FactoryFramework Advanced Shop Floor Management

Transcription

1 FactoryFramework Advanced Shop Floor Management FORCAM, Inc. 250 East 5 th St., Cincinnati, OH Mohamed Abuali Director Delivery Operations State-Of-The-Art Shop Floor Management

2 Presentation Agenda FORCAM Introduction Shop Floor Management with Factory Framework Technical Capabilities Machine Data Collection Order Data Collection with SAP Integration Personnel Data Management SFM OEE Performance Reporting and Visualization Additional SAP Integration Functionalities Configuration Capabilities with Live Demonstration Project Plan and SFM Workshop Summary and Conclusions FORCAM 2014 Page 2

3 FORCAM s Passion FORCAM provides proven manufacturing solutions to Continuously Improve Productivity To be the global solutions provider of the best-in-class Manufacturing Execution Systems FORCAM 2014 Page 3

4 FORCAM - History Shareholder SAP Founder Dietmar Hopp Stamping Plants Productivity + 20% within 12 months Founding FORCAM USA New Plant Münchsmünster Founding FORCAM UK Web Technology SFM Evaluations Machine-Connector 400 Heterogeneous Machines Press Plants Asset worth US$ 2.5 Billion Global Roll-Out (> 90 Plants) SME Business + 25% increased operating time and availability of all facilities Press Plant Leipzig & China Research Partnership Release 5.0 SAP Spin Off Innovation Award 15,000 Monitored Assets + 12% Efficiency Increase within 6 Months Frost & Sullivan 2014 Award FORCAM 2014 Page 4

5 FORCAM International Presence Head Office Germany Friedrichshafen FORCAM Ltd United Kingdom Cheshire FORCAM Inc. Americas Cincinnati, OH, USA Team France Team Switzerland Benelux Team South Africa Team Poland Team Hungary Team China Team India Team Malaysia FORCAM 2014 Page 6

6 FORCAM Partner Network IBM Global Partner SAP Certified ERP Partner IMS Center Univ. Of Cincinnati Research Partnership TDM Systems Tool Management FactoryFramework Network Over 150 MES Experts Q-DAS Quality / SPC FORSIS Industrial PCs FORCAM 2014 Page 7

7 Our Customers Automotive OEM Automobile + Automobile Suppliers Aerospace/ Marine Aerospace Defence Machinery Medical Devices Other Industries - Minerals - Oil & Gas - Heavy Machinery - Food & Beverage - Pharmaceuticals FORCAM 2014 Page 8

8 AUDI Due to Factory Framework the press plants have increased their productivity by 20 % within the first year. Investing in a new solution architecture was well worth it. Axel Bienhaus, Audi AG FORCAM 2014 Page 9

9 BorgWarner The FORCAM technology is unique and exceeded our expectations in all categories important to us - strategy, functionality, costs. J. Bischoff, BorgWarner FORCAM 2014 Page 10

10 Weir Group In just 6 months Factory Framework has given us a 12% efficiency increase. Tony Locke MD, Weir Minerals FORCAM 2014 Page 11

11 Overall Impact on Customers Productivity: Audi (Stamping) +20% within 12 Months Weir Minerals +12% within 6 Months Technology and Scalability: From Machining Job Shops with 10+ Machines To Multi-Plant Shop Floor Management with 14,000 Machines Connectivity: MTU Aero Engines: Shop Floor Management with 400 Machine Tools (25 Various CNC Controls / PLCs) Seamless ERP Integration with Multiple Sites: FORCAM complements SAP ERP ideally. FORCAM 2014 Page 12

12 FORCAM s Approach Advanced Shop Floor Management If you cannot measure it, you cannot improve it. Lord Kelvin Shop floor transparency based on real-time, objective data collection Continuous process improvement with PDCA Reliable performance measurement and metrics FORCAM 2014 Page 13

13 Continuous Improvement Process at AUDI Act Plan PDCA Do Target state Actual state Check +20% AUDI and SEW Factory Framework delivered a 20% increase in overall productivity: Within the first 12 months at AUDI Within the first 3 months at SEW Euro-Drive FORCAM 2014 Page 14

