Smart Manufacturing
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Smart Manufacturing - Basics , IoT, Digitalization, Big data, Analytics, Lean Production Guestlecture @Hochschule Aschaffenburg
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Smart Manufacturing
- 1. DXC Proprietary and Confidential June 28, 2017 Smart Manufacturing M. Sc. Lukas Ott Sommersemester 2017 Hochschule Aschaffenburg
- 2. June 28, 2017 2DXC Proprietary and Confidential Thrive on change CSC and HPE Enterprise Services brought innovation to clients for 60+ years Together, we serve nearly 6,000 private and public sector enterprises across 70 countries Our clients benefit from our technology independence, global talent, expertise and extensive partner network We are uniquely positioned to lead digital transformations, creating greater value for our people, clients and partners DXC Technology is the world’s leading independent, end-to-end IT services company. We guide clients on their digital transformation journeys, multiply their capabilities, and help them harness the power of innovation to thrive on change.
- 3. June 28, 2017 3DXC Proprietary and Confidential DXC Technology at a glance $25BGLOBAL IT SERVICES LEADER 250+PARTNER NETWORK WITH BEST-OF-BREED PARTNERS 60+YEARS OF INNOVATION EMPLOYEES WORLDWIDE 170,000+ 91DATA CENTERS COUNTRIES 70+ CERTIFIED PROJECT MANAGERS 3,600+37STRATEGIC DELIVERY CENTERS ~6,000CLIENTS 200+ Fortune 500 companies14 STRATEGIC PARTNERS
- 4. June 28, 2017 4DXC Proprietary and Confidential Agenda • Smart manufacturing • ISA 95 – Unternehmensebenen • Short Interval Technology (SIT) • Diskussionsrunde “Die Zukunft der Produktion”
- 5. June 28, 2017 5DXC Proprietary and Confidential Smart manufacturing • Big data processing • Advanced robotics • Industrial connectivity devices and services • Cyber Physical Systems
- 6. June 28, 2017 6DXC Proprietary and Confidential Smart Connected Manufacturing Three strategic options for digitalisation in manufacturing industries Expand the top line Connected Customer eXperience Defend the core Connected Operations Excellence Exploit the opportunities Connected Business Models Digital Industry Services marketplaces Product-as-a-Service new offerings Startup – Scaleup – Incumbent innovation networks Connected Product business ecosystems Physical & Digital (Value Networks) Product Development Manufacturing Operations Supply Chain Operations Service Chain Operations Manage Business Marketing and Sales Applications Knowledge Data-Driven Services “smart” Functions Core Product ++ Usability & Innovation (Customer Touchpoints) • Enhanced efficiency through greater automation • Customized products at the cost of a mass- produced product • Higher revenues from digitally refined products • Access to new markets • Leverage internet business platform scale and speed • Collaborate with digital natives Digital Factory Digital Logistics Digital MRODigital TwinDigital Customer
- 7. June 28, 2017 7DXC Proprietary and Confidential Gartner Hypecycle - Explained
- 8. June 28, 2017 8DXC Proprietary and Confidential Gartner Hypecycle – Manufacturing - 2016 On the Rise Blockchain/ Distributed Ledgers in Supply Chain Execution Cyber Physical Systems Cognitive Expert Advisors Digital Twin Talent Science Digital Business Smart Robots At the Peak Machine Learning Predictive Analytics IT/OT Convergence and Alignment Sliding Into the Trough Cloud Computing in Manufacturing Operations Supply Chain Execution Convergence Internet of Things for Manufacturing Operations Manufacturing Segmentation 3D Printing in Manufacturing Operations Supply Planning Synchronized BOMs Corporate Social Responsibility Industrial Operational Intelligence Asset Performance Management Climbing the Slope Center of Excellence Lean Production Systems Supplier Quality External (Third-Party) Manufacturing Operational Technology Security Digital Manufacturing Mobility in Manufacturing Operations Overall Equipment Effectiveness (OEE) Track-and-Trace and Serialization Manufacturing Network Design
- 9. June 28, 2017 9DXC Proprietary and Confidential Iron Triangle of quality
- 10. June 28, 2017 10DXC Proprietary and Confidential Iron triangle of production
- 11. June 28, 2017 11DXC Proprietary and Confidential Production as control loop Input (article, amount, date, quality, costs, etc.) ruler production measuring element disturbances (technical/ organizational) article, amount, date, quality, costs, etc. - Source 2: Die perfekte Produktion
- 12. June 28, 2017 12DXC Proprietary and Confidential ISA 95 – Enterprise layers Business Planning & Logistics Manufacturing Operations Management
- 13. June 28, 2017 13DXC Proprietary and Confidential ISA 88 – Batch Controlled Production Design patterns for software, assets and processes
- 14. June 28, 2017 14DXC Proprietary and Confidential Control loop with ERP-system ERP-system production manual confirmation (day / shift) - Source 2: Die perfekte Produktion Input (article, amount, date, quality, costs, etc.) disturbances (technical/ organizational) article, amount, date, quality, costs, etc.
