Scrap Cost Per Alarm % of Scrap Saved with Faster Response $$ Saved Data Entry Labor Savings # of Operator Rounds Per Operator Per Shift # of Data Entry Minutes to Record Round Data Average Payback < 3 months without WLAN < 8 months with WLAN
  10. 10. PACKAGINGWORLD www.Packworld.com January 2014 Issue
  11. 11. WIP (using RFID) TDM is able to use RFID to report vehicle receipt, production progress and shipping updates back to Ford in real time. • Real Time Tracking Realized • “Precise” Visibility • Complete & Consistent data collection • Real-time data and visibility streamline operations and decrease downtime • Operators can focus solely on labor tasks with significantly less multitasking and data entry • Plant-floor operations are much more fluid with reliable automated data capture “The application makes decisions and directs traffic flow based on the information in the system, and it’s hands-off, so our operators aren’t riffling through paper, trying to see where things go and needing to make decisions. It’s all very visual,”
  12. 12. MOBILE MAINTENANCE IMPACT “The ET1/Mobile HMI is an excellent complement to our existing use of fixed local and networked based HMI. Putting the information in the hands of the craftsman working on the machine saves both time and resources. The ability to provide a graphical HMI interface as well as accessing work orders, parts lists, and manuals will allow us to reduce downtime and increase productivity. The uses of this device is only limited by your imagination.” International Food Processor 10/2012 Mobile Maintenance Benefits # of Maintenance Technicians Per Shift # of Shifts Per Day # of Workdays Per Week # of Workweeks Per Year Fully Burdened Cost Per FTE % of Maintenance Techs Using Mobile HMI Hours Worked per FTE Hourly Labor Cost Troubleshooting Time Improvement # of Maintenance Troubleshooting Events Per Shift # Avg Troubleshooting Minutes without Mobile HMI # Avg Troubleshooting Minutes with Mobile HMI # of Technicians Involved Per Event without Mobile HMI # of Technicians Involved Per Event with Mobile HMI $ Downtime Cost Per Hour $$ Saved Data Entry Labor Savings # of Work Orders Per Maintenance Tech Per Shift # of Data Entry Minutes to Record All Work Order Data at Shift End $$ Saved Average Payback < 4 months w/ existing WLAN < 10 months with new WLAN investment
  13. 13. DRIVING EFFICIENCY on the Shop Floor Business Need (Line Side Inventory) 1. Large Elimination of paper based procedures 2. Real-time Inventory Control ROI Factors • Real-time control of 1200 orders per day, 15% increase in output • 1.8 million more shipments with 2200 fewer man hours • Less miss-shipment coupled with 98% inventory accuracy • Inventory levels declined by 121,000 cases Business Need (Traceability & Quality) 1. Risk Mitigation 2. Raw Material Lot Tracking / Unbroken Chain of Possession 3. Product History & Genealogy 4. Process Conditions, Movement & Status 5. Isolate Impact of Process Variability “We needed a solution that would allow us to comply with the FDA mandate, but at the same time, not disrupt the manufacturing processes we already had in place,” said Rick DePinto, IT manager for Ce De Candy. “The Motorola enterprise mobility solution met our firm timing and budget requirements, increased our productivity, and improved data quality and process efficiencies, while providing the superior ruggedness that is essential in our warehouse environment.” Solution • Motorola Handheld devices & infrastructure • Manufacturing-driven control of inventory • Traceability – from “cradle to grave”
  14. 14. Driving Traceability in Produce Project: To trace tomatoes and other produce using RFID. Tags will be placed on produce boxes and pallets In the event of a recall, the state wants to be able to trace a product to the farm of origin and identity where inventories were sent, all within a few minutes. Hawaii Dept of Agriculture 1. Improve Quality and Freshness 2. Trace Product to Farm of Origin 3. Identify all Distribution Routes
  15. 15. Track & Trace (Traceability)
  16. 16. Asset Tracking (RFID Tray Tracking) Using trays with embedded RFID Chips and retro-fitting old trays with RFID Chips • Inside the ‘Four Walls’ • Track inventory within warehouse • Store batch data like expiration date • Outside the ‘Four Walls’ • Minimize Tray Loss • Track and charge customers that lose trays for trays’ cost • When using ‘Full Tray Product’ • Inventory transport and delivery trucks faster • Automatic ordering based on counts