14 Presentation Agenda FORCAM Introduction Shop Floor Management with Factory Framework Technical Capabilities Machine Data Collection Order Data Collection with SAP Integration Personnel Data Management SFM OEE Performance Reporting and Visualization Additional SAP Integration Functionalities Configuration Capabilities with Live Demonstration Project Plan and SFM Workshop Summary and Conclusions FORCAM 2014 Page 15

15 Architecture for Fully-Integrated OEE System FORCAM 2014 Page 16

16 Factory Framework - Modular Functionality PP CO MM HR PM PLM TDM CAQ ERP Adapter PLM Adapter TDM Adapter CAQ Adapter Factory Framework Dynamic Scheduling Alerting Order Data Management SFM Performance Analysis & Reporting Production Data Mgmt (PDM+DNC) Visualization Process Data (Traceability) Personnel Data Machine Data Connection FORCAM 2014 Page 17

17 Factory Framework - Interface View SAP ERP Baan QAD Windshield Siemens PLM Catia ERP PDM Worker Client Poke Yoke Ergonomic (Touch) Easy access Web- Portal Rights Management Global access Office Client Machine Connection Heterogenous PLC integration: Fanuc Siemens Mazak MTConnect... FORCAM 2014 Page 18

18 Seamless Integration with SAP ERP Performance Shop Floor Management FORCAM + SAP ERP Portal / BO PP CO MM HR PM QM.. Shop Floor Enterprise Shop Floor Realtime Event-oriented Detail & Mass Data Innovation Best Practice Solution task sharing, independent operation, optimized costs, riks-free investment Enterprise Transactional Booking-oriented Asynchroneous Processes Stability Platform VIDEO LINK Seamless Integration with SAP FORCAM 2014 Page 19

19 Certified SAP Integration FORCAM 2014 Page 20

20 CIP Organization: Role-based User Administration and Reporting Forman Production planning Plant Manager Overall plant performance Maintenance Maintenance order Hit lists Factory personnel Work order/ work instruction Machine Industrial Engineering Production data act vs. planned FORCAM's Shop Floor Management technology supports all organizational roles within the CIP-organization. VIDEO LINK SFM / OEE Reporting FORCAM 2014 Page 21

21 Presentation Agenda FORCAM Introduction Shop Floor Management with Factory Framework Technical Capabilities Machine Data Collection Order Data Collection with SAP Integration Personnel Data Management SFM OEE Performance Reporting and Visualization Additional SAP Integration Functionalities Configuration Capabilities with Live Demonstration Project Plan and SFM Workshop Summary and Conclusions FORCAM 2014 Page 22

22 Machine Data Collection (MDC) with Heterogeneous Adapters SFM Reporting, Analysis & Visualization Machine Data Collection (MDC) for Heterogeneous Controls/PLCs Plugin Siemens TCP/IP native Plugin Siemens RFC 1006 Plugin Modbus over TCP/IP Plugin OPC / OPC-UA Client Ethernet (Works LAN) Rockwell Allen Bradley Siemens 810/840D Omron OKUMA Heidenhein MAZAK Plugin MTConnect FANUC PLC S5/S7 Mitsubishi Makino FORCAM Fieldbus Controller for Legacy (Non-Ethernet) Controls (B&R / Elau / G&L / Koyo / Other) FactoryFramework connects to and acquires real-time data from various machine controls using a variety of readily-available protocols. FORCAM 2014 Page 23

23 Operating State Mapping Engine "Production" State Target: Standard OEE Key Figure Examples: Definition for "Production" Operation State Definition Production Schunk Coperion Mahle ZNF MTU Automatic operation 1 Automatic operation 1 Automatic operation 1 Automatic operation 1 Program running 1 Program running 1 NC program start 1 Program running 1 Feed rate switch = 100% 1 Override <>0 1 Override <>0 0 NC ready for operation 1 Rapid traverse = 100% 1 Cycle start 1 Cycle end 0 Manual operation 0 Spindle speed = 100% 1 Warm-up bit 0 Semiautomatic NC ready for operation 1 operation 0 Feed rate > 85% 1 NC alarm 0 Machine off 0 Program halt 0 FORCAM 2014 Page 24

