the power of productivity : forcam...

Global Manufacturing Intelligence

we speak machineforcam

The power of producTiviTy: fORCAM fORCE™

▪▪ LeTzTe seiTe innenTeil

“If you cannot measure it,you cannot improve it!”

Lord Kelvin, 1824 – 1907

▪▪ SeiTe 1

We Deliver Results in Productivity.

forcam force™– AT The hearTof Today’s smarT facTorysmarT facTory

The fourTh indusTrial revoluTion has already begun First there was the steam engine. Then industrial mass production

and automation. Now, a new age is dawning: Powered by IT, manu-

facturing processes are being networked across production sites.

This new age has been coined Industrie 4.0 in Germany.

At FORCAM, we can help you master this transition. We want you to

become as passionate about Industrie 4.0 as we are. The concept is

straightforward. Industrie 4.0 gives you access to all of your production

data at any time and from any location, enabling you to measure, con-

trol and optimize processes in real time. Empowered by this seam-

less fl ow of information, your shop fl oor and top fl oor will merge to

become a single intelligent whole – in other words, a smart factory.

FORCAM FORCE™ is the new IT solution that puts you in the driving

seat, with total control over your smart factory.

We are the partner of choice on the road to the Fourth Industrial Revo-

lution, always at your side as you step into the future. You can rely on

us to understand and share your goals, and to always deliver on our

mission:


The Fourth Industrial Revolution


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FORCAM – Pioneer of Industrie 4.0

FORCAM opened its doors for business in 2001, long before anyone had even started talking about Industrie 4.0. Company founder Franz Eduard Gruber, a former top manager at SAP, had a clear vision right from the start: "We want to make machines and factories smart." In other words, FORCAM’s aim was to empower industrial companies to boost productivity and use resources more eff iciently with the help of cutting-edge information technology.

Mercedes-Benz was one of the company's very fi rst clients. The Stuttgart-based car manufacturer quickly reaped the benefi ts of deploying FORCAMsoftware and was named "Factory of the Year" in 2007, 2008 and 2012. Additional big names followed, including Audi, BMW, MTU Aero Engines, the Schaeff ler Group and Hilti.

Today, we are one of the world's leading solution providers of Advanced Shop Floor Management technology solutions. Our technology is used globally to make over 60,000 machines more eff icient and processes more transparent. As such, we are making a key contribution to the cost eff ectiveness and tech-nology leadership of major industrial companies.

FORCAM FORCE™ milestones

As a pioneer and trailblazer in manufacturing intelligence, we are committed to strengthening our position as a technology leader. Our end-to-end, web-based solution FORCAM FORCE™ is

the latest example of our success in this area. It delivers all the functionality and capabilities a modern factory needs to succeed in Industrie 4.0. FORCAM FORCE™ is a modular solution that seamlessly connects heterogeneous machine assets with a cloud-based data management system. With its multi-language capability, it presents performance data to users anywhere, anytime.

FORCAM FORCE™ is living proof that even fi fteen years after fi rst opening for business, we have not lost any of our entrepreneurial spirit. We will continue to defi ne the pace as we move forward, driven by our courage to think outside the box and our passion for ground-breaking technologies. And by our promise to our clients:

We measure our success by your productivity gains – and every percentage counts!

fORCAm –Pioneer of IndusTrie 4.0

forcam

force™

The company at a glance

▪▪ Founded: 2001▪▪ Location: Ravensburg/Lake Constance▪▪ Subsidiaries: USA, China, Great Britain, Poland▪▪ Sales aff iliates: Benelux, Czech Republic, France,

Hungary, India, Switzerland, Slovakia, South Africa▪▪ Employees worldwide: 150▪▪ Industries: Automotive, aerospace & defense, enginee-

ring, machinery, medical devices, energy▪▪ Number of machines networked worldwide: > 60.000▪▪ Installed base: 160 + sites▪▪ Proven eff iciency gains : > 10%

