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 FORCAM 2014

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The Smart Factory: World Class Shop Floor Management Mohamed Abuali, Ph.D. Chief Operating Officer [email protected]

www.forcam.com

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FORCAM‘s Passion

FORCAM provides proven manufacturing solutions to Continuously Improve Productivity To be the global solutions provider of the best-in-class Manufacturing Execution Systems

 FORCAM 2014

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FORCAM - History

Stamping Plants

Shareholder SAP Founder Dietmar Hopp

Founding FORCAM USA

Productivity + 20% within 12 months

New Plant Münchsmünster

Founding FORCAM UK Machine-Connector 400 Heterogeneous Machines

Web Technology SFM Evaluations

Press Plant Leipzig & China

SME Business Global Roll-Out (> 90 Plants)

+ 25% increased operating time and availability of all facilities

Press Plants Asset worth

US$ 2.5 Billion Release 5.0

Research Partnership Innovation Award

15,000 Monitored Assets

SAP Spin Off

+ 12%

Efficiency Increase within 6 Months

 FORCAM 2014

www.forcam.com

Frost & Sullivan 2014 Award

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FORCAM – 2014 Best Practices Award by Frost & Sullivan

Frost & Sullivan certifies: “FORCAM is a plant production software solution provider that understands and supports Industry 4.0 needs.”

 FORCAM 2014

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FORCAM’s Testimonials and Industry Leadership

 FORCAM 2014

www.forcam.com

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Agenda

Changing Issues & Trends in Manufacturing Industry 4.0 Smart Factory Requirements of a Smart Factory References and Conclusion

 FORCAM 2014

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Changing Issues in Manufacturing Productivity is only the tip of the iceberg

Productivity & Profits

BIG DATA in Shop Floor Management: Availability, Utilization, Quality, Performance, Measurements, Metrics, Downtimes, Order Management, Scheduling, Machine Data, Synchronization, ERP, …

Smart Factory Needs

Courtesy of Prof. Jay Lee  FORCAM 2014

www.forcam.com

Center for IMS, Univ. of Cincinnati

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BIG DATA: The Next Frontier (McKinsey Global Institute)

 FORCAM 2014

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5 Vs of BIG DATA

VOLUME

VELOCITY

VARIETY

VERACITY

Value (Visibility & Meaning) Courtesy of Prof. Jay Lee  FORCAM 2014

www.forcam.com

Center for IMS, Univ. of Cincinnati

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BIG DATA in Shop Floor Management - Examples ● Automotive Tier Supplier ●

Scope: 1 Plant

● Automotive Stamping Plants ●

Scope: 5 Plants

Variety ●

Events: Orders/Operations/Labor/Machines ● Events: Orders/Operations/Labor/Machines

● 370-500 Bytes per Event Velocity

● 370-500 Bytes per Event

● 291,600 Events per Hour

● 1,458,000 Events per Hour

● 139 MB per Hour

● 695 MB per Hour

Volume

● 3.26 GB per Day

● 16.3 GB per Day

VALUE

Advanced Shop Floor Management Technology must provide sophisticated compression and events processing capability to meet the needs of BIG DATA in manufacturing  FORCAM 2014

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Agenda

Changing Issues & Trends in Manufacturing Industry 4.0 Smart Factory Requirements of a Smart Factory References

 FORCAM 2014

www.forcam.com

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Industrial Revolution – A Brief History of Time Industrial Revolution 1. Mechanization

2. Electrification

Transformation to a Digital Society 3. Automization

4. Networking

today

 Cyber Physical Systems  inBin, Cellular Transportsystems

2000

 Smart Phone / Devices  1 User Many Computer

1980

 PC Notebook  1 Computer - 1 User

1970

 Mainframe  1 Computer Many User

Source :

 FORCAM 2014

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What is Industry 4.0?