24 Operating State Mapping Engine Fault Code" States Alarms Standardized Operation States Machine-by-Machine Assignment FORCAM 2014 Page 25

25 Case Study - Machine Data Collection (MDC) MTU Aero Engines (400 Machines 25 Heterogeneous Controls) FORCAM 2014 Page 26

26 Real Time Signal Recognition and Web Visualization VIDEO LINK Machine Data Collection with Visualization FORCAM 2014 Page 27

27 Presentation Agenda FORCAM Introduction Shop Floor Management with Factory Framework Technical Capabilities Machine Data Collection Order Data Collection with SAP Integration Personnel Data Management SFM OEE Performance Reporting and Visualization Additional SAP Integration Functionalities Configuration Capabilities with Live Demonstration Project Plan and SFM Workshop Summary and Conclusions FORCAM 2014 Page 28

28 Integrating Order Data with Machine Data (ODC + MDC) Event-Driven Message Entry Workplace / Machine (WP) Order / Operation (Op) Personnel (Pers) ODC MDC Op. - start Op. - part qty WP - downtime Op. - continue Pers. log on Op. party qty Op. - end OP- start Pers. Log off Op. - start WP - downtime Op. - continue Message Timeline 22:00 06:00 14:00 22:00 06:00 00:00 00:00 FORCAM 2014 Page 29

29 Order Transparency with Order and Machine Data Integration SAP ERP PP Factory Framework Transparent Production Environment - Detailed Production Status in Real Time Production Shop Floor Person/Group, Quantity, Yield, Scrap, Rework FORCAM 2014 Page 30

30 Actual versus Target Peformance Reporting ERP Data Target/Planned Throughput Opportunity for Improvement Actual Performance Actual Throughput Machine Data VIDEO LINK Order Data Management at Worker Client VIDEO LINK Actual vs. Target Performance FORCAM 2014 Page 31

31 Presentation Agenda FORCAM Introduction Shop Floor Management with Factory Framework Technical Capabilities Machine Data Collection Order Data Collection with SAP Integration Personnel Data Management SFM OEE Performance Reporting and Visualization Additional SAP Integration Functionalities Configuration Capabilities with Live Demonstration Project Plan and SFM Workshop Summary and Conclusions FORCAM 2014 Page 32

32 Personnel Management - Booking Types Employee Order / Operation Machine(s) Booking Type Individual Work Centers can be allocated to several machines One to Multi-Operation Multi-Machine Multi-Operation Group Booking VIDEO LINK - Personnel Management at Worker Client FORCAM 2014 Page 33

33 Exact Production Cost Determination SAP ERP PP CO Factory Framework Actual-time-tracking of all activity types including multi machine operation Workday Book on Book off Sta rt Operator Works order 1 Sta rt Ma chine 1 Op End Ma chine 1 & Opera tor Works order 2 Op Production Shop Floor Sta rt Operator Sta rt Ma chine 2 A B C D End Ma chine 2 & Opera tor Person, Group, Quantity, Yield, Scrap, Rework Overhead costs, Cost centers FORCAM 2014 Page 34

34 Quick Cost Transparency Direct Analysis of Labor Costs in Production Order Display (SAP Standard) FORCAM 2014 Page 35

35 Presentation Agenda FORCAM Introduction Shop Floor Management with Factory Framework Technical Capabilities Machine Data Collection Order Data Collection with SAP Integration Personnel Data Management SFM OEE Performance Reporting and Visualization Additional SAP Integration Functionalities Configuration Capabilities with Live Demonstration Project Plan and SFM Workshop Summary and Conclusions FORCAM 2014 Page 36

