Challenge, Change, & Innovation in PLM, Manufacturing, & Compliance Brion Booth Manager - Enterprise Application Solutions
Varian Medical Systems 1 | CORPORATE COMMUNICATION
Varian Saves Lives ! Varian Medical Systems: Focus on saving lives. Through collaboration with customers & partners, the people at Varian develop technology leading solutions for advancing cancer treatment, radio surgery, X-ray imaging, and security.
Treat over 250,000 patients/day
Oncology Systems
FY 2012 Revenues ~$2.6 B 5,800 employees Manufacturing sites -NA, China, Europe 60 Sales/support offices globally Security and Inspection products
2 | CORPORATE COMMUNICATION
X-Ray & Imaging Systems
How did it all get started at Varian? PLM & manufacturing challenges & opportunities lead us to improve core engineering and manufacturing processes Reach RoHS Compliance
3 Basic Philosophies: • • •
What is my stuff ? How much does my stuff cost ? Where is my stuff ?3
3 | CORPORATE COMMUNICATION
• Lack of process compliance • Inadequate tools & infrastructure • Looming regulatory requirements • Big workload to become compliant
Engineering Change & BOM • Paper based and manual • Backlogs due to process inefficiencies • Inconsistencies across organizations • Manual configuration management
Mfg. Shop Floor • Paper based/manual processing error prone & abused. • Lack of integration between systems • Transaction timing • OLTP/UX in ERP not mfg focused
Mfg Process Control, & Compliance • Limited process enforcement • Regulatory data silo’d & not easily reported • Routers didn’t represent the build process – financial only.
Results in Ops
4 | CORPORATE COMMUNICATION 3/8/2004
5/3/2004
Date
Results in Pharma
9/6/2004
8/23/2004
8/9/2004
7/26/2004
7/12/2004
6/28/2004
6/14/2004
5/31/2004
5/17/2004
80.0%
4/19/2004
4/5/2004
3/22/2004
90 Day Avg
2/23/2004
2/9/2004
1/26/2004
1/12/2004
Results in Med Device
12/29/2003
12/15/2003
4 Wk Average Yields
Benchmarking … Sequence 130 - Final QA Yields
100.0% 95.0%
90.0%
85.0%
MES Deployed
75.0%
Business Transformation: Digital Product Collaboration PLM Outcomes: - Leverage and reuse product engineering data - Establish continuous data stream - Design Manufacturing Service
- 3D Model Material EBOM MBOM - Re-use of parts and information - Enable one global engineering platform - Capture Electronic E-BOM’s and parts - Building block for “virtual product” - Quicker access to product and process information - Global version/revision control Device Master Record (DMR): Drawing SAP Platform becomes the system of record
5 | CORPORATE COMMUNICATION
PLM Systems Landscape Integrated SAP Software was platform of choice for REACH RoHS and EC process ProE OrCAD
PDM
Mentor Graphics
PLM 7.01
Solid Works, AutoCAD
SPRC (RoHS) Drawings
Clear Case DX Designer CADSOFT Eagle
SAP DMS
CAD Apps PP
Drawings P-drive
MM
Data resides in SAP ERP (Material, BOM, Vendor, DIR etc)
SAP ERP /PLM
Altium
•
Simple application architecture, no additional cost for hardware, software and integration.
•
Included NetWeaver Business Client (NWBC) UX and logic services to streamline PLM process. Several new engineering screens, workflows, & interfaces 6 | CORPORATE COMMUNICATION
Business Transformation: Manufacturing Execution
Improve: Quality, First Pass Yield, Cycle Time, Error reduction, Avoidables, Data Availability, Analytics & Reporting, User Experience & Integration, SPC (Instantaneous)
7 | CORPORATE COMMUNICATION
Business Transformation: Manufacturing Integration & Intelligence (MII)
8 | CORPORATE COMMUNICATION
Business Transformation-Digital Product Collaboration From EBOM to Full Configuration Management EC4 ProE 3D Assembly Functional Requirements -15
Rev A
Compliance Documentation
Rev C Rev B
3D PDF Assembly ProE 3D Model
EC2
Rev A
-06
Highlights
PDF Drawing ProE Drawing
1. Establish a System of Record and also provide a structure for navigation and search across product information
Test Plan
Rev C Rev B
3D PDF Assembly SolidWorks 3D Model PDF Drawing SolidWorks Drawing
Rev A
-05
Functional Specification
Rev C
Rev B Schematic Board 3D Model OrCAD Schematic Board Layout Model
EC3
-10
Mechanical Part
Testing Plan
Rev C Rev B
Electrical Part
Components Compliancy Certificate
Software Part Document
-08
Rev A
Manufacturing Spec Sheet
Rev C Rev B
File EC
3. Foundation for full traceability
Functional Specification
Rev A
2. Foundation for Configuration Management
Eng Change
Firmware Binaries Functional Specification
9 | CORPORATE COMMUNICATION
-10
Rev A
Integration Testing
Rev C Rev B
PLM Benefits: Compliance, Revenue Protection, Cost Avoidance, Agility, Process Consistency, Protect EU Revenue
~30% of total Varian revenue in 2014 and thereafter Speed of design process Increase component selection and alternate Optimize component spend Leverage standard components and reuse Automate component data acquisition
PartMiner interface with SAP, capture AML, data sheets & pricing
10 | CORPORATE COMMUNICATION
2012
2013
2014
2015
2016
Mfg Execution Benefits: Paperless Processing, Process Enforcement, Compliance & Analytics Real Time SPC: Manual/automatic data collection - Any source Process control Event driven NC, Rwk, Notification Workflow MII - Automatic from AtP
Standard in ME: Analysis on all things manufacturing MII & BOBJ options available
11 | CORPORATE COMMUNICATION
Device History Record • • Test Log:
•
Measurement data by SN ! Tools: Calibration Verification !
Created in real time – can view anytime. Ties together BOM levels/ops by SN Customized through MII & DHTMLX extensions
Serialization Components & Sub Assemblies !
12 | CORPORATE COMMUNICATION
