fujtsu manufacturing industry value proposition 2016 manufacturing industry value...manufacturing...

Fujitsu Value Proposition for Manufacturing Industry

#EnablingDigital with Fujitsu Connected Enterprise

Copyright 2016 FUJITSU

Business Challenges

1

Manufacturing Customers

Services After Sales

Product Lifecycle

Management / Resource &

Development

Reduce Inventory

Reduce Lead-time

Improved Sales & Operations

Delivery

Differentiation / Shorten Time-to-Market

Transform / expand Product to Service

New Sales Channels / B2B and B2C

Sales

Minimized production downtime

Increased manufacturing automation

Cost / Sourcing control

Production

Increased partner collaboration

Shorter Time to Market

Extended revenue stream

Preventive maintenance

Control of Installed Base

Workforce safety


Digital is different things to different people

Business-model transformation

Transforming customer & user experience

Digitalizing business operations

Product leadership & innovation

Copyright Fujitsu Services 2016


Industrie 4.0 vs Industrial Internet

3

Industrie 4.0 – 4th Industrial revolution Industrie 4.0 is the extension of industrial

digitalization to the Internet of Things (IoT) in manufacturing

Industrie 4.0 constitutes an evolution and an integration into IoT of previously separate IT- application areas in automation (MES, PLC) and administration (ERP, SCM) – today, such concepts are often called Industrie 3.0 (3rd industrial revolution, since 1970)

Stakeholder group ”Plattform Industrie 4.0” consists about 70 members, 50 of which are industrial companies. Companies are individually selected and become members by invitation only. FUJITSU has been a member since last June

Industrial Internet Consortium Has been coined as a name by the Industrial

Internet Consortium (IIC), founded in 2014 This industry consortium was founded by 10 US

members and follows their charter of enabling the industrial application of the Internet of Things (IoT)

“Industrial” means anything that is the basis of a business. The IIC wants to enable solutions in energy, health, transport and other sectors, not just in manufacturing

The IIC has now more than 250 members, most of which are IT or OT companies

FUJITSU is in the 9 member steering committee


Smart Manufacturing

Industry 4.0 and Industrial Internet (Industrial IoT)

Industrial loT Solutions

Wearables, Devices, Sensors

Cloud, Infrastructure, Networks

IoT Platform

Applications

Smart Utilities & Smart Field Services

Smart Automotive

Smart Healthcare

Smart Agriculture

Smart Transport & Smart City

Smart Financial Services IIC: Fujitsu leads the testbed on “Factory

operations visibility & intelligence”


Digital Transformation: ”The Connected Enterprise”

Leverages the convergence of Information Technology and Operational Technology to enable smart, connected operations and significantly improve operations effectiveness and reduce operating cost

5


IT & OT seamlessly working together

The seamless integration between Information Technology & Operational Technology is the key for successful Connected Enterprise implementation.

④ Data Accumulation

① Physical Devices & Controllers

② Connectivity

③ Edge Computing

⑤ Data Abstraction ⑥ Application

⑦ Collaboration & Processes

IoT World Forum Reference Model

OT Event Based Data in Motion Real Time

IT Query Based Data at Rest Non-real time

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Enabling Digital: The Fujitsu Connected Enterprise

①

②

③

⑤

⑥

OT Fujitsu GlobeRanger iMotion

Connected Asset

Semantic (ISO 15926 Data Model)

Industrial Operational Intelligence

Predictive Maintenance and Service

Manufacturing Analytics &

Manufacturing Performance Management

Asset Tracking & Visibility

Semantic (ANSI/ISA 95)

Simplified Work Management

MFG Execution Quality Inspection

& Control

Connected Workers

Connected Manufacturing

Other Industrial M2M

④

IT

⑦

Fujitsu Ubiquitousware

3rd party

sensors


What does it mean for Manufacturing Operations?

Machine Data (Industrial M2M)

Material Movements (RFID)

Workplace Safety data (location, human wearables)

Business Data

Business Networks (Aka, AIN) and System of Records ERP EAM SCM QM CRM

Plant/Fied

Copyright 2016 FUJITSU 9

Fujitsu Connected Asset Connected Logistics & Warehouse Assets


What does Fujitsu Offer in Smart Asset Management?

Understanding your Business and Asset Management

Fujitsu GlobeRanger Solution

In what areas of the business does asset shrinkage occur? Why? How much is that costing the company per year?

Real-time alerts for security breaches within defined boundaries. Reduced lost/stolen assets (often multi-million €).

Is there real-time visibility of all assets at any given time, and who has them? How can you optimise your assets in different parts of its business?

Real time visibility of exact location of assets including chain of custody to ensure assets are signed out (and in) to/from specific individuals.