- 15. June 28, 2017 15DXC Proprietary and Confidential Control loop with MES-system production MES-system data acquisition (real- time) ERP- system - MES-system Short-term. control - Short-term data Long-term data and evaluations, production acknowledgment Source 2: Die perfekte Produktion Input (article, amount, date, quality, costs, etc.) disturbances (technical/ organizational) article, amount, date, quality, costs, etc.
- 16. June 28, 2017 16DXC Proprietary and Confidential Automation pyramide ERP / PPS MES Automation Mid-term Real-time & technology Machine- level APS System control Source 3: MES- Fig1.2
- 17. June 28, 2017 17DXC Proprietary and Confidential Manufacturing techniques 1. molding (e.g. casting, sintering , 3D-printing) 2. forming (e.g. stamping, rolling, bending) 3. chopping (e.g. sawing, drilling, milling) 4. joining (e.g. welding, soldering, bonding) 5. coating (e.g. painting, varnishing) 6. change material property (e.g. hardening, tempering, baking, curing, annealing)
- 18. June 28, 2017 18DXC Proprietary and Confidential Job-shop manufacturing Examplary for one product A process 2 cutting process 1 pressing process 3 screwing process 6 painting process 4 process 5
- 19. June 28, 2017 19DXC Proprietary and Confidential Flow production process 2 cutting process 1 pressing process 3 screwing process 4 painting
- 20. June 28, 2017 20DXC Proprietary and Confidential Group manufacturing cuttingpressing screwing painting Group 1 Group 2
- 21. June 28, 2017 21DXC Proprietary and Confidential Make-to-Order / Engineer-to-Order Station B Cutting Station A Pressing Station C Screwing Station D Painting
- 22. June 28, 2017 22DXC Proprietary and Confidential Short Interval Technology • Lean Production (Schlanke Produktionsprozesse) • Manufacturing Execution System (MES) • Lean Planning (Schlanke Planungsabläufe) • Manufacturing Scorecard (Prozessorientierte Kennzahlen)
- 23. June 28, 2017 23DXC Proprietary and Confidential The weak points of classical production • to strong focus on individual processes • lacking transparency • lacking quality • lacking efficiency • exaggerated inventory • long cycle times • bad adherence to delivery dates
- 24. June 28, 2017 24DXC Proprietary and Confidential Individual processes – horizontal isolation
- 25. June 28, 2017 25DXC Proprietary and Confidential Functional level – vertical isolation
- 26. June 28, 2017 26DXC Proprietary and Confidential The building blocks for perfect production • clarification of status quo • lean production processes • lean information sequences • process oriented operating figures • Near real-time availability of information (data-centric approach) • Manufacturing Execution System • Advanced Analytics • OEE – Index = availability rate * performance rate * quality rate
- 27. June 28, 2017 27DXC Proprietary and Confidential Lean Production 1. over production 2. waiting time 3. transportation 4. inefficient processing 5. inventory 6. needless movement 7. errors Waste through lacking staff integration and motivation Waste through bad information interfaces
- 28. June 28, 2017 28DXC Proprietary and Confidential Increase of machine and factory productivity • 5S-methode • Seiri (sort out) • Seiton (adjust) • Seiso (clean) • Seiktesu (standardize) • Shitsuke (self-discipline) • Setup Time Reduction (SMED) • observe, measure and document • classify in internal and external tasks • eliminate unnecessary tasks • document and train
- 29. June 28, 2017 29DXC Proprietary and Confidential Increase of machine and factory productivity • Total Productive Maintenance (TPM) • removal of main focus issues • autonomous maintenance • planed maintenance • preventive maintenance • education and training of the staff • Optimization of the value stream • orientation on the customer pulse • introduction of flow production (One Piece Flow) • introduction of FIFO or KANBAN-supermarkets
- 30. June 28, 2017 30DXC Proprietary and Confidential Support of the continuous improvement processes
- 31. June 28, 2017 31DXC Proprietary and Confidential Target-oriented process improvement • focus on the overall process • increase of transparency • improvement of quality • increase of machine and workstation efficiency • reduction of inventory • reduction of cycle times • improvement of delivery dates • effective staff integration
- 32. June 28, 2017 32DXC Proprietary and Confidential Corporate management for data collection
- 33. June 28, 2017 33DXC Proprietary and Confidential Digital Twin
- 34. June 28, 2017 34DXC Proprietary and Confidential Production control as a control loop – detailed view
- 35. June 28, 2017 35DXC Proprietary and Confidential Integration of the software landscape into the company caption: CAD Computer Aided Design CAE Computer Aided Engineering CAM Computer Aided Manufacturing DIS Distribution DMS Document Management System ERP Enterprise Resource Planning FIN Finance MES Manufacturing Execution System NC Numerical Control PDM Product Data Management PLM Product Lifecycle Management PPS Product Planning and Scheduling
- 36. June 28, 2017 36DXC Proprietary and Confidential The integrated production database
- 37. June 28, 2017 37DXC Proprietary and Confidential
- 38. June 28, 2017 38DXC Proprietary and Confidential Interfaces with higher-level sytems
- 39. June 28, 2017 39DXC Proprietary and Confidential
- 40. June 28, 2017 40DXC Proprietary and Confidential Conflicting objectives in production planning Low set-up costs Constant capacity load utilization High degree of on- time delivery performance Low work in progress Individual goal
- 41. June 28, 2017 41DXC Proprietary and Confidential ORGANIZATION: Focuses on the people within the enterprise: their culture, their capabilities, their roles, their team structures, and their organizational units LOCATION: Specifies where the enterprise does business, both in terms of geographic location types and in terms of specific physical facilities at specific locations BUSINESS PROCESS: Addresses what the enterprise does, how it does it, in what sequence it does it, what rules it follows, and what type of results it obtains TECHNOLOGY: Identifies the hardware, system software, and communications components used to support the entire enterprise APPLICATION: Encompasses the capabilities, structure, and user interface of software provided to the business users DATA: Addresses the content, structure, relationships, and business data rules surrounding information the enterprise retains permanently P O L D A T Domains of Change in a Holistic Perspective
- 42. June 28, 2017 42DXC Proprietary and Confidential Diskussionsrunde „Die Zukunft der Produktion“ Einfluss von Maschine Learning
- 43. June 28, 2017 43DXC Proprietary and Confidential Outlook and abstract Smart manufacturing Short Interval Technology Future of manufacturing
- 44. June 28, 2017 44DXC Proprietary and Confidential Thank you! Questions? Feedback!
