“Unlock Your Manufacturing Data to Drive Manufacturing Optimisation and Results”.

SYSTEMS INTEGRATION MANUFACTURING OPTIMISATION

www.simotechnology.com

Manufacturing Solutions for the Future Seminar and Exhibition

“Unlock Your Manufacturing Data to Drive Manufacturing Optimisation and Results”.

Presenter: Pat Desmond, Managing Director, SimoTech

Presentation Topics

• Manufacturing Intelligence Overview

• Business Drivers

• What Data are we looking for?

• Typical Solutions/Vendors

• Developing the Business Case

• Execution Strategies

• Some Challenges

The Case for Change

“If you always do what you havealways done, you will always getwhat you have always got”

Henry Ford 1863 – 1947

Benjamin Franklin 1706 – 1790

“If you fail to plan, you are planning to fail!”

Roy Keane Saipan 2002

Speaker Background

25+ Years in Manufacturing AutomationWide range of industries including Life Sciences, Food, Waste

Water, Oil & Gas, Chemicals Primary focus on advancing operations by using the latest

technologies Primarily working with the end users to realise the results on

the ground

My ‘DATA’ Career Profile

1 MB 8 Inch floppy 128 GB

“I am passionate about using every available piece of data to maximise processes.

That why I got into the automation business in the first place”

SimoTech Overview

“SimoTech provide Automation and Manufacturing Information Systems Professional Services and Solutions to Manufacturing Industry”

Particular expertise is in the area of Manufacturing Information Systems for regulated industries such as Life Sciences and Food & Beverage

Experienced in all levels of hardware and software from field instrumentation to Manufacturing Execution Systems

SimoTech’s team has worked as End Users, Engineering Consultants, System Integrators and Project Managers so we are uniquely positioned to understand the challenges from all aspects

“We provide Global Experience at Local Level”

Manufacturing Intelligence Overview• Manufacturing Intelligence (MI) refers to an important class of information

technology that enables better decision-making and improved business performance based on the ready availability of real time status and performance metrics throughout the organization

• MI typically applies to production, planning and asset management activities

• Typical objectives of MI are to achieve higher levels of production against assets, reduce the cost of production and, ultimately, improve the bottom line

• An MI platform aggregates, relates and presents operational and business data in real time

• It does so in a manner that is intuitive and useful for every individual who plays a role in delivering business results

• It can be applied initially to an individual site, and evolved to include all sites, divisions, regions and the overall enterprise.

Business vs Manufacturing Intelligence

Objectives Business Intelligence ManufacturingIntelligence

Timeframe Historical Data (Months, Quarters,

Years)

Real-Time Data (Min, Hrs, Days)

Areas of Interest Financials, CRM, Supply Chain

Manufacturing,Engineering,

Quality,

People Corporate Corporate, Local

Focus Strategic Tactical

Cost Impact on Organisation Bottom Line

> 10 % of turnover > 1 % of turnover

Corporate Business Drivers Ensure consistent quality and performance across global operations

Balance manufacturing with demand to optimize material usage and asset utilization

Improve and meet regulatory compliance

Implement more flexible and agile manufacturing operations to respond to rapidly changing market conditions

Improve response to events that occur on the plant floor

Meet demanding requirements and metrics for on-time delivery through reduced repair time and increased OEE

Reduce the cost of design, deployment, and support of manufacturing and IT systems at global manufacturing plants

Industry Metrics

Successful new product introductions – measured as the average share of NPI’s that hit quality, time and volume targets

Overall Equipment Effectiveness (OEE) – composite metric accounting for availability, performance and product quality

On Time and Complete Shipments – products delivered on time and complete as compared to original commitment

Operating Margin – a ratio of the profitability calculated as net income divided by revenues or net profits divided by sales

The Challenge facing Manufacturing

I know the solution is here

somewhere !

