Manufacturing - IT

1. By Ajay V. Gangakhedkar
Manufacturing - IT

2. Ajay Gangakhedkar
• Started My Career as an Engineer
– Qualified in Instrumentation and Controls Engineering
– B.E. passed in 1991
– Licensed Professional
• 22 Years Work as an Engineer
– In Industrial Control & Automation
– Enterprise Automation, Optimization and Monitoring
Systems
• 2 Years Work as an Business Consultant and
Technical Advisor
– Various Product Companies
– Small Technology Start-ups
Ajay Gangakhedkar

3. Ajay Gangakhedkar
Today’s Presentation
• Few cents For Tomorrow’s Engineer
• About Manufacturing
• Manufacturing IT
• Use Cases
• Q&A

4. Ajay Gangakhedkar
Suggestion #1
“Find Your Niche – Specialize – Be Different”
• Become REALLY GOOD at Something!
– Specialists paid better than Generalists
– Value of extra-curricular Learning
• Internships, volunteering, projects…
• Follow what’s going on in the World
– Read Blogs, News, Trends…

5. Ajay Gangakhedkar
Suggestion #2
“Learn How to Work Hard”
• School is Easy
– Don’t develop Lazy or Sloppy Habits
– Build your Character and Habits NOW
• Get Good Grades
• If you can’t be a Good Student – Why would anyone
believe you will be a Good Employee?

6. Ajay Gangakhedkar
Suggestion #3
“Nobody Cares about Technology..”
• They Care about Benefits to the Customer
– Technology must be delivered through
Products and Services
• Price, Features, Ease of Use…
– Focus on the Customer/User
• Design Thinking – Product Design

7. Ajay Gangakhedkar
Suggestion #4
“A Rising Tide Lifts all Boats”
(“When the Wind is Blowing Hard enough even hens`
can Fly”)
• Need to know Trends and Spot
Opportunities
• Invest your Life like you would Invest your
Money (Pick a good career path)

8. Ajay Gangakhedkar
Suggestion #5
“Be Important to Someone”
(“Have a Great Mission”)
• Excite Yourself
• Excite Your Fellow Employees
• Excite Your Customers
• Excite Your Employers

9. Ajay Gangakhedkar
Suggestion #6
“Develop an Attitude”
• Knowledge
– Math, Physics, Dynamics, Statics…
• Skills and Competencies
– Problem-Solving, People Skills…
• Attitudes and Beliefs
– Empowerment, Internal Locus of Control, Goal
and Action Orientation, Positivity…

10. What is Manufacturing?

11. Ajay Gangakhedkar
Manufacturing Engineering
It is a discipline of engineering dealing with
various manufacturing sciences and
practices including the research, design and
development of systems, processes,
machines, tools, and equipment. The
manufacturing engineer's primary focus is
to turn raw materials into a new or updated
product in the most economic, efficient, and
effective way possible.

12. Ajay Gangakhedkar
Manufacturing Revolution
1. Industrial Revolution
Follows introduction of water-
and steam-powered
mechanical manufacturing
facilities
End of 18th century Start of 20th century Start of 1970s TODAY
Follows introduction of
electrically-powered mass
production based on the
division of labor
1784
First mechanical Loom
1870
First production line,
Cincinnati slaughterhouses
2. Industrial Revolution
3. Industrial Revolution
1969
First programmable logic
controller (PLC)
4. Industrial Revolution
Uses electronics and IT to
achieve further automation of
manufacturing
Based on cyber-physical
systems, new protocols
like MQTT/CoAP, and
RFID for product
identification
complexity
time
2014 -
Machine-to-Machine (M2M),
Product-to-Machine (P2M)

13. Ajay Gangakhedkar
The Product Design Process
Step 1 - Idea Development - Someone thinks of a need and a
product/service design to satisfy it: customers, marketing,
engineering, competitors, benchmarking, reverse engineering
Step 2 - Product Screening - Every business needs a formal/structured
evaluation process: fit with facility and labor skills, size of market,
contribution margin, break-even analysis, return on sales
Step 3 – Preliminary Design and Testing - Technical specifications are
developed, prototypes built, testing starts
Step 4 – Final Design - Final design based on test results, facility,
equipment, material, & labor skills defined, suppliers identified