  17. 17. WARNING Line 6! E-stop Pressed Marquee Manager Gateway for: • OPC • ODBC • RSLinx • FactoryTalk View SE • RSView32 • FirstPAGE Server • FirstPAGE Alarm Manager Server • Marquee Manager Server FirstPAGE Alarm Manager Gateway for: • OPC • ODBC • RSLinx • FactoryTalk View SE • RSView32 MOTOTRBO Radios The Solution Software Bridge from Plant Floor alarms & events to mobile devices and two-way radios STAFF COMMUNICATIONS ALARMS AND ALERTS WARNING Line 6! E-stop pressed
  18. 18. OPTIMIZING ACROSS THE ENTERPRISE Real Time Alerts Enterprise Wide Improvements Service, Productivity, Efficiency, Inventory, …more • Service Alerts • Order Submission • Inventory Allocation • Delivery Notification • Management Alerts • Competitive Activity • Pricing Updates • Inventory Visibility • Service Directives • Collections Notes • Promotion Approvals • More……. From and To all Mobile Users
  19. 19. 77% correlation between profitability and inventory turns 10% of the inventory value is the typical cost of carrying inventoryWAREHOUSE & DC - “Demand-Driven Inventory Optimization and Replenishment: Creating a More Efficient Supply Chain,” by Robert A. Davis, 2013 - “Inventory Optimization: Show Me the Money,” Supply Chain Management Review, July 19, 2011
  20. 20. NEW INNOVATIONS More capable devices and networks… Smaller: New categories of mobile devices are now possible to connect entire workforces Digital: Combined voice and data applications, with movement towards IP for interoperability Wearable: Superior ergonomics drive productivity, accuracy and data capture for traceability Modular: Hardware serving your micro-niche Browser-Driven: Flexible OS and UI capabilities RFID-Enabled: Passive data collection for visibility Service-Based: New procurement and pricing models ease burden and mitigate IT risks Touch-Centric: Expanding capabilities data input and rich visual rendering in touch-centric devices
  21. 21. PAGE 21 UPGRADE INBOUND HANDLING OPERATIONS • Speed up the flow • De-skill the workforce • Execute perfectly • Drive out waste PROJECTED FIVE-YEAR GROWTH OF MULTIMODAL VOICE AND SCREEN GUIDANCE BY 2018. %
  22. 22. EFFIENCY in Yard and Infrastructure Business Need (Trailer Tracking) 1. Large production facility with many trailers, yards, and dock doors 2. Resource intensive management involving all manual processes 3. Lack of real-time, actionable information for assets in the yard 4. Increasing distribution costs need mitigating strategy ROI Factors • Facilitate yard process redesign • Drive yard operational efficiency • Expand asset visibility beyond the 4-walls to the yard • Reduce manual yard checks • Reduced late, demurrage and detention fees Business Need (Operational Efficiency in Mobile Environment) 1. Enhance Inventory Accuracy & Warehouse Efficiency 2. Provide Wireless Backbone to Support Laptop Needs • Durability was Key – Moisture Resistant, High Heat • Cost, Proven Reliability and Strong Partnerships • Partner Experience in Site Surveys and Hardware Staging ROI Factors • ROI in 9 Months • 10% Labor Savings – Achieved Almost Immediately • Increased Visibility into Real-Time Production By Line • Reduced Truck Load Time
  23. 23. 50-70% of potential service revenue is lost because of poor record keeping and management $1BAverage revenue lost each year by consumer packaged goods companies due to out of stock conditions on the retail shelf. FIELD OPERATIONS - AMR Research, via Zebra Technologies “Improving Route Accounting with Mobile Printing Applications” - “A Comprehensive Guide To Retail Out-of-Stock Reduction In the Fast-Moving Consumer Goods Industry,” by Thomas W. Gruen, Ph.D., University of Colorado at Colorado Springs and Dr. Daniel Corsten, IE Business School Madrid 24 % Of manufacturers indicate that ‘increased customer service orientation’ is the most important transformation to their company’s future business success over the next 3-5 years
  24. 24. OUR SOLUTIONS ARE BUILT ON A DEEP UNDERSTANDING OF THE CHALLENGES YOU FACE IN YOUR FIELD OPERATIONS. FIELD SERVICE DIRECT STORE DELIVERY PRE SALES & MERCHANDIZING PROMPT SERVICE PROVIDED, FIRST TIME FIX COMPLETED Dispatch receives work order and reconfigures existing route plan. Technician schedules are adjusted based on proximity, expertise, and equipment availability so work can be completed promptly, protecting customer satisfaction and reducing cost to serve. SALES CALL COMPLETED, ORDER PROCESSED Sales representative previews new product with store manager, secures initial order and end cap placement. Also notes competitive pricing and ensures planogram compliance while on site. DELIVERY MADE, CUSTOMER INVOICED The route sales representative delivers the perfect order and replenishes the shelf. Billing is completed quickly and accurately. During stop, store manager mentions intermittent issue with one of the refrigerators, so sales rep opens up ticket with the field service team.