How do you ensure that the right employees are handling certain assets having undertaken the relevant training?

Know what each individual is entitled to check out according to role and training.

How does asset stocktaking occur? Optimization of asset usage based on actual usage rather than advised holdings. Automatic recording of moving of assets through gates.

How do you manage servicing the assets to ensure this is conducted at the right time and in the right location for this to happen?

Real-time alerts for asset recall for servicing /maintenance. Can record the servicing and repair history for every item tracked.


GE Turbine

Warehouse Optimization and Tool Tracking

Business Challenges:

Need better accountability of inventory for manufacturing and shipping processes

Fix lack of location accuracy of inventory

Sub-optimal process of finding missing or misplaced inventory

Optimize tool tracking and accountability

iMotion-Based Solution:

All inventory is RFID tagged on receipt at the dock door

All zones, aisles, shelf sections and bins tagged with location RFID tags

All forklifts enabled with wireless RFID reader & antennas

Solution tracks inventory from receipt to put-away to pick to consumption

Tool check-out window, personnel doors and dock doors instrumented with readers

Business Benefits:

Real time visibility of all inventory in the warehouse

Significant reduction of “misplaced” inventory

Better view of the velocity of inventory IN and OUT of the warehouse

Full passive, electronic tracking of tools with alerting for late check-ins

Company Overview:

GE Turbine is the world’s largest supplier of gas turbines and is a subsidiary of General Electric (GE); A Digital Industrial Company

which transforms industry with software-defined machines and solutions that are connected, responsive and predictive.


Daisy Brands iMotion Increases Inventory Velocity and Operational Efficiency

Company Overview:

Daisy Brands is the largest producer of sour cream in the U.S. At its 50,000 sq. ft. facility in Dallas, the company uses a

flexible warehouse management system that allows forklift drivers to make inventory decisions and update the system.


Comply with retailer mandate.

Generate internal efficiencies with mandate-driven RFID investment.

iMotion-based Solution:

140 cases of sour cream loaded onto a pallet. Bar-coded SKU used to generate RFID label

which is applied to the shrink-wrapped pallet.

RFID tag number and SKU number linked and stored in database.

Forklift readers read RFID tag number on pallet which is displayed on vehicle-mount

computer screen. Driver inputs inventory movement information into system through

touch-screen – ending location and reason for move.

iMotion links WMS to RFID readers on forklifts, barcode scanners and RFID printers.

Shipment validated against ERP system, shipping memos, and invoices generated.

Business Benefits:

Greater operational efficiency – truck loading time reduced by two-thirds with elimination

of data entry and recording tasks.

Greater visibility into product inventory by type and location. Elimination of paperwork,

phone calls, e-mails and faxes to determine product availability.

Shipping errors prevented through immediate notification.


Fujitsu Connected Asset Predictive Maintenance & Service


Actionable insights into operations

Industrial Operational Intelligence

Microsoft-SAP Innovation Awards Winning Solution


Predict Act

Source: Gartner

Sensor Data

Business Data

Environmental

Data

Pattern

and

Root

Cause

Analysis Pre

dic

tions

• Create work order

• Change product

specs

• Alter maintenance

schedule

• Preposition spare

parts

• …

Sense

Predictive Maintenance


$50 billion total assets

Enhance operations and maintenance by combining information technology (IT) with operational technology (OT):

Boost productivity,

Improve asset reliability

Gain real-time visibility into all aspects of operations

Customer case – One of largest Utilities in NA

Improved Operational Efficiency Manual hours saving estimated at thousands of hours per year Reduced Operational Risk Risk avoiding benefits estimated at multiple million USD

Reduced Operational and Maintenance Cost Transforming from preventive to predictive maintenance


Customer case - Aircraft maintenance

Scheduled aircraft maintenance Scheduled maintenance

Maintenance tasks and retrofit tasks

Required parts and materials Part authenticity, life cycle, condition, provider

Required tools Up to date calibration

Required technicians Calendars, up to date certifications

Shop floor space Integrations

Work assignments Parts Tools HR system Premises


Fujitsu Connected Manufacturing Asset Tracking and Visibility


Manufacturing (Work-in-Progress)

What do we offer? • Real Time WIP: Problem solving before they occur. Real-time visibility with alerts at every stage of the WIP to enable

immediate corrective action. Post-mortum is too late. Paperwork is too slow, labour intensive and inefficient. Can drive productivity by at least 30%.

• Data Automation: Manual errors will always impact cost. Any manual element in a manufacturing process will lead to error, inefficiencies, and delay. Install sensors to monitor, filter data according to thresholds, and apply business rules to automate. Even reducing minor errors that have a big impact can lead to 95% reduction in wastage costs.