14. Ajay Gangakhedkar
Product-Process Grid

15. Ajay Gangakhedkar
Intermittent VS. Repetitive Facility
Layouts

16. Ajay Gangakhedkar
Process Selection Considerations
• Process selection is based on five
principal considerations
1. Product-Process Grid
2. Degree of vertical integration
3. Flexibility of resources
4. Mix between capital & human resources
5. Degree of customer contact

17. Ajay Gangakhedkar
Process Decisions-Vertical Integration
& Make or Buy
• Vertical integration refers to the degree a firm chooses to do
processes itself- raw material to sales
– Backward Integration means moving closer to primary operations
– Forward Integration means moving closer to customers
• A firm’s Make-or-Buy choices should be based on the following
considerations:
– Strategic impact
– Available capacity
– Expertise
– Quality considerations
– Speed
– Cost (fixed cost + variable cost)make = Cost (fixed cost + Variable cost)buy
• Business are trending toward less backward integration, more
outsourcing

18. Ajay Gangakhedkar
Process Performance Metrics

19. Ajay Gangakhedkar
Selection
• Product design and process selection are
directly linked
• Type of product selected defines type of
operation required
• Type of operation available defines broader
organizational aspects such as
– Equipment required
– Facility arrangement
– Organizational structure

20. Ajay Gangakhedkar
Product and Service Strategy
• Type of operation is directly related to
product and service strategy
• Three basic strategies include
– Make-to-stock; in anticipation of demand
– Assemble-to-order; built from standard
components on order
– Make-to-order; produce to customer
specification at time of order

21. Ajay Gangakhedkar
21
Product and Service Strategy Options

22. Ajay Gangakhedkar
Flowchart for Different Product
Strategies at Antonio’s Pizzaria

23. Ajay Gangakhedkar
MANUFACTURING IT

24. Ajay Gangakhedkar

25. Ajay Gangakhedkar
Manufacturing IT systems and their
impacts
Market/ Customer
Requirements
Specifications Planning Policies
CAD/ CAM/ PDM
Std. Part Library
ERP
MES
OM Controls
SCM
Design Knowledge
Mfg. Knowledge
Machine Tools
Product Delivery
Service Delivery
Actual Production
Steps
Tool/ Equipment
Maintenance order
Manufacture Products

26. Ajay Gangakhedkar
ERP
Definition:
• ENTERPRISE RESOURCE
PLANNING(ERP) is a cross-functional
enterprise applications driven by an
integrated framework of software modules
that supports the basic internal business
processes of a company

27. Ajay Gangakhedkar
Before ERP
Vendor
Sales dept.
Demographic Files
Warehouse
Inventory Files
Accounting dept.
Accounting Files
Check
for
parts
“we
need
parts”
“we
ordered
parts”
Place order
Sends report
Ship parts.
Sends report
Call
back
“not
in
stock”
We
ordered
parts

28. Ajay Gangakhedkar
Components of an ERP
• Financial Management
At the core of ERP are the financial modules, including general ledger,
accounts receivable, accounts payable, billing and fixed asset management.
• Manufacturing Operations
Include product configuration, job costing and bill of materials management.
include Capacity Planning, Materials Requirements Planning, forecasting,
Production Scheduling, work-order management & shop-floor control
• Business Intelligence
BI tools allow users to share and analyse the data collected across the
enterprise and centralized in the ERP database.
• Human Resource Management
Modules can include payroll, performance management, time tracking,
benefits, compensation and workforce planning
• Integration
Key to the value of an ERP package is the integration between modules, so
that all of the core business functions are connected.

29. Ajay Gangakhedkar
With ERP
Vendor
Sales Dept. Accounting
Purchasing Dept.
Warehouse
Database
Ship parts
Invoice Accounting

30. Ajay Gangakhedkar
Benefits of ERP Implementation
• Eliminates the duplication, discontinuity and
redundancy in data
• Provides information across departments
• Provides control over business processes
• Increase Productivity, better inventory
management, promotes quality, reduced
material cost, boosts profits
• Better Customers interaction, increased
throughput, improves customer services

31. Ajay Gangakhedkar
PLM
Different marketing strategies -which will be
used in that system- should be applied
according to the product, environment,
competitor, the company’s position. All products
have a short term or long term life and new life
cycle starts from when this life ended up. That
cycle includes five steps.

