This document contains summaries of three case studies of companies using Internet of Things (IoT) and Internet of Everything (IoE) solutions to improve their manufacturing operations: 1) Stanley Black & Decker gained better production visibility and transparency, reduced labeling errors, and improved labor utilization by leveraging Cisco WiFi and AeroScout RFID tags. 2) Harley-Davidson increased flexibility to adjust production levels using a converged plantwide Ethernet architecture from Rockwell Automation and Cisco that improved troubleshooting times. 3) Sub-Zero Wolf accelerated new product development, reduced downtime costs, and saved over $40,000 annually in travel costs through video collaboration solutions to improve design, production,

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capturing knowledge
for my transitioning workforce
I need to achieve
How can
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improve
improve
workforce
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introduce new
products faster?
How do I achieve
How can I
better manage my
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Stanley Black and Decker
 Get better transparency of real-time
production to schedule
 Dissect why actual labor costs
exceeding standard costs
 Need to understand effects of shift
changes
 Gain better visibility to real-time OEE
 Leverage Cisco WiFi in the plant
 Combine with AeroScout RFID tags
 Integrate RFID Tags to PLC to
Quality Scale
ResultsChallenge Solution:
“With the help of the Cisco and AeroScout Industrial solution, we are on our way
toward realizing our vision of a virtual warehouse and fully connected factory, with
complete visibility and traceability.”
-Gary Frederick,
CIO Industrial Division, Stanley
Toolmaker improves operations with IoT
External
 24% in OEE improvement in
router tool line
 Reduced labeling error rate by
16%
 Improved labor utilization from
80 to 92%
 Reduced inventory holding costs
by 10%
Customer Validated Bus. Outcomes

3. Cisco Confidential 5C97-731884-00 © 2014 Cisco and/or its affiliates. All rights reserved.
Harley-Davidson
Retooling for High Productivity and Flexibility with IoE
 Harley-Davidson moved to
reduce costs and increase
efficiencies
 Hundreds of motorcycles
built each shift, with low
cycle time per operation
 Manufacturing complexity
with 1200 different
configurations
 Deploy Allen-Bradley Stratix
8000 Series Switches
 Rockwell Automation I/O,
power supply, programmable
controllers, and complete
suite of solutions
 Deploy Cisco Unified
Wireless
 Deploy Visual Manufacturing
 An end-to-end Converged
Plantwide Ethernet
Architecture that enabled
Harley-Davidson to achieve
its goals of world-class
manufacturing
 Factory automation and
digital media solutions
increased flexibility to quickly
increase or cut production
ResultsChallenge Solution
“What used to take hours or days to triage and troubleshoot problems now takes seconds.”
David Gutshall
Infrastructure Design Manager, Harley-Davidson Motor Company
Customer Validated Bus. OutcomesExternal

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Sub-Zero Wolf
 Meet launch schedule for 60 new
products
 Adhere to stringent quality
requirements and manage issues
from new supply-chain partners
 Increase staff productivity time and
collaboration while reducing travel
and costs (engineering was not in
same location as manufacturing
 Integrated manufacturing mobile
video capabilities into daily
workflows and processes
 Upgraded wireless networks to
support mobile devices and video
streaming and conferencing within
manufacturing facilities
 Integrated solution into existing
video infrastructure and tools
ResultsChallenge Solution:
“With this solution, we found a way to see and discuss very detailed video and images
from afar in a highly secure manner. We are now using video collaboration on a daily
basis to finalize designs, correct production line issues, work with suppliers, and train
installers and servicers.” -Paul Sikir
VP of Engineering
Premium Appliance Manufacturer Innovates with IoE
External
 Shaved 10-20% off new product
introduction cycle time
 Estimated internal savings in
downtime costs of $2,500 per
production line per hour through
faster resolution of design or
manufacturing issues.
 For one project, Sub-Zero
estimates an annual travel savings
of more than $40,000.
 Over $100,000 savings in field
testing costs.
Customer Validated Bus. Outcomes

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