on the way to smart factory

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MT65: On the Way to a Smart FactoryManufacturing Innovation with IoT Solutions

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Industry trends: Dell – IDG Research Survey 2015

Top priorities over next 12 months:• Security, analytics and upgrade core applications

IoT impact:• 25% are doing very little in terms of IoT• 40% already have networked connected devices• Top benefits:

– Business innovation– Reduced TCO– Competitive edge– Improved process performance

• Investment barrier: Budget constraints and security concerns

Other trends:• 77% increased ERP complexity• 56% evaluating ERP cloud based solutions• Primary challenges – Cost and business process

integration

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Industry trends: “Smart Factory”

Decreased cost:

• Connected devices

• Network bandwidth

• Cloud storage

Increased data

• Devices (Machines and products)

• Systems (ERP to shop floor)

Requirement –“Real time” decision making

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Internet of Things

Impacts every aspect of your life, personal and professional.

Today’s technology cost is so low, the ability to build creative solutions can transform company operations.

How a company leverages the current industry trends will not only differentiate their business, but gain insight to making better business decisions in real time.

Internet of Things (IoT)

Connected manufacturing

Connected asset management

Connected retail

Predictive maintenance

Connected logistics

Connected buildings

Connected home

Connected car

Connected family

Connected cities

Connected healthcare

Connected policing

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Internet of Things


Private and public networks 10’s of billions of connected things High-performance computer infrastructure

Things Sensors Transport Connector Application layer

In-memory database layer

Libraries

Sensors alone do not transform operations. They have existed for years, along with various software packages to collect and analyze.

Data points without connectivity do not transform business operations. Networks need to be designed to handle this increased traffic while managing the security requirements.

The key is to combine sensors, networks and high computing to empower decision making from operators to executives


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Internet of… Industry 4.0

Internet of Things and Industry 4.0

Internet of Things (IoT) Connecting information, people and things is the greatest resource ever to drive insightful action. This era is the Internet of Things – the ability for machines to monitor, analyze and truly automate business – in real time.

Industry 4.0 Providing a manufacturing roadmap focused on transforming operations, by leveraging the latest in technology and business processes.

Combined, IoT and Industry 4.0 are more than the latest marketing trend.

The opportunity now exists to “rethink” what is truly possible by empowering operators to executives with a real-time decision making process, enabling a “Smart Factory”.

Providing the ability to “build anything”

Content People Things

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Internet of Things and Industry 4.0

Why the change?

Economy - Strong product customization under a mass production environment.

Impact to manufacturers?

Require connected machines, people and systems to allow real-time decision making, accross the supply chain.

Key elements:

Focus on self optimization, self configuration, self-diagnosis and intelligent support of workers

Cross company + Supply chain

Multiple plants

Production cell(s) - Plant

Machines

People Systems

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Challenge

TreeHouse has several shop floor information systems unevenly deployed across SAP and non-SAP footprints. The corporate initiative is to use a single set of consistently calculated operational metrics such as Overall Equipment Effectiveness (OEE), schedule adherence and attainment and quality. The challenge was to find a solution agnostic for whether the location is live on SAP or which shop floor systems are deployed and provide increased confidence reported metrics.

Products involved• SAP Manufacturing Integration & Intelligence (SAP MII – 12.2)• SAP ERP (ECC 6.0)• Time Tracking Software, 3rd party ERP system and shop floor

systems

Project highlights and benefits

• Enabler to operational improvement: facilitates actionable meetings of timely information with personnel who can drive improvement

• Rapid template deployment: application can be configured to each plant thus avoiding need for new custom development and maintenance hassles

• Flexible platform for future functionality: ongoing plans to add additional reporting and data capture features

• Platform independent: application is built on GPL open source query plugins eliminating the need for specific browser/java versions

Shop Floor TransformationFood industry

Customer project: Combined implementation SAP ERP and SAP MII

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Smart Factory – point of view

ERP – MES integration

Manufacturing execution layer

Enterprise and planning layer

Machine and device integration Analytics

Mobility

Big DataIn-memory

Cloud

Connect

Transform

Re-imagine

Interconnecting and automating processes simplify work for end-user and increase efficiency on the shop floor

Transforming data from different sources (sensor, ERP etc.) into information usingIoT technologies to become more predictive and identify insights that drive efficiency on the factory floor

Mobility solutions, modern UX, In-memory technology and cloud infrastructure increase innovation

Rapid deployment of standard and new technologies drive ROI in manufacturing environments

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Internet of Things Solution Framework

Dell IoT fabric and services for Digital Factory ecosystem

SCADA/ Sensors/ Devices layer

Edge Layer

Dell Edge Gateway

Advanced Analytics layer

UI layer

Dell tablets/Mobile Apps

IoT Life Cycle Mgmt Platform (Partner)

CEP Engine(Partner)

BPM/API Management (Partner)

Service layer:

Smart Connected Products

Smart Connected Operations

Service layer:

Smart Connected Integration

Service layer:

Smart Connected Enterprise

Service layer: Advisory and transformation

Multiple factory locations 1-N

Service layer:

Smart Connected Apps SAP MII, SAP ME, SAP Fiori

SAP MII

SAP PCo

End-to-end Security:

Asset Management

IAM: Dell Quest

Integration layer

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Dell approach...