• Tool Management: $2.75m pa in labour savings (for 100 workers). Get workers focused on work not finding tools or equipment. Check in/out facility, accountability for assigned tools, real time alerts for maintenance and calibration, Labour savings of approx. 15 mins per worker per task. This applies to any sector with significant tool volume/value.


Meggitt Composites Work-in-Process, IoT Sensor Monitoring and Alerting


Need better insight into each stage of the manufacturing process

Lack of visibility into the Work In Process (WIP) queue and in-stage dwell time

Need better accountability of freezer and oven controlled raw materials and

baked subassemblies

Tool tracking and asset utilization

iMotion-Based Solution:

RFID tag each part, kit or subassembly manufactured in the manufacturing

process

Install RFID infrastructure at all process steps

Track each part through the manufacturing process

Collect and report on all time and process metrics

Integrate freezer and oven sensors for lifecycle tracking

Business Benefits:

Real time visibility into the velocity of the manufacturing process

Visibility into the queue time and process time for each stage

Graphical dashboard of the entire manufacturing process to monitor, measure

and make real-time corrections

Full electronic accountability of raw material life cycle through freezer transitions

Company Overview:

Headquartered in the UK, Meggitt PLC is a global engineering group specializing in extreme environment components and smart sub-systems for

aerospace, defense and energy markets.


NeonLite Electronic & Lighting (HK) Improvement of Production Capacity through Greater Material Traceability

Business Benefits:

Manual data capture and entry eliminated.

Single integrated system to support inbound logistics, raw materials

management, and manufacturing work-in-process.

15 to 20% increase in production capacity, 10-15% increase in revenues.

Company overview

NeonLite, maker of the Megaman brand, is one of the world’s top manufacturers of energy-saving lighting products that are distributed in more

than 80 countries worldwide.


To ensure its commitment to the environment by reducing material waste

and consumption.

Extend material visibility from raw material through the manufacturing

process to finished product.

iMotion-based Solution:

Component parts and finished goods placed in tagged trays as they move

through assembly line or into a storage warehouse.

Handhelds and portals used to read the tags at various points.

Alerts and exception reports generated when errors detected.

Interfaces with ERP Syteline warehouse software.

http://www.megaman.cc/global/index.php


Fujitsu Connected Manufacturing Manufacturing Performance & Quality Management


Business Processes - ERP

Manufacturing Operations – MES

Manufacturing Control

Manufacturing Systems – Information Sources

23

Production schedule, material use, shipping and inventory levels, finance,

logistics etc

Batch management, manufacturing execution/operations

management systems, maintenance and plant performance

management systems

Real-time Logic / Batch controls and software

Intelligent Devices: Physical Process /

Sensors / Analyzers / Actuators Physical Production / Manufacturing


Business Processes - ERP



Physical Production / Manufacturing

Manufacturing Systems – Information Flows

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Production planning, order requirements, product

definitions, availability, electronic work instructions,

produced and consumed material, product tracking and

tracing information

Resource requests, material definitions, product

deliveries, material availability, material lots, product

shipments, equipment assignments, maintenance

requests, maintenance progress, equipment

capabilities, maintenance schedule

Work instructions, recipes, set points,

process values, alarms, adjusted set

points, production results,




Connected Manufacturing Solutions – Operator Dashboard

Real-Time Dashboard – Orders View

Simplified UI

Mobilization

Process and

Quality

Enforcement

Improved

Efficiency

Knowledge

management

25


Food Manufacturer

Integrated manufacturing and quality management solution connects machine, processes, data and people

Customer case – Meat processing company

Improved Operational Efficiency Mobilized and paperless plants

Improved Food Safety and Quality Business Use Self Service

Reduced Operational Cost Tens of millions USD potential saving of recall/refunding


Finnish Manufacturing Company

Thousands of log files/hour/operation across production lines Data volumes 30GB / day

Customer case – Advanced Analytics

Automated quality control Monitor / alert / react for production lines in real rime

Adhoc quality analytics Visualisation of data with self-service tools

Long term trend analysis Predictive modeling


Fujitsu Connected Workes Workforce Health & Safety Fujitsu UBIQUITOUSWARE


Connected Workers

Before

ヘッドマウントディスプレイに情報を表示

Efficient working processes thanks to mobile/wearable device and Augmented Reality technology

Displayed by HMD Work procedure Device condition

Complex processes

Look for information from manual

Document in a report

Real-time data-sharing

Security & Improved task accuracy

Efficiency by hands-free

After

Head Mount

Display

Real-time sharing Inspection result Device information

Wearable

Keyboard

Simplified Work Management

Quality Inspection & Control


Ensuring the right information available in context


Workforce Management / Health & Safety

Ensure workers safety and visualize their environment

Using the vital wrist band we can see when conditions deteriorate increasing the chance of heat stroke. Issue alerts and provide support when an accident occurs.