- 45. June 28, 2017 45DXC Proprietary and Confidential Sources • https://www.heise.de/newsticker/meldung/Adidas-Sohlen-aus-dem-3D- Drucker-fuer-den-Massenmarkt-3679027.html • Die perfekte Produktion, Springer Vieweg, ISBN 978-3-662-45440-4 • Manufacturing Execution Systems – MES, Springer, ISBN 978-3-540-49743-1 • https://en.wikipedia.org/wiki/Value_stream_mapping • https://en.wikipedia.org/wiki/Project_management_triangle • https://en.wikipedia.org/wiki/PDCA
- 46. © DXC 2017
Editor's Notes
- Volume, Velocity, Variety, Variability, Veracity, Visualization, and Value. Velocity Velocity is the speed in which data is accessible. I remember the days of nightly batches, now if it’s not real-time it’s usually not fast enough. Variety Variety describes one of the biggest challenges of big data. It can be unstructured and it can include so many different types of data from XML to video to SMS. Organizing the data in a meaningful way is no simple task, especially when the data itself changes rapidly. Variability Variability is different from variety. A coffee shop may offer 6 different blends of coffee, but if you get the same blend every day and it tastes different every day, that is variability. The same is true of data, if the meaning is constantly changing it can have a huge impact on your data homogenization. Veracity Veracity is all about making sure the data is accurate, which requires processes to keep the bad data from accumulating in your systems. The simplest example is contacts that enter your marketing automation system with false names and inaccurate contact information. How many times have you seen Mickey Mouse in your database? It’s the classic “garbage in, garbage out” challenge. Visualization Visualization is critical in today’s world. Using charts and graphs to visualize large amounts of complex data is much more effective in conveying meaning than spreadsheets and reports chock-full of numbers and formulas. Value Value is the end game. After addressing volume, velocity, variety, variability, veracity, and visualization – which takes a lot of time, effort and resources – you want to be sure your organization is getting value from the data.
- Basis der ISA 95 ist die ISA 88
- ISA 88 – Batch Controlled Production for software, assets and processes Norm für chargenorientierte Fahrweise
- Regelung mit ERP-System (Anwendungsmodule – SD (Sales und Distribution) , MM (Materials Mangment), Produktionsplanung (PP), QM, PS (Project System) , PM (Plant Maintenance))
- Regelung mit ERP-System (Anwendungsmodule – SD (Sales und Distribution) , MM (Materials Mangment), Produktionsplanung (PP), QM, PS (Project System) , PM (Plant Maintenance))
- Advanced Planning and Scheduling (APS) Automatisierungspyramide ISA-88 ISA-95 IEC-62264 Je nachdem ob Discrete Job-shop
- Wertstromdigramm – Value stream map
- Wertstromdigramm – Value stream map
- Lean Production ( Überproduktion, Wartezeit, Transport, Ineffiziente Bearbeitung, Lagerung, Überflüssige Bewegungen, Fehler) + Verschwendung druch mangelnde Mitarbeitereinbindung und –motivation , Verschwendung durch schlechte Informationsschnittstellen
- SMED (Single-Minute Exchange of Dies) – Single digit minute (less than 10 minutes) OTED (One-Touch Exchange of Die) “Maximize flexibility while maintanining productivity. „ - Jerry Hyouck Woo, Kim (DXC.technology) - 2017
- Unterstützung des kontinuierlichen Verbesserungsprozesses (KVP) PDCA-Circle
- Each area of activity in corporate management has a particular data collection method assigned to it which is also independetn of the others Avoid vertical isolation!
- SPC - Statistical process control NC – Numerical control
- RFC - Request for Comments
- OPC (object linking and embedding for process control)
- Venetzung – mit Cloud und Mobility Funktion – As a servivce Semantisch – Daten mit Bedeutung für maschinen verständlich machen ( Zukunft A.I. / Sprachassisten)