how to start your journey to data-driven manufacturing
TRANSCRIPT
How to Start Your Journey to Data-Driven Manufacturing Welcome!
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5 Steps to the Successful Realization of Smart Manufacturing
Step 2: Connect – Critical Assets | June 12th, 2020
Introduction of the Webinar SeriesJay Foran – Senior VP of Industry & Innovation at Team NEO
• Overview of Smart Manufacturing Cluster
• Overview of webinar series;o Each webinar builds on the first one;
o Each webinar includes content from and is presented by a partnering pair of Manufacturer and Solution Provider;
o The progressive webinars are presented at the end of each week for starting on June 5;
o Emphasis will be on the operational excellence, improved efficiency and profitability of SME Manufacturers;
o Concepts that help the SME Manufacturer address the influences of Covid-19 will be highlighted at each step of the Journey.
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“Connect” Webinar OverviewRick Earles – Senior Director of Industry & Innovation at Team NEO
Establish a high level understanding of data-driven manufacturing (DDM) and identify applications where it can improve your type of business
Ensure production-critical machines (old and new) are sharing their data on the corporate network
Evaluate metrics and determine key performance indicators (KPIs) that require optimization
Receive Real-Time data on all levels of the operations and enable sharing of insights
Make business decisions based on data analytics to continuously improve productivity, profitability, and efficiency
Presented on June 5
Today’s Presentation
• Connect: Ensure production-critical machines (old and new) are sharing their dataon the corporate network;
o Useful KPI/Sensor Schemes Used for Popular Applications;
o Use of Gateways/Edge Computers to Acquire Data and Establish a Heartbeat Among Critical Assets (including employees);
o Data Storage on Premises or in the “Cloud” – Historian/Data Lake;
o Blending the Information Technology and Operational Technology functions – Including integration with ERP;
o Addressing Cybersecurity.
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Connect
“Connect” Webinar Overview
• Agenda:o Introductions
− Kurt Schron: Sr. Financial Analyst at Jergens - a Manufacturer of standard tooling components vises, and workholding equipment.
− Francis Martin: COO, Vice-President, VantageOne – a Solution Provider a custom software and on-demand application services to drive digital transformation located in Cleveland, Ohio.
− John Rattray: Senior Sales Executive of MEMEX – a Solution Provider that specializes in customized software consulting and development, and Internet of Things (IoT) solutions for growing, data-driven businesses.
o Manufacturers’ Use Case and “Connect” for Data Driven Manufacturing Journeyo Question and Answer Session
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“Connect” Webinar Overview
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Manufacturer: Jergens - Ready for IIoT - Connect
Kurt Schron - Sr. Financial AnalystE: [email protected]: 540-706-6856M: 540-818-2212
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Who is JergensIndustrial Manufacturer based in Cleveland, OH with 3 Divisions
TCD JIS
ASG
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What do we define as IIoT? Data Driven Manufacturing
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Jergens current IIoT background and Technology Deployment
• On Premise Install of Infor Syteline ERP
• Mixture of Systems for Loading CNC Programs
• QC Calc using Ethernet Output on 1 Machine
• Limited Hardwired Connections to Machines
• Shop-Trak Terminals for Job Cost Tracking
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Jergens Timeline - Preparation
12/2018Executives Attended Blockland Cleveland
3/2019- Attended 1st Team NEO Cluster Event- Identified IOT/Machine Monitoring
as Corporate Initiative
4/2019- Held Meetings Internally - Met with
- Executives- Supervisors- Operators
5/2019- Smart Manufacturing Workshop @ Jergens- SMEs meeting with All Members of Our Team
5/2019 to 10/2019- Vendor Selection
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Jergens IIoT Readiness
IIoT Readiness taken 3/18/201Key Advantages• Have C-Suite Executive Buy in• Have Staffed MFG Engineering Team • Identified Project Manager to Drive Project
Identified Goal: Increase Machine Utilization and Reduce Unplanned Downtime
Key DisAdvantages• Many Older Legacy Machines• Little Historical Data on Downtime• High Mix / Low Volume Environment• Multiple Product Lines with Very
Different Cycle Times
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Why IIoT? –Pain Points & Metrics Desired
Pain Points • Don’t Know When Machines Go Down• Reactive, No Notifications of
Active/Live Issues• Job Counts Inaccurate• Not Timely Data Availability• Operators Have to Leave Machines To
Track People Down• No Data About ‘Why’
Metrics Solutions• Utilization• Automated Good / Total Part Counts• UpTime Indicators• Downtime Reason Tracking
Results based on Interviews with:• Executives• Supervisors• Operators
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Vendor Requirements & Comparisons
• Full Data Access • Secure• Query able & Customizable• Alerts• Realtime Data• Triggers / Ping & Buzzer• Capture Sensor & PLC Data• Integrate with Syteline• Intuitive & Easy for Operators• Timeline of Implementation• Dashboards Available Everywhere• Full Data Capable of Predictive Maintenance
Nice to Haves:• Includes Tracking of Assembly Stations• Data Feed of Predictive Maintenance• Communication Protocol• Tracking of Physical Tools / Tool Life• Tracking of Assets within Jergens Facility
(RTLS)
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On Premise vs Cloud Hosted?