32. Ajay Gangakhedkar
Main Components of PLM
• Data management
It enables appropriate stage for management. It provides information about
product features, bills of material, data distribution, project structure
• Program and project management
It’s about the process of developing a product. It gives information on
planning, management and checking.
• Cooperation
It supports project management and it relies on WEB standards which are
based on XML(Extensible Markup Language)
• Quality management
It provides an integrated quality management for each sector.
• Management of corporate assets
It directs equipment and physical assets

33. Ajay Gangakhedkar
Factors impacting PLM
Scale: Companies want to grow continuously.
Complexity: The diversity of product increases because of
product and the process of production.
Time of cycle: It’s important for competition.
Lean production: It’s about using less energy and material.
Global competition: The competition has increased
significantly.
The arrangements made by governments and
international agreements: It’s about environmental
degradation, work and arrangement of job security.

34. Ajay Gangakhedkar
PLM Software sub systems
• Product Portfolio Management (PPM)
• Computer Aided Design / Engineering /
Manufacturing (CAx)
• Product Data Management (PDM)
• Manufacturing Process Management (MPM)
• Digital Manufacturing (DM)

35. Ajay Gangakhedkar
Solutions of PLM
o PLM Solutions are organs. It has been developed for the
improvement of organization by IT
o Work to rely on customer
o Responding quickly to changing market conditions
o Shortening the duration of the market to offer new products
o Workflow that allows optimization of product
o Reduction in the cost of prototype
o Continuous innovation process and implement new
technologies effectively
o Reduction of waste
o Being in closer contact with customers and suppliers

36. Ajay Gangakhedkar
Advantages of PLM
 to simulate the developed model
 to design the product before the other companies
 to pull down the cost
 to save from time and energy
 to increase competitiveness in the world
 to create higher quality products.
 to launch new products in less time, at a lower cost.
 to understand what change really costs in terms of time and
money
 to control your production processes and not let them control
you.
 to increase profits and market share

37. Ajay Gangakhedkar
Business Systems
Plant Production Scheduling,
Operational Management, etc
Manufacturing
Operations Management
Dispatching Production, Detailed Production
Scheduling, Reliability Assurance, ...
Batch
Control
Discrete
Control
Continuous
Control
1 - Sensing of production work process,
manipulate the production work process
2 - Work unit (operation): Monitor, supervisory
control and automated control of the
production work process
3 - Work Unit and Flow Defined. Work flow /
recipe control produces desired end products.
Analyzes Work Data, Maintains records and
optimizes the production process.
Time Frame
Days, Shifts, hours, minutes, seconds
4 - Establishes the basic plant schedule -
production, material use, delivery, and
shipping. Determines inventory levels.
Time Frame
Months, weeks, days
0 - The actual production work process
MOM/ MES

38. Ajay Gangakhedkar
Use Case..
• If an operator in a food or pharma plant
makes a mistake that causes injury or
death to a CUSTOMER…
• … the CEO is implicated!

39. Ajay Gangakhedkar
How many times do such events
happen?
Quite regularly
Very Rarely

40. Ajay Gangakhedkar
Perfetti Van Melle makes
Alpenliebe in large numbers…
In one batch, they decide to make
STRAWBERRY Alpenliebe..
The chances of CHOCOLATE getting into a
STRAWBERRY batch is…
Quite high
Negligible

41. Ajay Gangakhedkar
Now…
Production is switched between
CHOCOLATE and STRAWBERY, multiple
time every day…
The chances of CHOCOLATE getting into
the STRAWBERRY batch is…
Quite high
Negligible

42. Ajay Gangakhedkar
Some packs of a ‘popular’
Brand were found with worms

43. Ajay Gangakhedkar
Now..
• ... ALL ITEMS belonging to
• ... ALL BATCHES of
• ... ALL INGREDIENTS
• of the DEFECTIVE BATCH need to be
OFF THE SHELVES OF ALL STORES...