The Virtual IT World and the Real Production World continue to grow together. With the development of so-called Cyber-Physical Systems (CPS), i.e. the networking of embedded IT systems to each other and to the Internet; we are considered by many Experts and Researchers to be at the beginning of the 4th Industrial Revolution. Prof. Dr. Dr. Wolfgang Wahlster German Research Center for Artificial Intelligence (DFKI) Quote: Fraunhofer IWU

 FORCAM 2014

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Developments and Trends in Production & IT

 FORCAM 2014

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What are Cyber-Physical Systems (CPS)? ● Cyber – computation, communication, and control that are discrete, logical, and switched

● Physical – natural and human-made systems governed by the laws of physics and operating in continuous time

● Cyber-Physical Systems – systems in which the cyber and physical components are tightly integrated at all scales and levels Ref: NSF CPS Program

 FORCAM 2014

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Agenda

Changing Issues & Trends in Manufacturing Industry 4.0 Smart Factory Requirements of a Smart Factory References

 FORCAM 2014

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Smart Factory Characteristics of the Industrial Production of Tomorrow

 Strong customization of products  Highly flexible large-scale production  Integration of customers and business partners in value creation processes

 Expansion of production through high-quality after-sale services Features of a Smart Factory

 Embedded software systems communicate with each other via the    

Internet Available data and services globally Networking across all digital channels (wireless / wired, local / global) Data virtually evaluated for real production optimization Human-machine interfaces (touch screen, voice / gesture control) 18

 FORCAM 2014

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1. Shop Floor Management Shop Floor Management (SFM) is the strategy for the continious optimization of the factory performance by eliminating errors and waste. Requirements: 1. Leadership

2. Technology

Traditional Low correspondence to reality

Advanced Distinct correspond. to reality

Approach: Reports, ERP system

Approach: Personal Verification

Result: Gap between management & process

Result: Managers know processes

Management Style: “Management by Remote Control“

Management Style: “Management by Process Improvement“

Traditional

Advanced

Background information only with delay from IT-systems or on paper

Up-to-date Interactive Online

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 FORCAM 2014

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Shop Floor Management (Contd) • Modern Shop Floor Management supports all roles in production - from the machinist, the maintenance technician and factory managers. • It establishes a closed-loop communication that delivers the right information to the right person at the right time. • Regular meetings provide the analysis of objectives and targets safely using real-time factory data.

       

 FORCAM 2014

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Productivity Values Machine Failures Production Flow Organization Quality Logistics Work Order Work Plans

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2. KPIs - Overall Equipment Effectiveness (OEE)

Desktop

CKT – D

Group

OEE

Efficiency

OEE Year Overview

Efficiency Year Overview

OEE

Efficiency

Performance

Performance Year Overview

Performance

Quality

Quality Year Overview

Quality

The most important metric for modern Shop Floor Management is OEE (Overall Equipment Effectiveness). It allows precise target-performance comparisons by the three parameters.

 Availability  Performance  Quality

– How long was the production time? – How fast was the production? – How good was the production? 21

 FORCAM 2014

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3. High-Performance Technology (CEP) Handling large amounts of data in real time requires a high performance solution. Using complex event processing (CEP), a technology for real-time analysis of event streams from the financial world. CEP is optimal with the proven Manufacturing Execution System (MES) links in a rule-based approach.

Management

Operators

Maintenance

OEE Cockpit

Planned versus Actual

Pareto Hit List

Production Manager Live Web Visualization

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4. Shop Floor Connectivity

 Real-Time Integration to CNCs and PLCs  Plug-In Concept for All Machines (MTConnect)  Configuration via Web Interface 23  FORCAM 2014

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5. Planned versus Actual (Shop to Top Floor) The seamless integration with leading ERP solutions such as SAP is an essential prerequisite for the success of the shop-floor technology.