  25. 25. 1. OPTIMIZING SALES, DELIVERY, MERCHANDISING Signature Capture Personal Area Network “PAN” Image / Video Utilization Gained Productivity Sales Increases Best Practice Training Company Compliance Innovation in Image Capture & Scanning Decreased Costs…… Proof of Performance…….. Productivity WLAN-WiFiWWAN-Carriers + + Improved Revenue Decreased Costs Gained Productivity Gained Productivity Decreased Costs Improved Service
  26. 26. “Turn right onto East Avenue…” Route Optimization • Bread Crumbing • Geo-Fencing Asset Tracking • Geo-Coding • Goods localization Fleet Management • Telematics Seamless integration • GPS and Engine diagnostics • DOT and IFTA Reporting 2. Practical Use of Telematics, GPS, Location Based Services
  27. 27. 3. OPTIMIZING PRODUCTIVITY AND REVENUE RECOVERY Voice Recognition Gained Productivity Hands Free Capture PCI Compliant Platform Delivers New Savings Debit / Credit Payment Increased Sales Improved Revenue Hands Free Data Capture Gained Productivity Voice / Data Convergence Voice (Person to Person) Decreased Cost Gained Productivity
  28. 28. OPTIMIZING ACROSS THE ENTERPRISE Real Time Alerts Enterprise Wide Improvements Service, Productivity, Efficiency, Inventory, …more • Service Alerts • Order Submission • Inventory Allocation • Delivery Notification • Management Alerts • Competitive Activity • Pricing Updates • Inventory Visibility • Service Directives • Collections Notes • Promotion Approvals • More……. From and To all Mobile Users
  29. 29. Tools Rockwell Microsite: http://www.motorolasolutions.com/rockwellautomation
  30. 30. www.plantcalculator.motorolasolutions.com
  31. 31. CALCULATING THE ROI FOR A MOBILITY PROJECT Safety & Environmental • Soft and Hard Costs Time Savings • Hard Costs – Downtime • Soft Costs – Labor Productivity Equipment Savings • Hard Costs – Reconfiguration • Soft Costs – License Utilization Material Savings • Hard Costs – Scrap / Waste www.plantcalculator.motorolasolutions.com Investment Type Technology Investment Cost per Device $1,500 Wireless Coverage Cost per Plant $200,000 Other Upfront Costs (Software, Training, etc.) $57,500 Recurring Service Contract Costs per Device $250 Total 5 Year Investment $364,750 ROI in 3 months with Cost Reduction 5% In downtime resolution 10% In alarm troubleshooting time 5% less scrap per downtime event
  32. 32. BEST PRACTICES FOR REALIZING YOUR CALCULATED ROI Envision, Document, and Execute a Mobile Strategy • Engage Cross Functional Team Representing All User Groups Embrace the Opportunities for Nascent Solution Interfaces • Control Systems (PLCs) – Mobilize and Route Alarms and Alerts • Visualization & HMI – Operator Rounds, Maintenance Technicians • ERP / WMS / MES Systems – Inventory Management, Asset Tracking, Traceability Enhance ROI by Selecting Industrial Devices and Networks • Operations-Critical Solutions Built for Your Workflows & Environments • Size for Today and Tomorrow’s Voice and Data Communications Needs Explore Joint Solutions from Encompass Partners
  33. 33. BUILDING A CUSTOM TCO MODEL https://partnercentral.motorolasolutions.com/TCO
  34. 34. Motorola MFG Resources • Industry Week Webinar: http://bit.ly/plantmobility • MSI MFG Page: http://www.motorola.com/Business/US- EN/Business+Solutions/Industry+Solutions/Manufacturing • Rockwell/Motorola Microsite: http://www.motorolasolutions.com/rockwellautomation
  35. 35. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. We care what you think!  On the mobile app: 1. Locate session using Schedule or Agenda Builder 2. Click on the thumbs up icon on the lower right corner of the session detail 3. Complete survey 4. Click the Submit Form button 35 Please take a couple minutes to complete a quick session survey to tell us how we’re doing. 2 3 4 1 Thank you!!
  36. 36. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. PUBLIC INFORMATION Thank you for participating! Please remember to tidy up your work area for the next session. We want your feedback! Please complete the session survey!

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