44. Ajay Gangakhedkar
… Within 48 hours!
• What are the chances that a manufacturer
can achieve this?
Quite high
Negligible

45. Ajay Gangakhedkar
We NEED Traceability
• Rapid sense and respond to problems
– Incoming part/ material/ product quality
– Manufacturing defects
– Feedback from warranty data and
consumer related reporting
• Need to root cause the problem – need
supplier data: serial number, lot number, etc.
• Government mandates
• Continuous improvement

46. Ajay Gangakhedkar
Maintain world Class Product
Standards
Avoid expensive Manufacturing Errors,
in the face of RAPID change
Recover from a Manufacturing fault
with minimal damage
It can be achieved by enabling
Organization to:

47. Ajay Gangakhedkar
By Developing Manufacturing
Application Framework
Company
Production
Canonical Schema
Information
Data Model,
Objects and
Definitions
Domain
Definitions
Metrics
Construction
Categories for
Information
Analytics
Functional Segregation
& Metrics
by Scenarios and Domain
Functions &
Data Flows
of Interest
Supply Chain & Mfg.
Scenario & Metrics
Manufacturing
Use Case
Metrics
Customer Supplier
ProcessPurchaseOrder
AcknowledgePurchaseOrder
ShowDeliveryReceipt
ProcessInvoice
ConfirmBOD
Use Cases and
Transaction Set
Construction
QA
Service
R&D Inbound
Logistics
- Mfg.
Ops.
Production
Package
Inputs
(Supplier)
Conversion
(Mfg.)
Distribution Consumer
Material
Prep
Out-
bound
Logistics
Mkting
& Sales
Assembly

48. Ajay Gangakhedkar
And Establishing Levels of
Interoperability
Standardized
Externally
Standardized
Internally
Published
Available
Defined
Repeatable
Not Defined.
Are the procedures for this system
shared across …
Maturity
0
1
2
3
Procedure
Scale Scope
Value Chain
Enterprise
Business
Unit
Site
Area
Unit, Line,
Cell, etc.

49. Ajay Gangakhedkar
Interoperability Maturity Model
Framework scopes connectivity to applied to Logistics and
Operations Systems
Maturity Level
Environment
Interoperability Attributes
P
Procedure
A
Applications
I
Infrastructure
D
Data
Enterprise
Level
( Universal)
4
C Standardized Externally Common Concepts Standard
Communications
Common Model
B
A
Domain
Level
( Integration)
3
C
Standardized Internally
Common Views Standardized Protocols Synchronized
Information
B
A
Functional
Level
(Distributed)
2
C Published Integrated User
Interface
Standard Transport
Disparate Formats
B Available
A Defined
Connected
Level
(Peer-to-Peer) 1
C Repeatable
File Import and Export
Proprietary or simplistic Simplistic and
limited
B
A
Isolated
Level
(Manual) 0
C Not Defined. No Commonality Removable media Closed
B
A
Increasing
Maturity

50. Ajay Gangakhedkar
Maturity Level
Environment
Interoperability Elements
Procedure Applications Infrastructure Data
Enterprise
Level 4
Standardized
Externally
Common
Concepts
Standard
Communications
Common
Model
Domain
Level 3
Standardized
Internally
Common Views Standardized
Protocols
Synchronized
Information
Functional
Level 2
Published Integrated User
Interface
Standard Transport Disparate
Formats
Available
Defined
Connected
Level
1
Repeatable File Import &
Export
Proprietary or
simplistic
Simplistic and
limited
Isolated
Level
0
Not Defined. No Commonality Removable media Closed
MES Core Value
Common …
• Data Model
• User Interface
• Access Methods
Common
Model
Enabled By Data
Model
Consistent
Approach
Browser, Portals,
etc.
This is Just the Manufacturing Intelligence Element of MES
The Appeal of MES Coincides
with Motivations

51. Ajay Gangakhedkar
Set of Implementation
Standards
Processes Documents
General
Standards
Delivery
Physical Transport
Terminology and Models
Discovery
and
Management
Interfaces
Architecture
Messages
Speak the Same
Language
Information
Semantics
Information
Exchanges
Isolate Infrastructure
and Technology
Play by the Same
Rules
Automated
Discovery
For example
XML

