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LIVEWORX.COM | #LIVEWORX
SPEAKER(s):
SESSION ID:
9th of June 2020
CASE STUDY: HOW AUTOLIV OPTIMIZES OEE ACROSS THE ENTERPRISE
IF1295CA
Daniel Jackson
Director of Manufacturing IT,
Autoliv
Maciej Redel
Sr Manager & Digital Lead
Kalypso
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2
#LIVEWORX
Daniel JacksonDirector of Manufacturing IT,
Autoliv
Bringing a unique perspective to digital transformation in manufacturing, based on a diverse background in Operations, Production Control & Logistics, and IT.
Maciej RedelDigital Lead,
Kalypso
Driving innovation with digital technologies –Internet of Things, Analytics, AI/ML, AR/VR. Hands-on practitioner.
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3
#LIVEWORX
AGENDA
Autoliv’s Factory of The Future initiative
Kalypso’s Smart Connected Operations
SCO at Autoliv◊ Performance management dashboards
◊ Analytics based workforce planning
Lessons Learned
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5
#LIVEWORX
AUTOLIV IN BRIEF
FACTORY OF THE FUTURE INITIATIVE
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6#LIVEWORX
AUTOLIV’S GLOBAL FOOTPRINT
$8.7 billionsales
7% sales growth
10.5% adjusted* operating margin
40% market share
Americas
31%of sales
Europe
32%of sales
Japan
9%of sales
China
18%of sales
Rest of Asia
10%of sales
6
27 CountriesAcross All Key Automotive Regions
19 Crash Test TracksEnabling Crash Simulations Globally
64 FacilitiesIn Close Proximity to OEMs
14 Tech Centers
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7#LIVEWORX
AT THE FOREFRONT OF TECHNOLOGY TO SAVE MORE LIVES
PEDESTRIAN AIRBAGS AND HOOD LIFTERS
Protect
Pedestrians
STEERING WHEELS
With the Lives of Others in Your
Hands
FRONTAL AIRBAGS
Save Lives and
Reduce Injuries
CHILD SEATS
Protect
Children
SEATBELTS
Top Life-Saving Device
PYRO SWITCH
Stop the
Fire
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8#LIVEWORX
DIGITAL TRANSFORMATION OF MANUFACTURING SYSTEMS WILL REQUIRE A CHANGE IN DESIGN AND ARCHITECTURE
Current
ISA-95 architecture Future
Software Design
Real-time, processing,
quality control
Proprietary and
standard apps
Mobile applications, SaaS
Cyb
ers
ec
urityAgile application
development
Big data aggregation and storage
Advanced analytics and Machine Learning
Device management: Discover, connect..
Development, data management, connectivity management
IIoT
platform
Edge
compute
Edge
platform
Next Gen
Apps &
Micro-
services
PLM
ERPScheduling, material, finance
MESProduction, quality,traceability, maintenance, ..
PLC/SCADAShop floor sensors
Cyb
ers
ec
urit
y
Future
Infrastructure Architecture
Sensors, Cameras, Actuators
Plant servers
PLCs
Data center
Cloud
WAN
SecurityConnectivit
yReliability
Edge
Connectivity
Ma
nu
fac
turin
g S
yst
em
s
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9#LIVEWORX
FACTORY OF THE FUTUREInitiative summary
Process Automation
Sample of projects• Automatic downtime response
• Automatic changeover
• Automated assembly
• Auto-adjust based on data
• Automated inspections
Material Flow
Sample of projects• Automatic machine loading
• Automated component feeding
• Automated finished good conveyance
• Digital Material Replenishment
• Automated palletizing
Physical to Digital
Sample of projects• AR Operator training support
• Electronic Work Instructions
• Electronic Performance Dashboard
• Mobile checklist
• Product and Process tracking
Data & Analytics
Sample of projects• Internal & External supplier data
used for process
• Predictive Maintenance
• Data used between processes
• Machine & process data used for statistics & quality analysis
Benefits• Labor Efficiency
• Reduce Scrap & Downtime
• Improved Quality
Benefits• Labor Efficiency
• Material utilization
Benefits• Reduce manual reporting time
• Improve Quality & Traceability
• Reduced time for training
Benefits• Improved Quality
• Improved OEE
• Material usage & reduced scrap
• Traceability
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10#LIVEWORX
Kalypso is a professional services firm.
We help our clients discover, create, make and sell better products with digital.