36 Target-Oriented Performance Measurement & Benchmarking 60,5% 60,5% 49,5% 51,7% Plant 1 Plant 2 Plant 3 60,5% TRUE OEE Target Multi-Plant Performance Benchmark 60,5% Plant 1 60,5% Plant Performance 66,0% 55,0% Group: M1 M2 Group: M3 M5 66,0% Hall, Cell, Line, Group Performance 66,0% Group: M1 M2 72,0% 60,0% 70,0% 40,0% 55,0% Machine 1 Machine 2 Machine 3 Machine 4 Machine 5 Machine Performance FORCAM 2014 Page 37

37 Web Visualization (with ANDON Capability) Real-time web visualization of current production status worldwide via web data access with Factory Framework Creation of one's own displays with the editor and operation of multiple views independent from each other - e.g. machine, production line or shop floor layout Fully Configurable with a Report/Visualization Editor Display on large format screen in the production / ANDON board FORCAM 2014 Page 38

38 Performance Reporting and Optimization Transparency in real-time through detailed imaging of TPM methods to uncover bottlenecks and improvement potentials Plant-wide transparency in real-time through web technology Coherent key figures (OEE, NEE, TEEP) Large selection of predefined reports with different views: workplace, order, material, personnel Creation of one's own reports with the report editor FORCAM 2014 Page 39

39 Reporting Dashboards and OEE KPI Cockpits Individually Adjustable Graphic Screen All key figures that are important to you in one single overview. Display of crucial key figures and machines Ergonomic and well-arranged Individually configurable FORCAM 2014 Page 40

40 Presentation Agenda FORCAM Introduction Shop Floor Management with Factory Framework Technical Capabilities Machine Data Collection Order Data Collection with SAP Integration Personnel Data Management SFM OEE Performance Reporting Additional SAP Integration Functionalities Configuration Capabilities with Live Demonstration Project Plan and SFM Workshop Summary and Conclusions FORCAM 2014 Page 41

41 Bi-Directional SAP ERP Integration SAP ERP PP CO MM HR PM QM 1 2 Master Data Order, Op, dates, PT Status, Quantities, Stoppages FactoryFramework 5 Order Data Management Quantities, Stoppages 4 Machine Data Collection Quantities, Stoppages 3 Booking of Order Messages Personnel Messages Statistics, Notes, Warnings Quantities, Stoppages 3 VIDEO LINK SAP Work In Progress FORCAM 2014 Page 42

42 SAP ERP Integration with Corrections SAP ERP CO MM PP Automatic in SAP: Cancellation and New Booking Factory Framework Simple and Quick corrections in FF Office Client Quantities Scrap Stoppage Reasons Order Data Management VIDEO LINK Corrections FORCAM 2014 Page 43

43 Alert Management (with optional SAP PM integration) SAP ERP PP CO MM HR PM QM Factory Framework Booking 3 Order data management Alerting 2 Alerting, Notification Process data 1 Control, compare, alarm, transfer 1 Machine data FORCAM 2014 Page 44

44 Presentation Agenda FORCAM Introduction Shop Floor Management with Factory Framework Technical Capabilities Machine Data Collection Order Data Collection with SAP Integration Personnel Data Management SFM OEE Performance Reporting Additional SAP Integration Functionalities Configuration Capabilities with Live Demonstration Project Plan and SFM Workshop Summary and Conclusions FORCAM 2014 Page 45

45 Configuration Capabilities with Live Demonstration Factory Framework Software Overview - LIVE Hierarchic Configuration Machine Data Collection (Formula Engine) OEE Time Basis User Rights Access Management Language / Literal Editor Web Visualization and Reporting Editor Alerting with Auto-Reporting FORCAM 2014 Page 46

46 Presentation Agenda FORCAM Introduction Shop Floor Management with Factory Framework Technical Capabilities Machine Data Collection Order Data Collection with SAP Integration Personnel Data Management SFM OEE Performance Reporting Additional SAP Integration Functionalities Configuration Capabilities with Live Demonstration Project Plan and SFM Workshop Summary and Conclusions FORCAM 2014 Page 47