Dated March 2016

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Our Clients

Welcome to the visionaries' club. FORCAM supports companies around the globe that regard productivity as an innovation opportunity and not just a cost factor. In simple terms, smart factories secure long-term competitive bene-fi ts and, as a result, jobs. This is a view that progressive industrial companies around the globe share with us. In the following you will fi nd a selection of customers from our reference base.

auTomoTive▪▪ Alcan ▪▪ Audi▪▪ BorgWarner▪▪ BMW▪▪ Daimler▪▪ Mercedes▪▪ Schaeff ler Gruppe▪▪ Grammer▪▪ Mahle▪▪ Mann+Hummel▪▪ Porsche▪▪ Voestalpine▪▪ Yanfeng

…

Machine, Tool and equipmenT engineering

▪▪ Arburg▪▪ Bosch Rexroth▪▪ Bühler▪▪ KUKA▪▪ Krones▪▪ Nordson▪▪ Sandvik▪▪ Schuler▪▪ SEW

Aerospace and defense

▪▪ General Atomics▪▪ GKN Aerospace▪▪ Hyde Aerospace▪▪ MAN▪▪ MTU Aero Engines▪▪ UTC Pratt & Whitney▪▪ UTC Aerospace Systems▪▪ Rheinmetall

Medical devices▪▪ DePuy Synthes ▪▪ Henke Sass Wolf▪▪ Karl Storz▪▪ MPS Micro Precision Systems▪▪ Sorin Group▪▪ SycoTec

Energy / Oil and gas ▪▪ National Oilwell Varco▪▪ Schlumberger▪▪ Weir Minerals

OThers ▪▪ Fissler▪▪ Heristo▪▪ Hilti

Empowered by The same vision

FORCAM is so much more than just a technology – it’s an entire philosophy to successfully manage and operate a plant."

James Owens, Plant Managerat BorgWarner

“

“

“

“

Strategically, the biggest risk of NOT having FORCAM’s Shop Floor Management Technology is that we would be out performed by our competitors."

Martin Thorden, President GKN Aerospace, Newington USA

Within a year, our stamping facilities were producing 20 percent more parts. With fi gures like that, you know that the investment in a new software architecture has really paid off ."

Axel Bienhaus, Head of Central Operational Management at the Press Plant Division of Audi AG

Looking back, the biggest surprise has been fi nding that the ‘real numbers’ on shop productivity and machine utilization were not as high as managers thought. We fi gured that our machines were cutting metal about 50 percent or so over two shifts. It was more like 40 percent when monitoring fi rst started. It is now higher than 55 percent and climbing."

Bill Metz, VP of Operations Richards Industries

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How FORCAM FORCE™ works

A look inside a smarT facTory Global manufacturing intelligence with FORCAM FORCE™

PROCESS STEPS:

1 Shop fl oor management and continuous improvement process (CIP)

2 Interfaces to all machine types and controllers

3 Real-time visualization of all production steps with performance comparison across all global production sites worldwide

4 Automated alarms with downtime reports

5 Controlling and reporting with insightful graphics and charts

6 Data synchronization to fully connect the shop fl oor with the top fl oor

7 Web-based, instant global access to insights in multiple languages across all time zones

ERP

SIEMENS FANUCMAZAK...FANUCMAZAK...

Visualization andPerformance Analysis

Alerting and Auto Reporting

Global Availabilityfor Benchmarking

Language and Time Zone

Independence

ERP Integrationand Feedback

Shop Floor Management

Reporting

Plug-In Conceptfor heterogeneous

Machines and Controls

CIP /OEEOEE Analysis

(Single Instance)

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Global Manufacturing Intelligence

fORCAM fORCE™– Simply smarTerHigh productivity is a key success factor in today's global economy. Yet productivity extends far beyond opti-mized machine utilization levels. Manyother factors have to be taken into consideration if plant operators wantto turn a conventional production fa-cility into a future-ready smart factory. These include low downtimes, fast re-pairs and, perhaps most importantly, the immediate availability of all pro-duction data.