Start with what you have

Architect for analytics to enable

“smarter” decisions

Put Security First

Start small with IoT projects that use the devices and data you already have, then grow based on real-world success. Dell can help you get past the hype to identify realistic use-cases and build strategic plans based on realistic ROI analysis. Our practical approach leverages your organization-wide technical and domain expertise and builds on your current technology investments.

• Clarify business outcomes and ROI• Strengthen IT and business partnerships• Start small and grow

Analytics-driven action provides the real business value of the IoT and Dell’s analytics, data management and infrastructure solutions provide the power to ensure your IoT solution delivers deep insights at the speed of business. Dell’s modular, open, future-ready solutions and scalable cloud services provide the ability to move from pilot to producing value quickly and cost-effectively.

• Build on your terms• Harness the power of analytics• Scale for performance

Dell’s end-to-end, connected security solutions, tools and expertise simplify security and manageability in IoT initiatives ensuring your data is secure and private from Dell endpoint devices to your datacenter to the cloud, and that you are compliant with ever changing regulatory requirements.

• Secure from device to datacenter to cloud • Protect data wherever it goes• Secure for compliance

12 Photo copyright is owned by the customer

Shop Floor TransformationComposite materials producer

Customer project: Multi-site process integration up to the machines

Challenge

Scapa Group wanted to automate manual processes at its newest production facility and upgrade to the latest version of its shop-floor SAP Manufacturing Integration and Intelligence (MII) solution, originally deployed by Dell. The challenge was how to rapidly deploy the solution with an upgrade component to a FDA regulated plant.

SAP products involved• SAP Manufacturing Integration & Intelligence (SAP MII –

15.0)

• SAP ERP (ECC 6.0)


• Manual processes are automated, giving Scapa real time data access and the ability to comply with track and trace industry regulations

• Streamlined production processes across manufacturing plants

– On-demand scheduling and increased visibility

– Raw material component management.

– Stock movement automation

– Quality / defect management

• Dell’s flexible support model provides additional strategic and technical resources available at any time

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“Smart Factory” – example landscape

Resolve implementation issues in specific areas

Infrastructure

• Network (wired and wireless)

• Hardware (Servers, desktops, laptops, tablets and mobile)

• Cloud Services, Security and Governance

• Application Management Services and Software Solutions

• Evaluation and deployment of physical hardware and software solutions to capture key data elements in the manufacturing environment

• Example: Installing temperature sensors on key machine components to enable predicative analytics

Sensor Deployment

• Empowering operators, supervisors and plant managers to proactively manage the manufacturing process through streamlined transactions and KPI enablement (OEE)

• Example: Creating shop floor operator dashboards to record key transactions and provide real-time metrics

Factory Operations

• Integrating and streamlining inventory management, transportation, sourcing/procurement, production planning/execution, distribution, sales/marketing and return processing into a cohesive process

• Example: KANBAN enablement

Supply Chain

• Automating and integrating the Product Lifecycle Management link from product inception through engineering design and manufacture to service and disposal

• Example: 2D to 3D Transformation

Product Lifecycle Management

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Shop Floor TransformationMedical devices producer

Customer project: Paperless manufacturing

Challenge

Old Legacy flash-based application and paper-based records to manage and run manufacturing operations on shop floor.

Need for an intuitive user friendly MES solution that involves operator/supervisor dashboards which seamlessly integrates the enterprise SAP ERP, document repository and shop floor machines.

SAP products involved

• SAP manufacturing integration and intelligence (SAP MII –15.0)

• SAP ERP (ECC 6.0)


• Elimination of legacy applications and paper records

• Seamless integration from enterprise ERP to shop floor

• User friendly dashboards for data entry and one place forall shop floor operations

• One stop shop for all manufacturing operations – instant access to all documents and quality data

• Improved visibility proactively addresses conditions • Integration to machines reduces human error and

increases operator efficiency

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“Smart Factory” – getting started

Resolve implementation issues in specific areas

Infrastructure

Sensor Deployment

Factory Operations

Supply Chain

Product Lifecycle Management

Approach #1: Shop Floor Strategy Workshop

Approach #2: Sensor Deployment Support

Approach #3: ERP Deployment Support

Approach #4: MES Deployment Support

Approach #5: OEE Reporting

Approach #6: Predictive Maintenance

The following areas are just some of the approaches our customers are considering when looking to modernize their shop floor.

Approach #9: Hardware & Network Upgrades Approach #9: Cloud Services

Approach #7: SCM Project

Approach #8: PLM Project

Your questions?

Thank You!