Established in 2004
2020 Acquired by Rockwell Automation
260+ Professionals
400+ Clients Served
INDUSTRY FOCUS
CO
MP
REH
EN
SIV
E C
AP
AB
ILIT
IES
Enterprise Technology
Business Process Management& Managed Services
Consulting
Digital
Consumer LifeSciences
Industrial High Tech
Ka
lyp
so L
P 2
02
0 ©
-P
rop
rie
tary
& C
on
fid
en
tia
l
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11
#LIVEWORX
Product Innovation enabled by Digital Product Creation (DPC)
Overall Equipment Effectiveness enabled by Smart Connected Operations (SCO)
KALYPSO PERSPECTIVE ON VALUE FOCUS AREAS FOR DIGITAL
1111
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12#LIVEWORX
Can the equipment operate at an improved rate with improved quality?
Can the equipment operate for more hours?
Mechanical Availability
Utilisation Management
Production Time (rate & quality)
Downtime Control Zone
Production Time Control
Zone
8760
(hours in a year)
We know digital is working when it is applied to improve performance. Positive changes in key measures are proof the digital solution is working
OVERALL EQUIPMENT EFFECTIVENESS (OEE) ENABLED BY SMART CONNECTED OPERATIONS
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13#LIVEWORX 13#LIVEWORX
KALYPSO’S APPROACH TO DIGITIZATION OF OPERATIONS
Reactive to Predictive
Optimize manufacturing control systems with Machine Learning
Improve Manufacturing Performance through predictive event
Mechanical to Digital
Deploy ThingWorx as platform
Establish connected control system foundation
Enable continuous improvement
Organize to Scale
Establish repeatable installation playbook and operating model
Develop Knowledge and skillset in organization to scale capability acrossmanufacturing portfolio
1
3
2
13
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14
#LIVEWORX
SMART CONNECTED OPERATIONS AT AUTOLIV
SOLUTION OVERVIEW
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15#LIVEWORX
OPTIMIZING OEE AT AUTOLIV WITHSMART CONNECTED OPERATIONS
PHASE 1: PERFORMANCE MANAGEMENT DASHBOARDS
PHASE 2: ANALYTICS BASED WORKFORCE PLANNING
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16#LIVEWORX 16#LIVEWORX
PERFORMANCE MANAGEMENT DASHBOARDS
• Manual, paper based and labor-intensive KPI calculation
• No real time visibility into many KPIs
• No real time aggregation of process information on different levels
• No single source of truth between PLC, OPC, MES and ERP systems
Replacing paper boards with touch screen interactive
dashboards
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17#LIVEWORX
FROM PAPER TO DIGITAL
8
Dashboards & control room are linked through an integrative information flow and continuous improvement
Information flow regarding
status, performance, trends,
line manning etc.
Information flow
through (aggregated)
KPIs, status information
and regular reporting
Line dashboards
AMT dashboards
AMG dashboards
Identification of
problems, trends etc.Development &
tracking of actions
Continuous improvement
through structured
problem solving (on the
lowest level possible)
Escalation of problems
which can not be solved
on this level
Problem solving
Performance control room
Machine status displays
KPIsStatus
Actions
tbd
KPIsStatus
Actions
tbd
KPIsStatus
Actions
tbd
KPIsStatus
Actions
tbd
KPIs
10.5
10.1
10.2
10.3
10.4
Problem solving
Problem solving
Problem solving
Illustrative
Real time process monitoring to power Continuous Improvement
OperatorLine
LeaderTeam
LeaderGroup Leader
Site Leadership
Source: Autoliv
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18#LIVEWORX 18#LIVEWORX
PERFORMANCE MANAGEMENT DASHBOARDS
• Real time KPI visibility
• Live data streamed from machines and MES
• Improved OEE and On Time Delivery
• Visual feedback on current bottlenecks on the production line
• Recommended actions and upcoming events
• Continuous Improvement mind
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19#LIVEWORX
ANALYTICS BASED WORKFORCE PLANNING
Challenge
◊ Shift start delay due to manual allocations performed on-the-spot in the drafting process based on intuition
◊ OEE lower than estimated in production plan due to sub-optimal worker to machine allocation
◊ Low transparency of overall impact of reactive decisions
Solution benefits
◊ Decisions based on data – not intuition
◊ Avoidance of non-productive time at shift start
◊ Improved OEE due to optimal worker to machine allocation
◊ Impacts of decisions analyzed through simulation
Business needs
◊ Recommend optimal production line workforce deployment: one week in advance, before shift start, and during the shift run
◊ Recommend corrective actions and re-allocation of workforce if needed based on actual performance, workforce availability and skill set
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20#LIVEWORX
ANALYTICS BASED WORKFORCE PLANNING
Digital Skills Matrix (DSM), informed by external systems, describes each worker in workers population.