However, the benefi ts of smart facto-ries reach beyond fi nancial gains. By ensuring that all processes dovetail to perfection, smart factories can give you a technological edge and sa-feguard the quality of your products. All of which enables you to increase your company’s value, secure pro-duction sites and, ultimately, protect

jobs. What’s more, you’ll be able to plan more accurately and, as a result, use resources much more eff iciently. Which is good news for your CFO and the environment.

The FORCAM FORCE™ Advanced Shop Floor Management technology takes all of these factors into considera-tion. It delivers a host of functions ranging from the connection of he-terogeneous machine clusters at diff erent sites to the global analysis of production processes across mul-tiple production facilities. FORCAM FORCE™ is a multi-site solution to support global operations. It runs on all browser-compatible devices, speaks multiple languages and crosses time zones with ease.

"

We stand by our promise to customers:

With FORCAM FORCE, we can boost your productivity by at least 10 percent.“Franz Eduard Gruber, Founder and Chairman of FORCAM

"

Adaptable is the new smart

Our fully integrated, single-platform solution off ers compelling benefi ts to all stakeholders in the production process, from machine operators through production managers and planners to IT managers. An intel-ligent and intuitive user interface brings complete and instant trans-parency to all production processes. Authorized users have real-time access to data over a cloud. This data also supports top-fl oor strategic decision-making, answering questions such as: Are we using our capacity to optimum eff ect? Is overall equipment eff ectiveness (OEE) high enough? Should we be investing in new machines? These actionable insights make FORCAM FORCE™ a key stra-tegic vehicle for your company.

Integral part of CIP

In addition to all of the above, FORCAM FORCE™ is a tool that can help you optimize your conti-nuous improvement process (CIP). It collects actual performance data from your machines and facilities and compares this with the planned targets (planned versus actual compa-rison), enabling you to systematically develop productivity potential within the framework of your continuous improvement process.

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FORCAM FORCE™ is a modular IT system, allowing customers to select and confi gure the building blocks that best fi t their needs.

FORCAM FORCE™ Modules

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Core Module BRIDGE

Building virTual Bridges beTween machines

Core Module Bridge

Machine clusters are often worlds apart – and not just because of the physical distance between producti-on sites. Diff erent manufacturers, mit machine ages, and software packagesand software packages create a highlydiverse landscape. FORCAM FORCE™bundles the streams of informationfrom heterogeneous machine clustersto create a uniform data platform.Suddenly a 15-year-old stamping plant, for example, can be synchronized down to the millisecond with a brand-new paint shop in another plant. At a singleglance, you can see exactly what ishappening on the ground from any-where in the world and from any device – tablets and smartphones included.

The FORCAM FORCE™ Bridge modulein the FORCAM FORCE™ solution pro-vides the machine interfacing and system networking functionality. Inaddition to data streaming, it featu-res submodules to integrate thirdparty software systems. Adapters can be used, for instance, to seam-lessly connect to Enterprise ResourcePlanning (ERP) systems from SAP andother vendors. Existing software plat-forms for PLM, TDM, CMMS and CAQ can also be easily integrated into theFORCAM FORCE™ landscape with plug-ins. FORCAM FORCE™ is the easy way to turn big data into smart data.

Sub ModuleMachine CommunicaTion

▪▪ Seamless, real-time integration of heterogeneous machine controls

▪▪ Automatic collection, processing, storage and presentation of data

▪▪ Signifi cant drop in manual reporting eff ort and likelihood of human error

▪▪ Support for all industry-standard control systems ▪▪ Plug-in connectivity for the following systems:

Sub Moduleforcam AdapTer for sap

▪▪ Seamless connection of SAP ERP with the shop fl oor▪▪ Easy installation without modifi cations to

SAP standard confi guration▪▪ Signifi cant reduction in SAP licenses needed▪▪ Capture of order data, machine capacity, shifts

and master data ▪▪ Shop-fl oor data fed back into SAP with time stamp ▪▪ Can also link to SAP HR and SAP PM

Sub ModuleERP AdapTer

New: Universal adapter for ERP-Systems.

Third-parTy sofTware plug-ins

Plug-ins are available to interface with third-party PLM, TDM, CMMS and CAQ software installations.