52. Ajay Gangakhedkar
System Function Segregation &
Interoperability
Level 2: Plant Work
Maintenance Production Quality Test Inventory
Production
data
collection
Production
execution
Production
resource
management
Production
dispatching
Production
tracking
Production
Performance
Detailed
production
scheduling
Production
Schedule
Product
definition
management
Production
performance
analysis
Production
Capability
Product
Definition
Maintenance
resource
management
Maintenance
Response
Detailed
maintenance
scheduling
Maintenance
Request
Maintenance
definition
management
Maintenance
Capability
Maintenance
analysis
Maintenance
Definitions
Maintenance
data
collection
Maintenance
execution
Maintenance
dispatching
Maintenance
tracking
Inventory
resource
management
Inventory
Response
Detailed
inventory
scheduling
Inventory
Request
Inventory
definition
management
Inventory
analysis
Inventory
Capability
Inventory
Definitions
Inventory
data
collection
Inventory
execution
Inventory
dispatching
Inventory
tracking
Quality
analysis
Quality
test resource
management
Quality Test
Response
Detailed
quality test
scheduling
Quality Test
Request
Quality
definition
management
Quality Test
Capability
Quality
Definitions
Quality
test data
collection
Quality test
execution
Quality test
dispatching
Quality test
tracking
Manufacturing Application (Use Case) Framework (MAF)
System Architecture Must Support Continuous Improvement
Must Allow Change in Production Processes
Clear demarcation of MOM / ERP+ responsibilities & functions
Level 4+: Extended Enterprise

53. Ajay Gangakhedkar
USE CASES

54. Ajay Gangakhedkar
Achieve Business Objectives

55. Ajay Gangakhedkar
Information flow @ Business tier
CRM
ERP
SCM
Demand
Specifications
Inventory
Status
Product
Specifications
Part
Orders
WIP
Status
Order
Status
Product
Engineering
Product
BOM
Process
Plan
Product
Order

56. Ajay Gangakhedkar
Information flow @ Production
tier # 1
ERP Product
Specifications
Product
Engineering
Product
BOM
Process
Plan
Product
Order
Production Schedule
Manufacturing BOM
Manufacturing Orders
Resource Requirements
Tooling
Design
MES
Tool usage
Instructions
Process
Plan
Process Change
Request
Production Status
Product Genealogy/ Inventory/ Cost
Tool/ Equipment
Maintenance order

57. Ajay Gangakhedkar
Information flow @ Production
tier # 2Product
Specifications
Product
Engineering
MES
Tool usage
Instructions
Process
Plan
Process Change
Request
Controls
Control
Set-Points
Equipment
Operation Instructions
Process
Status
Control
Program

58. Ajay Gangakhedkar
Typical Mfg. –IT Systems Scene
I
Measures
•Welding Current
•Contact Tip Voltage
•Joint Geometry
•Pool width, shape
•Arc Sound
Controls
•Power Supply Voltage
•Wire Feed Rate
•Torch position
•Travel Speed
Receives:
•VIN
•Operation Instructions
Tracks – Barcode/ RFID:
•VIN
•Matches with received info
Issue Instructions:
•Start (RC, WC)
•Start (PLC)
•Operational mode
•Welding Current Set-Point
•Welding Program No.
•Robot Program No.
Update Status:
•Safety Interlocks OK
•RC, WC Ready
•Robot in Operation
•Welding Current
•Manual Intervention
•Max Life reached
•Welding Error
•Emergency Off
•E.O. Sequence
MES Server
Line SCADA
Cell Controller
Weld Controller
Robot Controller
Barcode/ RFID

59. Ajay Gangakhedkar
Typical Mfg. –IT Systems Scene
II
MES Level
ERP Level
MES
Masterdata
ERP
Masterdata
Customer Order
Supplier
Vehicle
Explosion
Model Mix
Planning
Customer Order
Management
Scheduling &
Disposition
Outgoing EDI Call Off
Order
Management
MES
Order
Release
Vehicle Documentation: Vehicle Card, Quality Management, SW Management
Goods Receipt
PLM
PDM
Sequencing
Production
Order
BoM
BoM
Explosion
Sequencing
Assembly
Order
Order
Management
Assembly Order
Management
Inventory
Management
Consumption
Backflush
Pre Assembly
Order
Order
Management Pre Assembly
Order
Management
Material
Supply
Quality
Order
Line
Design
Scheduling
Plant Level
Central or Plant Level
Body Shop Paint Shop Pre Assembly
l l l l l l l l l l
Final Assembly