On Premise Cloud
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Jergens IIoT Installation, Network & Security
• Additional Wireless Access Points
• 40 Twin Cable Drops
• Created an additional VLAN network Just for the machines. No outside connection
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We prioritized starting with 10 Machines
• 10 ‘Easiest’ Machines to Connect– Transfer Machines– Mills– Lathes
• Machines From Across Multiple Product Lines
• Needed Software and Additional Hardware for 7 Machines
• No additional sensors
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Training
• 10 Hours of Training – Dashboards– Reporting– Admin– Advanced Features– ERP Integration (Currently In Process)
• Met with Supervisors & Operators throughout
• Supervisors & Operators Participated in initial fact gathering through vendor selection
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IIoT Growing Pains
• Still Working on our ERP Integration– We are on schedule
• 1 Machine Still not Connected– Our Ethernet Port is used by our QC Calc Software
• 2 Machines No Part Counts– No Machine Schematics at Time of Install
• 2 Machines Inaccurate Part Counts– Challenge is for each machine if there isn’t a dedicated part count how to
capture? – Chuck Open / Close is currently being used
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Dashboards on Shop Floor
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Integration with ERP
• ShopTrak (The Lake Co.) is Integrating Product with Merlin Software
• Operators Currently Use Single Terminal To Enter Job Start / End, Qty Information
• Operators will Login to Personal ShopTrak– Enter Job Start– Qty Pulled From Machine– Enter Scrap Qty– End Job– Idle/Downtime Reasons will be entered by
Operators• Tablet/Computers Installed at Operator
Stations, Some already have Computers
ShopTrak Code DescriptionS01 SetupB01 Break/LunchW01 Run Approval
W02 First Piece InspectionM01 MaintenanceW03 No OperatorW04 Waiting on MaterialW05 No JobW06 No GagesW07 Program IssuesT01 Tooling IssuesT02 Waiting On ToolingB02 Training/ShopTalkT03 Troubleshooting
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Next Steps
1. Finish Integration with ERP2. Begin Continuous Improvement (CI) Plans on first 10 machines3. Work in Stages of ~10 Machine Implementations Until Full Floor
Rollout4. Continue to Identify Additional Uses of Data
– Preventative Maintenance– Lead Times / Supply Chain Optimization– Tool Life Tracking
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Next Steps – Continuous Improvement
STEP 1 STEP 2 STEP 3 STEP 4 STEP 5
High-level Plan for Data-Driven Manufacturing
Connect to any machine, old
and new, KPI/Sensors
Monitor and Identify
Bottlenecks and
Constraints
Analyze causes for Downtime and Rejects
then eliminate them
Discover the hidden factory
and monetize the
benefits
Prepare Connect Visualize Analyze Optimize
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Solution Provider: VantageOne Software - IT & OT
Francis Martin - COO, Vice-PresidentE: [email protected] M: 440-413-5539
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Solution Provider: VantageOne Software - IT & OT
• Systems Integrator• Software development provider • Custom web, mobile, desktop and enterprise
application software and service solutions• Focus on IIoT• Bridge Information Technology (IT) and
Operational Technology (OT)
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Convergence of IT and OT
IT OTIT/OT convergence is the integration of Information Technology (IT) systems used for data-centric
computing with Operational Technology (OT) systems used to monitor events, processes and devices and make adjustments in enterprise and industrial operations.