PLM TDM CAQ

PLM TDM CAQ

PLM TDM CAQ

PLM TDM CAQPM

PLM TDM CAQPLM TDM CAQ

Allen Bradley Fanuc FORCAM I/O Set

Heidenhain Makino Mori Seiki

MTConnect® Okuma Omron

OPC UA Siemens … and many others

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Module Schedule & Dispatch

You need to zoom in on the details to see the big picture. In other words, you need to analyze and plan your production processes in detail in order to plan long-term capacity, cal-

culate delivery schedules and optimizepersonnel deployment. The core module SCHEDULE & DISPATCH in FORCAM FORCE™ gives you the in-sights you need to perform these tasks. It consists of submodules for order data management, capacity planning and dynamic scheduling.

SCHEDULE & DISPATCH links the previously disconnected top and bot-tom fl oors of a company to create one coherent unit. This eliminates the need to key in data multiple times

in diff erent applications or systems across your com-pany. A uniform databa-se not only simplifi es the evaluation of production data, it also makes planning much easier. You can defi ne, simulate and optimize your workfl ow based on real-time production indicators. The intuitive interface gives

schedulers an instant overview of capacity availability, bottlenecks and resource requirements.

With FORCAM FORCETM, it’s easy to plan for Overall Equipment Eff ectiveness (OEE) by linking the shop to the top fl oor.

Core Module SCHEDULE & DISPATCH

Oiling The wheels of producTiviTy

SCHEDULE & DISPATCH

OrderManagement

DynamicScheduling

CapacityPlanning

Sub Module

Order DaTa ManagemenT

▪▪ Production orders sent directly to machines▪▪ Order data management functionality for

operators, skilled staff and team leaders ▪▪ Planned versus actual comparison and

cost accounting in real time ▪▪ Automatic reporting of yield, scrap, and

rework quantities▪▪ Machine terminal interface confi gurable

to individual user needs ▪▪ Multi-lingual capability

Sub Module

CapaciTy Planning

▪▪ Global shift management and planning ▪▪ Implementation of multiple shift models per factory▪▪ Flexible shift updates and changes ▪▪ Immediate comparative overview of shift productivity▪▪ Time savings with direct import of data to

and from SAP / ERP

Sub Module

Dynamic Scheduling

▪▪ Optimized workfl ow scheduling ▪▪ Automatic calculation of overhead through

simulation runs ▪▪ Optimization of set-up and throughput times ▪▪ Simulation model to analyze planning alternatives

before starting production ▪▪ Clear overview of available and utilized capacity ▪▪ Graphic dashboard with variable display options

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Module Performance Analysis

At the end of the day, you want to boost productivity. And we want to use IT to help you achieve that. FORCAM FORCE™ gives you end-to-end, mea-ningful insights into your production

activities – anytime and from anywhere. We call it 24/7 control.

One of the factors that sets us apart from conventional performance mea-surement tools is the way we present our data. Our dashboard is easy to read and give you an overview of all key indicators at a glance. You can carry out real-time evaluations online and display the results in graphics or tables. You can also design your

own report templates – it’s as easy as creating a chart in PowerPoint.

In connected factories, measuring in-struments also have to be networked.

FORCAM FORCE™ provides three submodules for this: Reporting, Visualization and Alerting. All three submodulescomplement each other andinteract to deliver comprehen-sive management functiona-lity. The Reporting submodule,for example, presents per-formance data while Visua -lization provides an instant

snapshot. The Alerting component givesyou added reassurance and control. This automated reporting feature actively lets you know as soon as something deviates from the norm, enabling you to respond accordingly.

In short – you have everything you need for complete peace of mind. Nothing more and nothing less.

Core Module PERFORMANCE ANALYSIS

Why leave iT To chance?