Process Historian

MES

Machine Data

Automation Systems

Document Mgmt

Training Records

LIMSCAPA

Quality Systems

EnergyMgmt

Maintenance Mgmt

Engineering Systems

Inventory Mgmt

ERPProduction Planning

Production Systems

The Challenge facing Manufacturing

Process Historian

MES

Machine Data

Automation Systems

Document Mgmt

Training Records

LIMSCAPA

Quality Systems

EnergyMgnt

Maintenance Mgmt

Engineering Systems

Inventory Mgmt

ERPProduction Planning

Production Systems

I know the solution is here

somewhere !

Ab

ility

of

Org

anis

atio

n t

o r

esp

on

d t

o c

han

ge

BUSINESS

RULESPerform

To

Demand

CORPORATE

EXPECTATIONS

SHAREHOLDER VALUE

ORDERS

SPECIFICATIONSPerformance

To schedule

Overall processperformance metrics

Operating data transformed into assetperformance KPIs

Large volumes of extremely detailed production data from

multiple back-end data sources

INSTRUMENT

DEVICE

I/O

TAGS

EQUIPMENT

& ASSET

PRODUCTION MODELS

RECIPES/BOMS

& ROUTES

MATERIAL &

PRODUCT

FLOWS

Correlate of work process data,equipment data and product data

Incr

easi

ng

Stra

tegi

c V

alu

e t

o t

he

Ente

rpri

se

Sensors, Actuators, Motors

€€€Quarters

Months

Days

Weeks

Hours

Hours

Min

Sec

Manufacturing Intelligence Foundation

• What if everyone in your organization had an up to the minute view of performance against individual and group objectives?

• What if everyone was presented with all of the information they need to make good day-to-day decisions that will drive the individual and the organization to higher levels of achievement

• What if you took the learning of the ‘Old Timers’ and Subject Matter Experts and made it freely available to all

• What if you empowered employees, delivering the Right information, to the Right Individual at the Right Time”

Faster Decision Making, More Informed Decision Making, More Accurate Decisions, Less Reliance on Scare Senior Resources,