The Common Ground - IIoT:• Identifying and authenticating all devices and machines within the system• Encrypting all communications between these devices• Ensuring the integrity of the data generated from these systems• Assuming the manufactured goods contain software or firmware themselves, enabling the
ability to perform remote upgrades down the road and ensuring the integrity of those updates.
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Solution Provider: Memex Inc. – Measuring Manufacturing Excellence
John Rattray – Senior Sales ExecutiveE: [email protected]: 416-460-7637
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IIoT Innovation in Manufacturing - Connect
0101COSTIN
GRDATA101
Connected MFG Model
$$$
IIoT is being applied successfully in manufacturing today – generating a 300% IRR on average. The path is known, the benefits are extremely compelling.
Cost effective, proven solutions exist which drastically reduces the risk of an IIoT project failure.
The last meter problem has been solved. Data can be cost effectively collected from ALL MFG equipment and processes.
Metrics require data to function, real-time data is the most accurate, as it streams from the machine.
There is a direct link to increased productivity and increased profitability.
Internet Security applied to the factory floor should be part of the discussion.
Leverage IIoT
For big dollars
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Work Order Scheduling and Results Reporting
Direct To / From ERP
Evidence Based Real time data collection at each machine and Discrete Process on the
shop floor
Process Improvement , Benchmark Analysis,
Corrective Action, Repeat
Drive costs out of the manufacturing process,
leading to higher capacity utilization and higher
profits for the same level of effort
WIP, Raw Material, Valuable Tooling, and Finished Goods Tracking with RFID
& ERP
Horizontal & Vertical Integration
Vertical: Shop Floor To Top Floor, Integrating and optimizing all equipment and processes, from machine sensors to the ERP system
Horizontal: Across the Complete Plant, Integrating, communicating and optimizing the production operations.
Smart Manufacturing: How it comes alive
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Data-Driven Manufacturing – The Benefits
Real-time machine visibility + OEE numbers including alerts
Operator Productivity Increase
Reduce Downtime
Minimize Rejects
Root Cause analysis
Value Stream data collection & analysis
Labor productivity tracking
Usage-based Preventive Maintenance
Benchmark scheduling & value streaming
2 - 5%
1 - 10%
3 - 8%
2 - 4%
2 - 4%
2 - 4%
3 - 6%
1 - 2%
2 - 6%
10% - 50% Productivity
increaseThe
benef
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5 Steps to the Successful Realization of Smart ManufacturingConnect
5 steps to success
#1: Connect
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ISA-95 standard for machine connectivity
ERP – Business System
Manufacturing Execution System
Distributed Control System
Connection
Machine
$Profit
ERPLevel 4
Manufacturing MachineLevel 0
OEE ApplicationLevel 3
MERLIN Server AgentLevel 2
Machine AdapterLevel 1
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Plant of the future – No machine left behind
CORPORATE HQ
Corporate-widereporting
Shop floor to top floor visualization
CorporatedashboardReal-time metrics,
on-time delivery
ERPMERLIN HMI
Adds bi-directional operator control of
any machine
MERLIN SERVER
LEGACY machines FOCAS enabled machinesMTConnect
enabled machines OPC enabled machines
Level 0
Level 1
Level 2
Level 3
Level 4
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Machine Connectivity – SoftwareLevel 1 Software Adapter on
machine
OPC
Proprietary Protocols
Serial to Ethernet Adapters
Fanuc Focas 2
MTConnect
Ethernet Port on Machine
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Machine Connectivity – Legacy MachinesAx760-MTConnect Adapter : A quick and easy way to find
and monitor signals from your machine
Provides Ethernet connectivity to any machine or device
Embedded Webserver for configuration and
monitoring
Outputs MTConnect Industry Standard
data tags
Plug compatible with Fanuc I/O link bus and passively detects data as well as 16
additional digital inputs, 12-24 VDC Power Supply from
machine
MTConnect Compliant, field upgradeable to newer
releases
Allows Feed Rate and Spindle Override tracking from Fanuc i
series controls
Ax760-MTC
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Customer Installations
Machine Description
Fanuc Series 18i-TA with I/O LinkAx760MTC –MTConnect enabled
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Customer Installations
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Customer Installations
Machine DescriptionWNT 2000 Panel Saw with MTConnect enabled
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Solution Stack: Connectivity Hardware
Take control of your shop floor, equip your machine
tools, and assembly, production or
processing line with the true power of edge computing.
and optimize efficiency
MERLIN MTC-One
Ax 760 - MTCWith Ax760-MTC enableolder machines on your shop floor to output available machine state, alarm states, controller modes, and muchmore in Real-Time.