PERFORMAnCE ANALYSIS

Reporting Visualization Alerting

Sub ModuleReporTing

▪▪ Transparent performance reporting for optimized production

▪▪ Precise evaluations – down to the second – across multiple machines and production sites

▪▪ Evaluations for workplace, orders, materials and staff

▪▪ Real-time, workplace-based OEE reports ▪▪ Direct comparison of operational statuses

and cumulated downtime reporting▪▪ Administration of rights for user roles▪▪ Time zone synchronization▪▪ Multi-lingual capability

Sub ModuleVisualizaTion

▪▪ Graphical representation of production status▪▪ Drill down from site views to individual machines▪▪ Global, web-based access for authorized users▪▪ Flexible interface design using drag and drop ▪▪ Easy-to-build overview charts and customer

dashboards▪▪ Import function for background images

from all conventional graphic formats

Sub ModuleAlerTing

▪▪ Alerts issued across sites for pre-defi ned events with escalations

▪▪ Automatic push to various channels (e.g. e-mail, text message)

▪▪ Variable rule for deadlines, set-up times anddowntime thresholds, etc.

▪▪ Linking to automatic responses such as reports or fi le archiving

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Module Energy Control

Core Module ENERGY CONTROL

The biTs & byTes of energy efficiencyFORCAM FORCE™ can help you startyour very own energy revolution. OurENERGY CONTROL module records

and documentsenergy consump-tion at each of your production sites and maps this information against opera-tional data such as shifts and or-der volumes.

You can monitor and graphically visua-lize energy and production-relatedevaluations on demand to keep a close eye on consumption patterns.This module enables you to easily identify areas or machines that are consuming too much energy.

In a nutshell: A powerful FORCE for powerful energy savings.

TRACK &TRACE

Traceability

EnerGYconTrol

Energy

Module Track & Trace

Quality is a top priority for any manu-facturing facility. The question is how can you ensure consistently

high quality stan-dards over time? The answer is assimple as it is smart – with a software solu-tion that brings transparency to your productionfl ow, right down to the last nutand bolt. Whether

you’re dealing with damages, comp-laints or legal compliance, you're in good hands with FORCAM FORCE™.

FORCAM FORCE™ gets your entire production process on the quality track. Right down to the millisecond.

At any time, you can fi nd out when, how, where and by whom a product was machined, assembled, and sto-red? The TRACK & TRACE module allows you to fully trace every step in the production fl ow of a fi nished product – right back through the en-tire supply chain to each individual component. Every product can be uniquely identifi ed by a serial number or a batch/lot number.

But TRACK & TRACE can do much more.It also uses event-driven data recor-ding to measure and process all production-relevant indicators such as power, temperature and pressure, and store this data for further auto-matic processing. This additional module will turn your smart factory into a true transparency pioneer.

Core Module TRACK & TRACE

On The qualiTyTrack

TRACK &TRACE

Traceability

EnerGYconTrol

Energy

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Modul Document Control

Smart factories need smart data. In other words, meaningful real-time data presented in a user-friendly way. It’s all about getting the right information

at the right time in the right form. Giving operators immediate access to the information they need for their work increases safety and, as a result, productivity levels.

The DOCUMENT CONTROL module in the FORCAM FORCE™ suite visuali-zes data intuitively and simplifi es data administration. Orders are automati-cally streamed from the ERP system and linked with production-related information from CAD, NC and PLM systems. The Product Data Manage-ment submodule manages the fl ow of data while the DNC submodule stores and manages all NC programs as fi les. Based on freely defi nable key terms, the information is projected directly onto electronic production maps for each operator.

With FORCAM FORCE™, you can be sure all of your data is at the right place at the right time.

Core Module DOCUMENT CONTROL

AcTionable insighTs in real Time

Sub ModuleProducT DaTa ManagemenT

▪▪ Extensive search and fi lter functions

▪▪ Support of all data formats▪▪ Smooth interfacing with

CAD, PLM and ERP systems▪▪ Ergonomic, confi gurable user

interface▪▪ Central system administration

with user and revision manage-ment

Sub ModuledNc

▪▪ Editing of NC programs and transfer to any machine control

▪▪ Versioning and change tracking▪▪ Documentation and restoration

of diff erent versions▪▪ Automatic data synchronization

with document management

DocumenT conTrol

Product DataManagement DNC

Technology and ConfigurabilityTechnology and Configurability

Visualization of shop fl oor assets with real-time production status

Operating state development from the easy to confi gure report editor

Shop Floor Terminal – Interface for order and runtime feedback to the system

Planned vs. Actual comparison of work orders available on the shop fl oor

OEE monitoring for regular management report. This is often used as a KPI to benchmark shifts and plants.

