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EY Smart Factory:

The leading digital solution to achieve

break-through and sustainable

Manufacturing Excellence results

Athens, 12th February 2019

OEE 55% 70% 80% >85%

Unplanned

Downtime

<12% <8% <6% <2%

Unplanned MTBF

(Stops/day)

24 10 4 Unattended

Product Quality

Defects reduction

>50% >80% >95% ~0 defects

Process Failures

Reduction

>50% >80% >95% ~0 defects

SHE TIR ≤1.5 ≤1 ≤0.5 ≤0.2

Base Stable Progressive Leading

Companies are struggling to make a sustainable breakthrough in performance using traditional manufacturing excellence approaches

Sample Metrics

$200-300m savingsPhase 1

Phase 2

Phase 3

Phase 4

http://www.newdesignfile.com/postpic/2012/05/information-technology-

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2 3

Make smarter decisions and drive smarter

actions

Intelligent applications and processesHarnessing disruptive technology to deliver value

Digital coachEmpowered leaders to build capability and empower people

Make the people

smarter……

……Make the equipment smarter

Smart Maintenance

Smart Quality

Smart Energy

Smart Materials

EY Smart Factory Framework:Advanced technology, supported by standard ways of working, empowers a capable

workforce to deliver value

1

Accelerator

Digital strategy and transformation management

4Production systemIntegrated standard way of working for sustainable operational excellence

Shopfloor execution applicationDigital standard work processes driving execution excellence

AND/OR

CLIENT

OpEx system

Fully integrated work system

Fundamental shift to Operator technical

mastery and equipment ownership

Based on an uptime and Run-to-Target

approach

Extensive use of reliability engineering

analytics

Daily Management Systems at its core

1

2

3

4

5

• Integrated manufacturing system – incorporates all TPM,

Lean, Six Sigma, TPS, Reliability Engineering and other

learnings

• Database of over 3500 integrated manufacturing capabilities

across 5 maturity Phases

Catalyst contains a full manufacturing Integrated Work System which

integrates all leading practices in a format that improves adoption

Manufacturing Excellence Pillars


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2 3


actions



Make the people

smarter……


Smart Maintenance

Smart Quality

Smart Energy

Smart Materials



1

Accelerator




AND/OR

CLIENT

OpEx system

Assess, plan, learn, execute and

monitor

Catalyst OpEx

Platform

EY Catalyst’s supporting maturity phase progression

Virtual Manufacturing Excellence

Coach

OEE 55% 70% 80% >85%

Unplanned

Downtime

<12% <8% <6% <2%

Unplanned MTBF

(Stops/day)

24 10 4 Unattended

Product Quality

Defects reduction

>50% >80% >95% ~0 defects

Process Failures

Reduction

>50% >80% >95% ~0 defects

SHE TIR ≤1.5 ≤1 ≤0.5 ≤0.2

Base Stable Progressive Leading

Phase 1

Phase 2

Phase 3

Phase 4

Assess, plan, learn, execute and

monitor

Catalyst OpEx

Platform

Catalyst Online Learning

Modules -

Uses advanced Adult learning

training techniques to improve

capability build

Catalyst Community For

Knowledge Sharing -

Ability to create different communities

across factories and the organisation

on similar Equipment, OpEx Pillars,

other topics. Share best practices.

Catalyst Reader —

Ability to take relevant

leading practice

content and read off

line to increase

understanding and

skills

Knowledge share

Reader

Online Learning

EY Catalyst’s cloud-based operational excellence (OpEx)

platform, accessible to all and centrally controlled

Leading Practice Shop Floor

Execution

Shop floor execution application -

Leading practice work processes

that are covered in Catalyst training

and executed through this

application to ensure quality of

execution e.g. CIL, CL, Defect

Handling, Breakdown elimination,

etc

“Virtual Manufacturing Excellence Coach”

Manufacturing Excellence

leading practices,

assessments methods,

training and tools:

Linked to 4 Phase maturity

progression with automatically

generated 90 day work plans

based on continuous

performance and capability

assessment

Assessment &

Content Management


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2 3


actions



Make the people

smarter……


Smart Maintenance

Smart Quality

Smart Energy

Smart Materials



1

Accelerator




AND/OR

CLIENT

OpEx system

We have an opportunity to make a significant improvement in the

execution of OpEx leading practices

Changeover Efficiency

application

Breakdown Elimination

application

Safety & Quality Incident

Elimination

6 Daily Management Systems

• Centerlining

• Clean, Inspect, Lubricate

• Defect Handling

• Breakdown Elimination

• Safety & Quality Incidents

elimination

• Rapid Changeover

Daily Direction Setting

Manufacturing Excellence Pillar

Shopfloor performance

improvement application

Shopfloor meetings

application

Defect logging

applicationClean Inspect and

Lubricate application

Centerlining application

EY’s Smart Factory applications are intended to compliment other digital

factory applications

EY Applications

Although we have developed a suite of Smart Factory applications, the goal is to operate within an open system of multiple vendor applications – companies will choose different vendors for different areas

Other Vendor Digital Applications

My Tasks

EY Edge

Device

Client manufacturing systems – data depending on Smart Factory application

(Historian, MES, ERP, Maintenance Mgt, others)

Quality,

Energy, etc

My Tasks could manage actions & alerts across applications

Ability to share dataEY Edge device is pre-configured with data contextualisation to enable rapid set up of EY applications