60. Ajay Gangakhedkar
 Work Order
Execution
Data Collection
Labor Collection
 Personnel
 Training
 Qualification
 Accountability
 Maintenance
 Disposition
 Purchasing
 Supplier Quality
 Scheduling
 Inspection Plans
 Defect Tracking
 Project Planning
 Production
Planning
 Scheduling
 Inventory
Tracking
 Process Planning
 Instruction Authoring
MES
QA
CAPP
Supplier
Mgt
ERP
HR
Shop Floor Systems
Asset
Mgt
T&A
ERP/SCM Systems
Engineering Systems
Labor Reporting
Systems
 Eng Documents
 Eng BOM
CAD Models
Images
Change Mgmt
Generic Manufacturing Business Functions
PLM

61. Ajay Gangakhedkar
Manufacturing Overview –
EAF/LF/CCM
• Furnace charging
• Melting
• De-Slagging
• Tapping
• Reheating of liquid steel
• Homogenization of steel
temperature
• Achieve the desired chemistry
• Wire Feeding
• Desulphurization
• Quality Decider
• Controlled Casting
• Spray Cooling
• Slab Cutting
Electric Arc Furnace
Ladle Furnace
Continuous Caster

62. Ajay Gangakhedkar
Manufacturing Overview Rolling
Mills
62
• Hot Rolling
• Pickling
• Cold Rolling
• Annealing
• Galvanizing
• Slitting
Rolling Mill

63. Ajay Gangakhedkar
63
Source: 2020 Future Value Chain: Building Strategies For The New Decade - http://www.futurevaluechain.com/downloads/

64. Ajay Gangakhedkar
Why the Plant Floor Is So
Important…
Source: AMR January 2000
Highest quality
(Brand image)
Business Drivers
Lowest cost
Increased “ agility ”
(Product availability)
Expanded customer base
Effective New Product
Development
Reduced costs of
compliance
Highest margins
Reduce variability
Eliminate
production waste
Production
Produce to schedule
Time to first packaged
batch in control
Conformance to
cGMP,HACCP ,SOP
Control Costs
Produce to spec. /
manage change
Customer order &
product specification.
Eliminate SC waste
Delivery to schedule
Supply Chain
Time to peak sales
Regulatory
compliance
Optimize supply
chain costs
Fulfilled order /
satisfied customers

65. Ajay Gangakhedkar
Different Focus  Different
Systems
• MES and ERP were designed to solve
different problems
• Purpose
– ERP provides the means to make better
business decisions
– MES systems allow for faster, more efficient
and controlled plant floor activities
• Level of Granularity/Speed
– Protean cares about resource management
and activities for business reasons.
– MES systems require highly detailed process

66. Ajay Gangakhedkar
Area of Influence
Controls, Sensors & Field Devices
Automation & Control
Manufacturing Execution
CRM SCM
E-Business
Process
ERP
Information
Overlap
ERP area of
influence
MES area of
influence

67. Ajay Gangakhedkar
Reality says…
Controls, Sensors & Field Devices
Automation & Control
Manufacturing Execution
CRM SCM
E-Business
Process
ERP
ERP area of
influence
MES area of
influence
Mind The Gap

68. Ajay Gangakhedkar
Process ERP
PRISM ®
The Reality is…Islands of
Information
MES

69. Ajay Gangakhedkar
Financials & Corporate
Receiving RM Whse FG Whse Shipping
Production
Purchasing Customer Order
Management
Scheduling
Planning
Quality, Maintenance & Costing
…the Missing Link to Profitability
Islands of Information…Where to integrate?
Customer Calls:
New campaign =
change in demand
Do I have
it?
No
Will I have
it?
No
Can I make
it?
Yes!
Customer Order
Fulfilled!