 FORCAM 2014

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6. Information Availability The technology of Smart Factory provides individual important information on optimal surfaces (interfaces) with user-friendly ergonomics in modern design important factors for the acceptance of the Shop Floor Management.  Dashboards / Cockpit: Individually configurable graphical interface with KPIs  Electronic Manufacturing Binder (production data management with DNC): All necessary information automatically available  Trigger & Alarming: Automated report events to people and embedded systems for individual reactions  Traceability: Complete traceability of finished products throughout the supply chain down to the individual component

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8. Global Access Modern Smart Factory allows access to all the performance data anywhere, anytime

 Interactive Online Visualization: retrieval and visualization of the current production status worldwide via Web Data Access.

Setup Time > 150%

New Tool Required

 Factory Performance Anywhere, Anytime - by the availability on mobile devices-for example, from smartphones and tablets.

Your Morning Report

NC Prog Change 26  FORCAM 2014

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7. Information Deployment Electronic Manufacturing Binder: All information required for the operation must be made available promptly to the worker.

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Smart Factory - Components

Web Portal Office Client

 Web Portal Worker Client (Touch)

Web Portal Smart Devices

Real Time Shop Floor Management via Internet-Cloud

Global Web Portal e.g. China.

Mazak, Fanuc, Siemens, Heidenhain etc. 28  FORCAM 2014

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Agenda

Changing Issues & Trends in Manufacturing Industry 4.0 Smart Factory Requirements of a Smart Factory References

 FORCAM 2014

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Requirements of Industry 4.0 ● Cyber-Physical Systems • Mirroring the physical production world in real time in the cyber IT world

● What are the technology requirements for a Smart Factory? ●

Cyber Physical Systems

●

Big Data in Real Time (IN-MEMORY + CEP Technology)

●

100% WorldWideWeb

●

Instance-based, Server-Centric

●

Cloud-ready

●

Device Connection Engine

●

Time Zones (Anywhere, Anytime)

●

Language (Unicode)

 FORCAM 2014

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Smart Factory – Right Information for the Right Role

 FORCAM 2014

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Smart Factory – Multi-Site Global Production Network

Cyber Physical Systems

 FORCAM 2014

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Big Data

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Smart Factory – Digesting Big Data for Global Benchmark

Big Data

MES Cloud Instance-based (Multi-tenancy) 100% Web based Server-centeric

In-Memory CEP Rule Engine

Global Availability & Benchmark

 FORCAM 2014

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Requirements for the Technology of Tomorrow

Industry 4.0

Cyber-Physical Systems

Big Data

In-Memory Complex Event Processing (CEP)

Global Bencharmk

Instance-based Technology

Cloud-Ready

100% Web-based Server-centric

 FORCAM 2014

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Cloud

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Agenda

Changing Issues & Trends in Manufacturing Industry 4.0 Smart Factory Requirements of a Smart Factory References

 FORCAM 2014

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Links

Federal Ministry of Research (Germany) http://www.bmbf.de/de/19955.php?hilite=Zukunftsprojekt

Fraunhofer Institute of Production Engineering and Automation (Stuttgart) http://www.ipa.fraunhofer.de/Energieeffizienz_in_der_Produktion.1858.0.html

Fraunhofer Institute IAO, study Production Work for the Future – Industry 4.0 http://www.produktionsarbeit.de/content/dam/produktionsarbeit/de/documents/Fraunhofer-IAOStudie_Produktionsarbeit_der_Zukunft_-_Industrie_4.0.pdf

VDA-Movie http://www.youtube.com/watch?v=1dMSXM9PHfo

VDI-Referece MSR Technologies http://www.forcam.de/index.php?id=190

Wikipedia http://de.wikipedia.org/wiki/Industrie_4.0

 FORCAM 2014

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Click here to read the Frost & Sullivan Award Report

Mohamed Abuali, Ph.D. Chief Operating Officer [email protected]

FORCAM, Inc. 250 E. 5th Street Cincinnati, OH 45202

+1 (513) 878-2780

Thank you for your attention…  FORCAM 2014

www.forcam.com

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