47 Factory Framework - Phased Project Plan Top Floor (ERP) FactoryFramework Detailed Scheduling SFM Performance Analysis & Reporting Universal ERP Adapter Order Data Management Alerting Production Data Management + DNC Visualization Process Data Management Personnel Data Machine Data Collection Shop Floor Phase 1 Phase 2 Phase 3 Phase 4 - Machine Data Collection - Web Visualization, Reporting - Alerting - ERP Data (Orders/Ops) - Personnel Data - PDM/DNC - Dynamic Scheduling FORCAM 2014 Page 49

48 Systematic Project Plan FORCAM 2014 Page 50

49 Shop Floor Management (SFM) Workshop AGENDA (8:00 AM - 5:00 PM) Shop-Floor Muda Walk (8:00 AM) Introduction (8:30 AM) Participants Goals of the SFM Workshop Roles & Responsibilities FORCAM Lessons Learned and Case Studies (9:00 AM) Shop-Floor Management Solution Fundamentals & Technology (9:45 AM) Factory Framework System Overview (30 Min) Module Requirements and Detailed Specifications FF - Order Data Management with SAP ERP Integration (45 Min) FF Machine Data Collection (30 Min) FF - SFM Performance Reporting, Visualization, Alerting (30 Min) LUNCH BREAK (NOON) Shop-Floor Management Solution continued (1:00 PM) Office-Client and Worker-Client Specifications Processes, Interfaces, Usage Shop Floor Management Reporting Dashboard Reporting/Cockpit: OEE, GANTT, Actual vs. Planned System Administration and Rights Access Management Machine (Shop Floor) Integration Requirements (2:00 PM) Machine Types / PLC Types / Signal Acquisition ERP (Top Floor) Integration Requirements (2:30 PM) ERP Specifications - Orders, Operations, Bookings IT Requirements (Hardware / Server / Networks) (3:30 PM) Summary, Action Items and Next Steps (4:00 PM) Required Attendees: Project Manager All Project Team All Project Team Project Team (Select) Plant Maintenance IT (ERP) IT (Infrastructure) Project Manager FORCAM 2014 Page 51

50 SFM Workshop - Schedule, Attendees, and Deliverables Schedule 1 Day On-Site with 2 FORCAM Consultants Attendees Suggested Attendees (CIP Team) Project Leader / CIP Director / Plant Manager (Champion) Production (Lean) Manager Production Supervisor(s) IT Manager Maintenance Manager ERP Manager Production Engineers Deliverables 1. SFM Checklist - Requirements Specification Document 2. Fixed Price Quotation 3. Project Management Plan FORCAM 2014 Page 52

51 Global Template Approach (Multi-Site Project Deployments) All Sites Shop Floor Management (SFM) Workshop PILOT Pilot Site FORCAM 2014 Page 53

52 Presentation Agenda FORCAM Introduction Shop Floor Management with Factory Framework Technical Capabilities Machine Data Collection Order Data Collection with SAP Integration Personnel Data Management SFM OEE Performance Reporting Additional SAP Integration Functionalities Configuration Capabilities with Live Demonstration Project Plan and SFM Workshop Summary and Conclusions FORCAM 2014 Page 54

53 Architecture for Fully-Integrated OEE System FORCAM 2014 Page 55

54 Our Value Proposition Top Customer References in Discrete Manufacturing State-of-the-Art Technology, Awarded by Frost & Sullivan Server-centric J2EE Web-based Technology Architecture Outstanding Scalable Shop Floor Management System Seamless Universal ERP Integration with Order Data Management Real Time Machine Data Collection with Heterogeneous Adapters Performance Measurement and Reporting with OEE Personnel Data Management Alerting and Alarming Strong Configuration Capabilities Global Delivery Team for Template-based Rollout (for Multi-Site Deployments) FORCAM 2014 Page 56

55 Thanks for your attention! FORCAM, Inc. 250 E. Fifth Street, 15th Floor Cincinnati, OH (513) FORCAM 2014 Page 57