Monitoring workers for staff management & ensuring worker safety

Detect falls by monitoring both acceleration & barometer pressure

Avoid the chances of getting heat stroke by estimating heat stress from pulse, active mass, temperature & humidity

Lone worker monitoring

Opportunities


Fujitsu UBIQUITOUSWARE

Sense real time the environment, motion, location and vital signs

Sensors Acceleration

Geomagnetism Barometric

Pressure Gyro Mic

HCE Low power

consumption, Analysis

algorithm

Fall Detect a fall by sensing changes in movements & barometric pressure

Posture Identify posture (standing, sitting & lying) by sensing movements in 3D

Exercise Intensity

Calculate energy consumption from movements & active mass

PDR Precise positioning by estimating moving direction & distance

Location Log

Complement & correct location data as well as stored positioning data ＊Precise outdoor positioning together with GPS

Heat Stress

Issue alerts based on the heat stress caused by temperature & humidity ＊Detect together with heart rate and temperature & humidity sensors

Physical Load

Issue overload alerts by estimating physical loads from changes in heart rate


Getting started - on Digital Journey

“Think big, start small; learn fast and scale quickly”

• Focussed session – up to 2 hours • Interventions- e.g. trends, art of the possible, threats &

opportunities • Outcome – common understanding, sponsorship & agreed

priorities

Executive Workshop

• In-depth session – up to half a day • Interventions – e.g. facilitated discussion, demonstrations,

concept jam • Outcome – identified opportunities for solutions

Digital Innovation Session

• Develop consistent strategy for digital – up to 4 weeks • Interventions – e.g. visioning workshop, road-mapping • Outcome – agreed approach, outcomes, initiatives and

milestones

Digital Vision and Roadmap

• Real-life application of digital – up to 3 months • Interventions – e.g. day in the life, hackathon, agile

solutions integration • Outcome – business case for the solution

Proof of Concept and Value

Copyright Fujitsu Services 2016


De-risking

Productivity

Transformation

Partners

Consumer

Packaged Goods

Discrete

Metal

Food, Beverage &

Pharma

Forest

Construction

Energy

Application services for Manufacturing industry

Industrial IoT solutions Industrial IoT &

Industry 4.0 solutions

Connected Enterprise Connected Enterprise

Industrial IoT solutions

Connected Enterprise

Industrial IoT &


C7 for projects

Market Place,

StoreCenter, REA

Connected Enterprise

C7 for projects

Industrial IoT &


Intelligent Dashboard

Workplace Productivity

RunMyProcess

Intelligent Dashboard

Case & Doc

Mgmt

Consolidation

Business & IT Consulting - Process Optimisation,, Change, Technology and Strategy & IT Effectiveness

Transformational

AMS

Collaboration Business

Intelligence

ServiceNow SalesForce

Application

Modernization

Digital

Consulting

Application

Developm.

&

Integration

Fujitsu Middleware

GlobeRanger

Cu

sto

me

r Is

su

es

Digitalise

existing

processes

Redesign of

business

Application

Effectiveness

Operational

Efficiencies Food and Drugs

Traceablity

Pharma industry

solutions

Fujitsu companies

Performance

Management


Why Fujitsu?

Framework and method to help customers drive yield from the Digital Transformation

Lean tools help our customers rethink current supply chain and reduce costs and risks

Innovation driven company with availability of smart solutions such as GlobeRanger, RunMyProcess and UBIQUITOUSWARE

End-to-end service – from business process to applications and infrastructure layer, such as MetaArc – Digital Business Platform and Digital Performance Management

Fujitsu being a long term global partner with strong Nordic presence

Fujitsu is also Manufacturer

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Additional material

Make Industrial IoT happen with Fujitsu Connected Enterprise

https://www.youtube.com/watch?v=XX-Bg7knB6U

RFID based MES/WIP demo

https://www.youtube.com/watch?v=fBDZ5mN_qMk

Fujitsu Virtual Factory

https://www.youtube.com/watch?v=V8obxOs1LKE#t=62

Warehouse tracking

https://vzaar.com/videos/7299544

The Workplace of the future, created with Augmented Reality

https://www.youtube.com/watch?v=igapCs2JxG0&list=PLv3dNrIbuNATBt75hh13qm7Lql21zk7_Y

More information: Reijo Sihvonen, +358 400 433 407, [email protected]

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https://www.youtube.com/watch?v=fBDZ5mN_qMk



https://vzaar.com/videos/7299544



mailto:[email protected]

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