L&T Valves - Digital Valves & Processes

Valve World Americas Conference 2019
DIGITAL VALVES & PROCESSES
MOHANDAS
L&T VALVES

Digital
Wheel
Smart
Team
Smart
Valves
Smart
Docs
Smart
Shop
Smart
Sales
Smart
Service
DIGITAL WHEEL

SMART SHOP

Initiative 1 - Digital Manufacturing
• Control machines based
on parameters using IoT
• Monitor labor using
RFID
• SPEED tool for Production
Planning & Supply chain
• Supplier integration web
portal
• CMG process automation
• Digital Traveler card (Barcode
& RFID enabled)
• Visual display terminals
• Work plan & instructions
• Stores visual enablement
Processes Digital
Interface
Men &
Machines
Supply chain & Prd.
planning
digitalization
Shop floor
digitalization
IT enabled project
execution
Digital Manufacturing

Manufacturing – Conventional Way
Physical receipt of Material
GRN & QC acceptance of material
Material request & material issue
Assembly
Testing & TPI offering,
Painting & dispatch

Material Receipt from Vendor
Metal barcode affixed on the castings
received & QC acceptance by barcode
scanning
Sending & receiving from Sub-contracting
through barcode scanning
Store components in SAP assigned locations
by scanning barcode
Castings
Manufacturing Management with Digital Interface
BOF
Creation of Production order &
AMR in SAP
Material issue along with TRC by
scanning barcode on material (for
castings) & location barcode for
BOF components

Component verification through
tough pad
Assembly of valves with GAD/
Procedures displayed in terminals
linked with SAP
Uploading testing specification to
automated test stand through RFID
SCN posting & TPI inspection
confirmation through RFID device
Grid blasting & painting stage
completion through RFID device
Painting inspection confirmation
through RFID device
Packing completion & packing
inspection through RFID device
Manufacturing Management with Digital Interface

8Sales Engineering SCM
Product
Group
EBOM
Release Plan
Procurement
Plan –
Castings
Production
Plan
Dispatch
Plan
Integrated
Planning
Prepare Project Plan (backward scheduling) – Deadline for each milestone
To achieve OTD
Project
Tracking
Monitor Progress – Weekly
Catch up / Lead Time Reduction plan (Initiate & Implement)
GAD
Approval
Plan
Procurement
Plan - Actuators
Order
Approval
Order book Lead Time Norms
Planning
SPEED –
Customized backward-scheduling based PMP tool

SPEED – SAP enabled Project Management tool to Enhance Excellence of Deliverables
Highlights
 Clearly defined stages & work flow driven
 Deterministic demand to specific orders
 Continuous review for activity completion
 Effective project management for order completion
 Lead-time is consistent
 Easy to forecast
 Milestones set upfront at the start of the project

IT enabled Production Planning, Scheduling & Monitoring
• Weekly & daily production plans are finalized based on
SPEED plan
• Firm daily production plans are communicated through
digital displays in the respective cells & in the stores
• Actual production with respect to the targets - monitored
online & displayed

SMART DOCS

Valve Tracking - RFID
– Application:
• Hand held mobile application developed using
.Net
• Integration with SAP ERP ECC 6.0 using Web
service
– Hardware:
• Motorola MC919Z
• Mount on Metal Tags
– Key stakeholders
• QC, Central service & Customers
Physical tracking of valves as they pass through various
manufacturing process / stages.
– RFID tag for FG
Information to analyze and improve process
– Stages completion status
– Time spent at each stage
Process sync with current SAP order execution
transactions
Customer will know the valve details & QC related
documents.
Core objectiveOverview

Valve Tracking – Methodology
Wireless Access point
RFID Reader
(Handheld Computer)
RFID Tag
Valve
@ Customer Site
OmniDocs