More Satisfied Workforce, Less Risk

Leverage the Power of People

Supply Chain Connectivity via ERP

ConsumerGoods In

DistributionGoods In Goods Out

RetailerGoods In Goods Out

PackagingGoods In Goods Out

FinishingGoods In Goods Out

Bulk ProductionGoods In Goods Out

R& D /Pilot ScaleGoods In Goods Out

ConsumerGoods In

DistributionGoods In Goods Out

RetailerGoods In Goods Out

PackagingGoods In Goods Out

FinishingGoods In Goods Out

Bulk ProductionGoods In Goods Out

R& D /Pilot ScaleGoods In Goods Out

ERP ERP ERP ERPBusiness

Unit 1Business

Unit 2

Manufacturing Chain Connectivity

Getting rid of the information silos between plants and between business units

Packaging

Finishing

Bulk Production

R& D /Pilot Scale

Packaging

Finishing

Bulk Production

R& D /Pilot Scale

Packaging

Finishing

Bulk Production

R& D /Pilot Scale

Business Unit 1

Business Unit 2

Business Unit 3

Data

Data

Data

Data

Data

Data

Data

Data

Data

Data

Data

Data

Data

Data

Data

Data

Data

Production Train Connectivity

Getting rid of the information silos within plants

Raw Materials Dispensed to

Manufacturing

Unit Operation 1

Unit Operation 2

Unit Operation 3

Finished Goods Return to Warehouse

Raw Materials Dispensed to

Manufacturing

Unit Operation 1

Unit Operation 2

Unit Operation 3

Finished Goods Return to Warehouse

Raw Materials Dispensed to

Manufacturing

Unit Operation 1

Unit Operation 2

Unit Operation 3

Finished Goods Return to Warehouse

Data

Data

Data

Data

Data

Data

Data

Data

Data

Data

Data

Data

Data

Data

Data

Data

Data

Data

Data

Data

Data

Data

Reference Plant IS ArchitectureEnterprise

Zone

DMZ

Manufacturing

Zone

Enterprise Network

E-Mail, Intranet, etc. Site Business Planning and Logistics Network

Application

Server

Engineering

WorkstationDomain

Controller Site Manufacturing

Operations and

Control

MES

SCADA

Client Operator

Interface

OEM

Client Engineering

Workstation

Operator

Interface

Area

Supervisory

Control

Basic ControlBatch

Control

Sensors

Discrete

Control

Drive

Control

Continuous

Process

Control

Safety

Control

ActuatorsDrives Robots Process

Firewall

Firewall

Web

E-

Mail

Terminal

Services

Patch

Management

Application

MirrorWeb

Services

Operations

Application

Server

AV

Server

Cell/Area

Zone

Level 0

Level 1

Level 2

Level 3

Level 4

Level 5

Typical Software Solutions Providers

Werum PAS-X

Rockwell FT Production Suite

Camstar Entreprise Platform

Siemens SIMATIC IT

Wonderware Archestra

Siemens HQX

SAP Mii

Rockwell FT Vantage Point

Informetrics InfoBatch

GE Proficy RtOi

Operational Intelligence

Solutions

Manufacturing Execution Systems

Do you need an Execution System, and Information system, or both?

Implementation Strategy

Take it one step at a time, avoid the big bang

Prove The Theories Before Jumping In

• Build a team that is passionate about the opportunities (Visionaries and Salesmen)

• Start with a Pilot, take a vertical slice of the plant or organisation

• Involve Stakeholders from all disciplines• Encourage participation from global locations • Secure involvement of technology suppliers• Don’t assume the ‘market leader’ has the best solutions

(technology is changing everyday)

• Finally develop your detailed requirements

Plant Type 3 (Core + Site Specific

Customisations)

Plant Type N (Core + Site Specific

Customisations)

Plant Type 2 (Core + Site Specific

Customisations)

Plant Type 1 (Core + Site Specific

Customisations)

Roll-Out Strategy

Core Solution (Common to all

plants

Plant Type 1 (Core + Site Specific

Customisations)

Plant Type N (Core + Site Specific

Customisations)

Plant Type 2 (Core + Site Specific

Customisations)

Plant Type 3 (Core + Site Specific

Customisations)

Feed from the core and feed back to the core. Core changes should have a solid governance process

Formulating the Business Case

• Develop a Project Charter

• Identify Stakeholders

• Operations Project NOT an IS Project

• Identify the Success Criteria

• Establish the tangible and non tangible benefits

• Tie the project goals and improvements back to the business strategy

Typical ROI StrategiesROI Must be Tangible and Measurable

Cost of Labour Avoid or reduce head count, Use less qualified resources, less training Divert experienced resource to higher value tasks, Share expertise among plants, Encourage experience people to stay longer and avoid re-training

Cost of Capital Avoid buying additional equipment Get the existing equipment to run more efficiently Use under resourced equipment in the network

Cost of Lost Opportunities Reduce time to market on new products, Reduce downtime and supply more of the market Reduce manufacture to shipment time

Typical ROI StrategiesCost of Reputation Reduce product recalls, Increase quality Reduce consumer price

Cost of Raw Materials Use less raw materials, Ensure the raw materials we are using meet quality requirements

Cost of Overheads Reduce energy requirements Reduce management supervision Reduce transportation and storage

Challenges (The Obvious Ones)

• IT Infrastructure (speed, redundancy, storage capacity,resilience, connectivity, security)

• Data Quality and Context (Rubbish In, Rubbish Out)

• Data Validation (is the information going to be used forregulated product release or investigations)

• Business Re-Engineering and Re-Training

• Fear Factor (Is Big Brother watching, do people want to beheld accountable)

• Availability of Key Resources during project execution (Todays production always has priority)

• Can you really measure ROI (sure would we not would have gotthose savings anyway

• Over Expectation (this is not YouTube or Google, it does notcontain all the answers!!!)

• Scope Creep

• Industry Expertise (is the experience out there?)

• The Known Unknowns

Challenges (The Obvious Ones)

Thank You for Your Attention

Pat [email protected]

086-8504844