The Ax650 monitors and controller’s I/O. It supports up to eight signals in addition to power.
Ax 650
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Confluence of 3 data streams – IT and OT
AUTOMATED APPROACHMACHINE-CENTRIC
TRADITIONAL APPROACHOPERATOR--CENTRIC
HistorianSQL Database
PROACTIVE ALERTS
Real-time data
MTConnect/OPC/Hardware adapter
DATA PRODUCER
Connect directly tothe machine, automated
data collection in real-timeData collection dependsentirely on operator action
Two-way,Bi-synchronous
Open Database
REACTIVE INFORMATIONGenerating lagging metrics
ERP, MESDashboardDATA Consumer
Machine Data Operator Data
Business Systems Data
500+ API calls to any software
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Hidden Capacity: Eliminating The 5 Big Losses
0%
20%
40%
60%
80%
100%
120%
ACTUAL DESIRED AVAILABILITY
Productive Machine Shop Reporting Job MaintenanceThe improvement opportunities are always in one of
the following “buckets”
Machine
Shop
Reporting
Job
Maintenance
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MERLIN Performance Management Model
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MPMM Categories
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Baseline and measure the output by hour, by shift, by day. Actual vs Target
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Analytics – Analysis with dashboards and report detail
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Dashboard View
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Plant Utilization View
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Event Chart – know exactly to the second
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MERLIN: Value Proposition
Delivers a 10% - 50%
average productivity
increase
Earns 20%-plus profit improvement based on just a 10%
increase in OEEA fast ROI
Achieves payback in less than 4 months
with an IRR greater than 300%
Ensures no machine is left behind Connect ANY
machine
Reveals ongoing & sustainable factory productivity gains for years to come
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Questions & Answers
Francis Martin [email protected]
John [email protected]
Kurt [email protected]
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Why Act Now
More value than buying a new machine.
By measuringRPM – Real-time Performance Management
Increase capacity 10+%, saves machines, space, labor & more.
Increase profitability60+%
Competitive advantage, retain and capture more customers
Validation, traceability, efficiency, accurate data, lower costs.
Visibility for everyone means better performance
Culture of efficiency means extend job security
Increase company
profits
Strategic Competitive
Edge
Visibility = Efficiency
Productivity Increases of 10-50%
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In Closing…
• If you have any other questions, please contact Rick Earles at [email protected]• Recommended Reading
o OEE-College.com - Book on OEE - R. C. Hanseno ISA95-Standards - Machine Connectivity Standardso Smartbox – Cyber Security for machines
• Recommended Viewingo SME Manufacturing Resource Center – Society Manufacturing Engineerso Modern Machine Shop – Data Driven Manufacturingo YouTube – Videos of Industry 4.0 Software functionalityo Improved Utilization Through Machine Monitoring – MC2 Conference
• Recommended Resourceso MTConnect.org – Industry Standard for connecting machines. o OPCFoundation.org – OPC connectivity to machines.o Fanuc Focas Library – For connecting Fanuc controlled machines.
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In Closing…
• You will receive an email within 24 hours with a link to view the webinar recording,
presentation materials and additional resources.
• Please join us for Part 3 of the series:
“Visualize – Real-time Data” featuring Rockwell Automation
Friday, June 19th from 9:00 am – 9:45 am
Register now at smartmanufacturingcluster.org/events
• On behalf of the Smart Manufacturing Cluster and our presenters, thank you for joining
us today!
ContactsTeam NEORick EarlesSenior Director Industry & [email protected]
VantageOne SoftwareFrancis Martin COO, [email protected]
Jergens, Inc.Kurt SchronSr. Financial [email protected]
Memex Inc.John Rattray Senior Sales [email protected]
Thank You