Manufacturing Process Traceability With Apache Apex Roshan Kulkarni, Mindstix Software Labs
Apr 12, 2017
Manufacturing Process TraceabilityWith Apache ApexRoshan Kulkarni, Mindstix Software Labs
© Mindstix Labs 2017
Product RecallsToyota Motor CompanyMarch 30th 2017, ~2.9 Mn Vehicles, Faulty Airbags
Ford Motor CompanyMarch 29th 2017, ~440K Vehicles, Coolant Leaks, Fire Risks
NissanMarch 25th 2017, ~56K Vehicles, Power Steering Fluid Leak
Hyundai MotorsMarch 16th 2017, ~1 Mn Vehicles, Seat Belt Glitch
Why Recalls?
Product ConcernsManufacturing Defects, Safety Issues, Customer Endangerment
Legal ImplicationsStronger Consumer Protection Laws, Federal Investigations
Voluntary RecallsPerceived Exposure to Liabilities, Brand Credibility At Stake
Cascading Effects of A Global Supply ChainComplex BOMs, Nature of Global Sourcing
© Mindstix Labs 2017
Deep Financial Impact of Recalls
The Real Costs of Recall
Cost of Reverse Logistics
Direct Repair Costs
Cost of Litigation
and Settlement
Loss of Brand ValueSafe
Disposal of Faulty Parts
Replace’nt Units
Customer Comp’sn
or Full Refunds
Lost SalesEvery year, warranties and recalls cost the
global automobile
industry nearly $40
Billion…
© Mindstix Labs 2017
A Stark Reality Across VerticalsVerticals Examples
Automobile 2016Takata Airbags, 100 Million Units, $1+ Billion in Settlements
Food and Beverage 2007Peanut Corp, 3200 Products, 500+ Million Units
Pharmaceuticals 2010Johnson and Johnson, 43 OTC Drugs, $900 Million in Lost Sales
Consumer Electronics 2016Samsung Electronics, Galaxy Note 7, $5 Billion in Costs
Toys 2007Mattel, 19 Million Units
© Mindstix Labs 2017
What’s Needed – Manufacturing Traceability
Establish Product Lineage
• Pin Liability to Specific Suppliers and Sources
• Shift The Financial Impact of a Recall
• Narrow-cast the Impact of Product Recalls
Track Production Variables
• Root Cause Analysis of Reported Defects
• Drive Continuous Process Improvements
• Regulatory Compliance and Vendor Qualification
Generate Real-Time Alerts
• Pre-emptively Catch Production Misses
• Risk Assessment and Pre-emptive Recalls
1000’s of SKUs, 100’s of Processes, 100’s of Production Lines
© Mindstix Labs 2017
Product Lineage – Bill of MaterialTracking Genealogy
For Each Unit or BatchPlastic HousingSKU #4323
Printed DialSKU #19283
Electronic ModuleSKU #4738
Glass CasingSKU #37629
Push ButtonSKU #4638
LCD DisplaySKU #80927
Screw AssemblySKU #5638
Printed Circuit BoardSKU #8830
Surface Mount ChipSKU #383784
25 uF CapacitorSKU #123412
Surface Mount ConnectorSKU #5733
Supplier:Jacksonville Parts Co.
Consignment:CR213123
Bin Number:1231231
Consignment Date:July 25th 2015
Order Number:638239
Part Serial Number:539131
Part Name:Speedometer and Odometer
SKU:8372932
Lot Number:1241312312
Assembly Date:22nd December 2015
Assembled At:Chakan, Unit 2Assembly Line #6
Assembly Line Employee:Mr. John Doe
Assembly Line Supervisor:Mrs. Jane Doe
Final Assembly Sub-Assembly Souring InformationProduction Summary
© Mindstix Labs 2017
Product Lineage – Material Inward
Supply Consignments
SupplyCrates
VQAProcess
Bin Allocations
Main Store
Tagging Consignment Numbers, Supplier POs to Bins
DOL Material
© Mindstix Labs 2017
AmbientParametersLine Supervisor Production
Batching
Production Process Variables
SKU1 SKU2 SKU3 SKU4
IncidentReporting
Staged Feeder
Bins
Staged Feeder
Bins
Staged Feeder
Bins
SKU5
Output Bins
Staged Feeder
Bins
People Process
ToolsQC Testbed Test Reports
Assembly Line
© Mindstix Labs 2017
Shop Floor Events§ Ingress SKUs§ Egress SKU
§ Ambient Parameters§ Deployed Personnel
§ Deployed Tooling and Assets§ Tool Configuration§ Process Parameters
§ Testbed Parameters§ Testbed Reports
§ Incident Reporting, Near-Misses§ Batch Quarantine§ Tool Quarantine
Real-time Insights§ SKU Compatibility§ Stage Skip Alerts
§ Flow Rate and Violations§ FIFO Violations
§ Ensure Sufficient Test Sampling§ Notify Boundary Conditions§ Tool Overuse
§ Quarantine Violations§ Personnel x Product Matrix
§ Shelf Life Violation
Events and Real-time Insights
Audit and Archival§ Lineage§ Production Parameters
© Mindstix Labs 2017
Platform Expectations§ Capture Asynchronous Events - High Volume, Unordered
§ Guarantee Reliability of Event Delivery
§ Windowing of Events Into Production Batches (Event Time Based)
§ Generate Insights in Real-time
§ Large Scale Persistence - Linear Scaling of Storage
§ Operational Ease and Workflow Updates
© Mindstix Labs 2017
Event Processing FlowMQTT
Connector
(Enrichment)Sensor =>
Production Line
Window Aggregation(Event Time)
Dedup RF Tags
Persistent Store(HDFS)
Filter for SKU Compatibility
Filter for Quarantine
Batches
DashboardAlerts
DashboardAlerts
JDBC Lookup
JDBC Lookup
(Enrichment)Bin Tag =>
Sourcing Info
© Mindstix Labs 2017
Thank YouRoshan Kulkarni
Founder and CEO, Mindstix Software Labs