Runtime development on key assets to pro-actively identify downtime reasons

Page » 25

In The fuTure, you will decide how inTelligeTly your machines work.


Page » 27Page » 27

The FORCAM ACADEMY

At FORCAM, we have many great ideas that we want to share with you. Our Academy is a learning platform for FORCAM FORCE™. Course parti-cipants can discover everything there

is to know about FORCAM FORCE™, including its functions, system archi-tecture and use cases. Our training also covers individual confi gurationoptions for indicators and terminals. In addition, we offer courses for managers that explore the impact of change in shop fl oor management and in continuous improvement processes.

Just as FORCAM FORCE™ brings trans-parency to the smart factory, our

Academy brings transparency to the FORCAM FORCE™ user. We transform technical information into practical, usable knowledge so that you and your employees can use FORCAM

FORCE™ even more eff ectively for your daily work. We train and coach entrepreneurs, planners, operators, partners and our own employees. Depending on their level of knowled-ge, participants can take BASIC, ADVANCED or EXPERT courses. Our experienced trainers use clear, easy-to-understand, proven methods to share their knowledge – either in a classroom setting or via eLearning courses.

FORCAM Academy – knowledge sharing hub

!

Face-to-Face Training

Trainer lead eLearning

Self-paced eLearning

academyforcam™

Services & Support

Page » 29

Smart Factory in a Box

SMART FACTORY Starter Kit

Big power in a small package

Small investment

Low risk

Immediate results

Low risk

The SMART FACTORY Starter Kit fromFORCAM gives you an excellent kick-start in the world of Industrie 4.0. This kit is a smart, easy way to bring digital manufacturing intelligence to yourproduction site. Test-drive cloud-based machine connectivity, real-time repor-ting and dashboard visualization on a small scale. The kit contains all of therequisite software and hardware com-ponents, including the FORCAM I/O box, IBH Link, MTConnect and Siemens controls.The SMART FACTORY Starter Kit will boost machine productivity as soon as you get up and running. Why not take it for a spin yourself?

Contact

GeneraTion 4.0 – are you on board?

To take your fi rst step into the future, all you need is an old-fashioned device: a telephone.

Simply call us at + 1 513 878 - 27 80 or send an e-mail to [email protected]

Headquarter Americas at:

FORCAM INC. 250 East 5th StreetCincinnati, Ohio 45202USA

For a list of selected FORCAM sales partners close to you, visit our website at: www.forcam.com

Connectivity across all machines

+10 % eff iciency gain guaranteed

To take your fi rst step into the future, all you need is an old-fashioned device: a telephone.

Simply call us at + 1 513 878 - 27 80 or send an e-mail to [email protected]

Headquarter Americas at:

FORCAM INC. 250 East 5Cincinnati, Ohio 45202USA

For a list of selected FORCAM sales partners close to you, visit our website at: www.forcam.com

+10 % eff iciency gain guaranteed

Page » 31


We may whaT you'll bemain The fuTBuThow be d

FORCAM FORCE™ is always evolving. Just like a Smart Factory. Find out more about the latest modules and functions at www.forcam.com

may noT knowaT you'll benufacTuring

n The fuTure.BuT we do know

w you'll doing iT.

FORCAM FORCE™ is always evolving. Just like a Smart Factory. Find out more about the latest modules and functions at www.forcam.com

Page » 33Page » 33

FORCAM Inc.250 East 5th Street

Cincinnati, Ohio 45202

USA

+1 513 878 - 27 80

+1 513 562 - 15 05

[email protected]

www.forcam.com

The information and technical details presented in this brochure are subject to change. The information is dated January 2016.

the power of productivity : forcam...

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