Station Performance Model (SPM) depends on product, equipment type and historical worker performance. It predicts Worker-Station scores.
Worker Allocation Engine (WAE) optimizes allocation of available population of workers based on inputs from Station Performance Model.
Workers population
Station Performance Model
trigger
1. Plan for next week
2. Before shift start
3. During ShiftSchedule
Worker Allocation Engine
people data
HR MES Clocking OPC
machine perf data
Inform (features)
describe
optimize allocations
inform (Worker-Station Score)
re-allocate
allocate
allocate
Station St.05
Station St.10
Station St.20
Station St.xx
Digital Skills Matrix
ERP
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21#LIVEWORX
ANALYTICS BASED WORKFORCE PLANNING
Workers population
solve
Solution Space
Y = 18,000 Y = 23,500 Y = 25,000
Worker Allocation Engine optimizes allocation of available worker population to required station population across one site.
WAE uses combinatorial optimization (Kuhn-Munkres) approach to solving assignment problem, respecting business constraints:
◊ Worker availability
◊ Planned and unplanned attendance
◊ Skills
◊ CertificationsUnavailable Unallocated Sub-optimal allocation
Optimal allocation
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22#LIVEWORX
SCO ARCHITECTURE
MES
ThingWorx Foundation
Performance dashboards
Data ModelIntegration Services
Workforce dashboards
Planning dashboards
HR: workforce &
skills
OPC UA
PLCs
Machines
ThingWorx Analytics
Station Performance
Model
ERP: orders & schedule
Clock-in/clock-out
Digital Skills Matrix
Workforce Allocation
Engine
HMI
Smart Connected Operations built on backbone of ThingWorx Foundation, ThingWorx Analytics and OPC Aggregator technology from PTC
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23
#LIVEWORX
WHERE TO GO NEXT?
GLOBAL ROLLOUT
ANALYTICS & MACHINE LEARNING APPLICATIONS
AUGMENTED & VIRTUAL REALITY APPLICATIONS
23
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#LIVEWORX
LESSONS LEARNED
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25#LIVEWORX
LESSONS LEARNED – GOVERNANCE
Cross-functional team, cutting through Business, OT & IT silos, with strong support from Leadership to drive adoption
Defined strategy for Factory of the Future program and guiding principles
Delivery following Agile Methodology promoting team interactions and close collaboration
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26#LIVEWORX
LESSONS LEARNED – DELIVERY
Prototype, iterate and seek constant user feedback to achieve optimal UI/UX design and usability
Document Key Performance Indicators – align on terminology, data sources and formulas
Co-locate team for critical phases of the delivery – UAT testing and initial production rollout
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27#LIVEWORX
LESSONS LEARNED – ADVANCED ANALYTICS
Accept iterative nature of the Advanced Analytics projects and prepare to revisit hypothesis and adapt feature set
Establish understanding of fundamental Machine Learningconcepts and basic terminology across whole project team
Anticipate data quality issues – availability, reliability and accessibility. Expect some business rules not to be codified
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28#LIVEWORX
LESSONS LEARNED - SCALABILITY
Ensure solution is scalable across organization
Secure organizational alignment across sites
➢ Definitions & measurements methods
➢ Continuous Improvement process
➢ Technology stack
Establish separation between core solution and site configuration
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29#LIVEWORX
We looked at how Smart Connected Operations integrate machines, OT, and IT systems to provide real-time process visibility and improve OEE.
KEY TAKEAWAYS
We inspected how Advanced Analyticsis applied to optimize workforce and transforms operations from intuition-based to data-driven.
We shared some lessons learned and advice applicable for any organization embarking on Industry 4.0 journey.
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30
#LIVEWORX
Thank you!
WANT TO LEARN MORE?
VISIT
WWW.KALYPSO.COM/LIVEWORX2020
linkedin.com/in/daniel-jackson-94722b18
Daniel Jackson
Maciej Redel
linkedin.com/in/maciejredel
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LIVEWORX.COM | #LIVEWORX