70. Ajay Gangakhedkar
CONTROL
What do you need to manage?
ERP
Production
data
collection
Production
execution
Production
resource
management
Production
dispatching
Production
tracking
Detailed
production
scheduling
Production
schedule
Product
definition
management
Production
Performance
analysis
Product
definition
Production
capability
Production
performance
 WHAT and HOW to produce
 What CAN be produced
 When and What TO produce
 When and What WAS produced
Product Definition
Production Capability
Production Schedule
Production Performance

71. Ajay Gangakhedkar
© Siemens A&D 71
ISA 95.00.03 defines Production Operations
Production
data
collection
Production
execution
Production
resource
management
Production
dispatching
Production
tracking
Production
performance
Detailed
production
scheduling
Production
schedule
Product
definition
management
Level 2 Process Control
Production
Performance
analysis
Production
capability
Product
definition

72. Ajay Gangakhedkar
Wish List of - Iron Ore Mining
Enterprise People
Need to integrate mining
planning and plant control
applications by defining the
organizational standards
Tech. Service Manager
Spent half of the time in copying,
agreeing and crunching the
numbers on daily basis
Accountant
Unable to clearly define how our
systems enable business
processes and how to
communicate the scope of
projects in a way it creates
business ownership
CEO
Need a single site reporting
structure and system to avoid
continuous inter departmental
fight and argue over numbers
Maint. Supervisor
How to establish governance
processes and vendor
performance management if I
don’t want which mines to
manage
Com. Manager
Need a support on vision and a
future roadmap to get there and
achieve a reliable project plan
that should be flexible enough
to manage the actions in small
chunks
MES Manager

73. Ajay Gangakhedkar
Iron Ore Mining Industry current
Issues
1. Skills shortage and Resource nationalism
2. Industry and related application consolidation
3. Infrastructure access
4. Maintaining a social license to operate
5. Access to secure energy
6. Increased regulation and Climate change concerns
7. Pipeline shrinkage
8. Capital management and Price and currency volatility
9. Sharing the benefits
10.Fraud and corruption
7
3

74. Ajay Gangakhedkar
Mining Supply chain
Location &
Valuation
Mining &
Transportation
Operations
Stabilization &
Retirement
Key Players Mine
Explorers
Mine Operator
Contract Miner Or
Mine Operator
Mine Operator
Key
Activities
• Data
Acquisition
• Ore Body
Modeling
• Pre-Feasibility
Study
• Feasibility
Study
• Environmental impact
assessment
• Regulatory approvals
• Logistics
management and
material tracking, and
weighing
• Material Quality
checks
• Facility Management
(incl. Barcode/ RFID)
• Crushing, Grinding,
Flotation, Smelting,
and Refining
Operations Control
• Safety standards
compliance for
deployed systems
and operators
• Market projection of
the material produced
• Optimization of the
overall plant
operations
• Operator training and
Certifications
• Production and Plant
Maintenance KPI
Tracking
Mining Phases
Onsite Supply
Chain

75. Ajay Gangakhedkar
Process flow of Iron Ore
The objectives of the PACS services in Mining sector are to:
1. Provide a framework for meaningful, sustainable dialogue between the Business
Operations, Maintenance and Engineering IT community
2. Equip managers to take control of existing systems deployed systems and related assets
and understand their contribution to business need
3. Create a framework for allocating accountability and ownership for business systems and
Production data
4. Build an understanding of where business information resides within the organization's
systems environment and to integrate the Business process and the Engineering IT
landscapes
5. Provides a manageable basis for managing the current deployed assets in provide value
added services on the existing spend

76. Ajay Gangakhedkar
(i) What is Internet of Things
IoT senses and identifies the physical world
via sensing technology and intelligent devices,
performs computations, processing and
knowledge mining through networking,
realizes interaction between people and
things, things and things, achieves real time
control of the physical world, precise
management, and scientific decision makings.
IoT involves sensing, networking, processing,
security, and covers sensors/nodes/gateways,
RFID, embedded systems, telecommunication
equipment manufacturing and operation,
software development and integration, and
application services.
IoT can also be divided into four aspects: sensing,
transferring, reasoning, controlling.
Intelligent
card
sensor actuator RFID 2D code
medical
facilities
car
mobile PC
Electric
Appliance
Electric
Identify
Intelligent
Electric Meter
IoT Gateway
IoT Gateway
Application
Integrated
Cloud
computing
Parsing
Service
Network
management
Web
service
IoT
applications
middleware
Internet
telecommunicati
on
Private
network
Application
layer
Network
layer
Sensing
layer