Valve Tracking – RFID Tag
 Works on Radio Waves
 Having its Chip (I-Code SLIX) conforming to ISO/IEC 15693
 Easy to attach – Screwed or Stick type
 Operating Frequency  13.56 MHz
 Operating Mode  Passive (No in-built Battery)  Power supplied by Reader
 Operating Temperature  -25°C to + 85°C…Reach out to us for other environments
 Best covering range – 2 to 3 meters between RFID Reader & RFID Tag
 Rugged construction – Write Endurance of 100,000 cycles
 Highly Durable with Ingress Protection (IP 68)
 Flexible to Read / Write  Data Retention of 50 Years

Valve Tracking – RFID Reader
 Recommended Devices – Motorola Hand held Computers - MC9190 &
MC65 Series - Costing ~ 4,000 USD
 Customers to buy
 Highly Durable with Ingress Protection (IP 64)
 A tough, non-glare LCD screen allows for optimal reading in bright sunlight
and worry-free glass protection in rugged use
 Operating Temperature  -25°C to + 50°C

Valve Tracking System - RFID
Column Heading Description
Valve Sr. No. Valve Serial number
Sal. Ord. No. Sales order number
Sal. Item No. Sales item number
Mat. Desc. Material description
Cust. Code. Customer code
Cust. PO No. Customer PO Number
Tag No. Tag number
Customer Customer Name
IRN IRN
SRN SRN
Comp. Name Component name
Heat No. Heat Number
MPI No MPI Number
XRAY No XRAY Number
DPI No DPI Number
Vendor. Vendor
Documents Display QC documents for valve (Test Reports, GAD)

SMART SERVICES/
WEARABLE TECHNOLOGY

• L&T Valves found a unique application of wearable technology for the valve industry
• Customers can view our plant from their own offices via
employees wearing smart glass at our factory
• Inspection of manufactured valves – a critical requirement
in the valve industry – could now be done remotely by the
customer realizing cost savings in terms of travel/Third
Party inspectors
• Safe for the employees compared to camera which is obstructing the view; smart
glass keeps the background completely visible as per transparency settings
• Cost effective solution – costs around $1300 and may get cheaper as it gains
popularity
• We are now able to offer plant tours and audits to potential customers by proving
our manufacturing capability live over the wearable technology
Smart Glass – Wearable Technology

About the Smart Glass
Hardware
• EPSON – Moverio BT-350 Model
Software
• Brochesia

How it works
• Smart glass is worn by our users at factories. There is camera and
microphone in built in the smart glass.
• We provide login credentials to remote users (their email ID and a
password)
• The remote user clicks on link https://lntvalves.brochesia.cloud
• Once the remote user logs in, she or he can call any of our smart glass
users. The smart glass user has to accept the call. Alternately, the smart
glass user can call the remote user if the remote user is logged in.
• The remote user can see the factory on their laptop screen through the
camera in the smart glass and also hear the smart glass user through
the microphone on the smart glass.
• The remote user can be viewed by the smart glass user if the remote
user turns his webcam on and speak with remote user through his
laptop’s microphone.

SMART PRODUCTS

22
SMART VALVES - Ecosystem
“Valves That Add Values”

23
SMART VALVES
Cloud Solutions
Non-Cloud Solutions

24
SMART VALVES – Cloud Solution
Focus Areas – Critical, Hazardous & Remote Applications

25
Entry to Smart World

26
Smart Valve – Non-Cloud Solutions
Upstream PT
Downstream PT
Cavity PT
Gland Leak PT
4-20mA
4-20mA
4-20mA
4-20mA
4-20mA
Torque
Sensor
4-20mA
L&T
Applicatio
n
ModbusTCP
AMS
Application
T810
Modbus RS485
WirelessHAR
T
Gateway
Wireless
Hart
Repeater
Ex-Proof Enclosure
Battery
L&T
Gatewa
y
Ex-ProofEnclosure
SolarPanel

27
Intelligent Valves

28
Intelligent Valves

29
Road to Prescriptive Management

30
Thank You

L&T Valves - Digital Valves & Processes

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