Select the EY applications that are appropriate

Note

• Application interface

approach recognises

Plants typically have data

and systems issues

• EY Catalyst & Standard

Work Applications (No.2 &

No. 3) can be operating

within 4-5 weeks

• No. 4 IoT Predictive

Analytics Applications can

require more time to

ensure senor and data

calibration


icon_90996.png

2 3


actions



Make the people

smarter……


Smart Maintenance

Smart Quality

Smart Energy

Smart Materials

EY Smart Factory Framework:Advanced technology, supported by standard ways of working, empowers a capable workforce to deliver value

1

Accelerator




AND/OR

CLIENT

OpEx system

EY Smart Factory – Smart Maintenance Application;CBPM (Condition Based Predictive Maintenance)

EY Smart Factory

Application of Artificial Neural Networks to create digital twin of the equipment makes a process of constructing of a model of normal behavior easier and more reliable.

• Monitors in real-time the equipment’s performance against critical parameters using IoT, sensors and

• Machine learning (AI) algorithms determine behavior of the equipment under different external & internal conditions; learns optimal running parameters.

• Automatically alerts Operators and Maintenance when equipment runs outside desired targets to enable early intervention

• Predicts failure by recalculating failure times based on how the equipment is being run and its current condition.

• Better scheduling of Planned Maintenance based on actual equipment condition; extending Planned Maintenance periods

Condition Based Maintainers concept is focused on improving reliability and OEE while decreasing life-cycle cost by optimizing the planned stops and cost of maintenance.

EY Smart Factory – Smart Maintenance Application;Intelligent Maintenance (Digital Skill Augmentation using AR)

EY Smart Factory

► Operators use tablets / glasses to automatically identify the equipment & get the relevant technical info

► A combination of augmented reality and sensors on the equipment enable the Operator to visualize the

breakdown of the equipment and refer to standards to understand equipment issues

► It also helps eliminate errors in workflows such as CILs, Centerlines, Maintenance tasks, etc.

► Work instructions for service or

maintenance virtually available on the

wearable device

► Paperless, secure process enabling

higher efficiency

Virtual Manuals for service and repair functions

► Deviations from target machine

parameters are visualized on a tablet,

smartphone, smartglasses or

smartwatches

► Rapid identification of assets to be

targeted to maintenance activity

Cutting force error

► Real-time capturing of

maintenance order information

► Maintenance work is immediately

registered after completion and

confirmation by technician

► Spare part ordering

► Spare parts can be directly ordered

locally at the machine by looking at

the defective part

Visualization of asset conditions

Maintenance & Remote Service

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EY Smart Factory - Smart Quality Application;

IPO (Intelligent Process Optimisation)

EY Smart Factory

• Effective production process control is hindered by the inability to directly

observe or estimate industrial process parameters, including external factors,

equipment condition, temperature, raw material conditions, etc.

• Product laboratory tests are expensive, lengthy, infrequently performed, only

allowing a small number of samples to be tested.

Results depend directly on laboratory equipment, human factors, and sample

quality. Uncertainty and product quality fluctuations are increased.

Corrective actions cannot be taken during the actual process, not real time data

The solution lies in IPO, which are statistical / machine learning (AI) models based

on information from easily measured process variables delivered by IoT sensors

and provide on-line estimates of unobservable ones.

Objective: to improve quality and yields in chemical processing and reduce variation in raw material

inputs in industries such as Food, Pharma, Home & Personal Care, and Chemicals

IPO is monitoring the processing in real time and predicting yield and quality issues before the process completes.

Operators are alerted during processing and can make immediate adjustments to improve the output,

or equipment can be self correcting.

Manipulated Variable e.g., Feed Rate Advanced Control

(APC system)

Optimum

video

Smart Factoryhttps://players.brightcove.net/5076297001001/r19F4B3Mx_default/index.html?videoId=5768851631001

https://players.brightcove.net/5076297001001/r19F4B3Mx_default/index.html?videoId=5768851631001

Better outcomes

3 Performance culture create value

Help empower and 2 engage people

Standard ways of 1 working

321

End-to-end digital ecosystem

Integrated andcontextualized data

Problem centric application of technology

Smarter people

Smarter equipment

Data

Insight

Decision

Action

Manufacturing transformation in the digital age:Transforming each element of the information value chain enables breakthrough performance improvement and competitive advantage

Significant cost and process

improvements facilitated: 7 to 10 times

return on investment

Average 10% to 25% OEE and

productivity improvements.

Focus on value provided

One of the leadingmanufacturing consultingfirms in the world

Unique alliance with P&G and

Microsoft provides access to a

proven ‘off the shelf’ manufacturing

excellence solution. Strategic

alliances with key technology

providers.

Strategic alliances

EY teams have deployed IWS and Smart Apps at hundreds of plants across the world of Consumer products, Life

Sciences, Diversified Industrial products, Chemicals and O&G industries

EY has been ranked by industry and

technology analysts as one of the

leading manufacturing consulting

firms in the world based on depth

and breadth of consulting services –

EY teams have over 3.000 SC&O

professional across 150 countries.

EY Smart Factory journey: Delivery and impact achieved over the last five years

George Panagiotopoulos

EY Director, Advisory Supply Chain &

Operations

[email protected]

+30 6937 321096

For further information, pls contact:

Robert Dziedzic

EY Assistant Partner, European Advisory

Center, Manufacturing

[email protected]

+48 508 018 332

mailto:[email protected]

mailto:[email protected]

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