2014 Software Global Client Conference

Transcription

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2 Manufacturing Operations Management Solutions WW OPS EXEC 08

3 Agenda Manufacturing Operations Management Overview MESA Model Wonderware MES Offerings Operations Performance Quality Value to Customers Enterprise Integration Wonderware Skelta BPM Future Investments

4 World-Class Manufacturing & Production World-class firms are always examining their business processes and continuously seeking solutions to improve in key areas such as: Reducing Lead Times Shortening Time to Market Cost Cutting Exceeding Customer Expectations Streamlining Processes Managing the Global Operation

5 Manufacturing Execution/Operations Management Area of investment to improve operational efficiency and integration Transactional Real-Time

6 World-Class Manufacturing & Production Areas of Focus: Performance Measurement and Information Systems Enterprise Integration Standardization of Processes Operations Capabilities Quality Where to start? MES! ROI? Which system? TCO? Regulatory Compliance

7 Level 0, 1 & 2 Control Level 3 Manufacturing Execution System Level 4 Business Planning & Logistics Wonderware Manufacturing Operations Management ERP PLM EAM SCM Wonderware Enterprise Integrator (WEI) Production & Performance Applications Work Order Execution Track and Trace, BOM, Specs, Procedures, Inventory, In-line Quality, OEE Real time data processing Harmonization and Storage Event detection, Adaptability, Communication Batch Continuous Discrete 3 rd Party

8 Wonderware MES offering and experience Wonderware has offered MES functionality since 1996 About customer system installations Ecosystem and services experience established Wonderware MES strategic investment from 2006: A single scalable software, covering the MES functional requirements: Production Operations Inventory Operations Quality Operations Performance Tracking 600+ licenses of today s Wonderware MES installed globally Single site (majority) as well as many multi-site deployments

9 Wonderware MES Software Broad MES Functionality according to MES/MOM standards Production Operations (incl. Inventory), Quality Operations and Performance Management Enables step by step functional implementations Sustainable Standard Software Highly configurable Flexible, consistent enhancements in scope and size Integration with Customer processes Superior shop floor integration and execution Integration with Wonderware Workflow Standardization support and reusability Enterprise Integration Wonderware MES Software Operations Performance Quality

10 MESA Functional MES Model Wonderware MES Software Operations Management Performance Management Quality Management Sales & Service Management Dispatching Production Units Labor Management Supply Chain Management Operations/ Detailed Scheduling Product Tracking & Genealogy Quality Management MES Maintenance Management Resource Allocation & Status Performance Analysis Data Collection Acquisition Document Control Enterprise Resource Planning Process Management Control Avantis System Platform

11 Wonderware MES Software - grows over time Operations Performance Quality Common Certifications Labor Management Data Collection Procedure Steps Inventory Product Specifications / Parameters Bill of Materials Production Events Tracking Quality Specifications Sample Plan Definition Sample Plan Execution Statistical Process Control (SPC) Equipment Utilization and Downtime Overall Equipment Effectiveness (OEE) Line Management and Bottleneck Identification Work Order Management and Tracking

12 The Foundation Work Order Tracking Process/Product/Quality Specifications Electronic Records of Execution/Quality/Performance Work-Order request Production Results Automatic Data Download/Collection Physical Execution on Production Equipment Work Instructions Manual Data Entry

13 Wonderware MES/Operations Overview Business Value Foundation for Agile Production Processes Improve Production Consistency Empower Supply Chain Applications Enforce Compliance & Governance Key Capabilities Full-Featured MES Capability Dock-to-Dock Real-Time Visibility to Production Activities Comprehensive Manufacturing Genealogy Open, Modular, Scalable, Extensible

14 Step Execution WIP Order Product & Management Inventory Definition Management Setpoint Work Instructions Management. Define Configure Create Import Order Work a Product Management Hierarchy Steps Orders Definitions (or Manually of Tasks) Storage/Stock for from Import each External from Operation Locations e.g. Applications ERP within to Track a Route Materials Configure Define Values Electronic Attach Routing and Fixed (e.g. Folders Multiple Instructions, Enforce Min., BOMs Moveable Step Max., with Associated BOMs, (e.g. Execution Nominal), Setpoints, versioned) Order Instructions, Documents and SOPs, for and each Finished or Track Data Comments Work Instructions WIP Collection Materials & Inventory and Requirements Work (Multiple as Bulk Management Instructions Versions) and/or to a Work Lot Order for each Setpoint Attached Semi Finished Work Material Instructions to a Step Based Associate View Many Setpoints Different with Document a Particular Types Work (e.g. Center/Machine, PDF, Microsoft a Assign Define Documents, Configurable Multi-Level BOMs Grades and States to all Materials Step each Operation Execution BOM Items Web Pages, a to Process a Step etc.) Material or a Procedural Step Route Calculate Assign Sequence Define Link Work Machine Multiple Work and Instructions Orders Enforce Substitute and Manually BOM Expiry and Setpoints Materials Documents or Dates through to for a a Finite to each Step Products, Capacity BOM Item Download Setpoints to Automation Devices Scheduling Work Capture Configure (FCS) Attach Orders, Setpoint Application Work Operations, Genealogy Step Management Instructions Activity Trail Work (e.g. of to Centers all Collect Materials WIP or and Data, Procedural Inventory Consume Steps Activities Material) Capture Work Order Events (e.g. Status Change, Production, Consumption) Work Instructions Wonderware MES/Operations Features

15 Wonderware MES/Operations Use 1 5 Verticals in survey response: Food & Beverage CPG Chemicals Assembly

16 Wonderware MES/Performance Overview Business Value Improve Asset Utilization (OEE) Increases the Capacity of Existing Assets Empowers Operators Key Capabilities Detect, Capture & View Utilization Events Manual & Automated Data Collection Real-Time Visibility to Production Performance Enables Bottleneck and Root-Cause Analysis

17 Wonderware MES Performance Features Equipment Utilization Equipment Production Line Management Utilization Performance Progress Equipment Performance Detect Calculate Provide Define lines and a OEE Clear Capture including for Indication Equipment Utilization parallel of Work / paths Line (uptime/downtime) Order and segments Progress to Events the View Trigger Operator Determine Equipment Events in Bottleneck Real-Time and Events Display position within the line Production Progress Monitor Analyze Calculate Display line Event and OEE summary Record and Frequency Other Equipment information Custom and Duration State KPIs such as production counts, Automatically Assign Estimate utilization What Expected state States or of Manually bottleneck Completion Affect OEE Assign position, Calculation Date Reason and and Time Codes work order status Line Management

18 Business Value Improve Inline Quality Operations efficiency or automatically sample quality data Identify, Correct Deviations in Real-Time Meet Regulatory, Customer Compliance Key Capabilities Dynamic Sample plan generation based on work order (products, operations specs) Automatic data sampling or manual sampling procedure enforcement based on WO status SPC Alarms, Alerting and Charts Wonderware MES/Quality Overview 6σ

19 Wonderware MES/Quality Features Sample Specification Plan Definition Management Management Statistical Specification Management Sample Plan Process Execution Control Management (SPC) Standard Import Specifications the Run Sample Rule Selection Plan from from an an External Source (ERP/PLM) Sample Collection Plan Definition Notification Mgt. SPC Define Configure Charts Product What XBar and Range Characteristics Process and Specifications Sigma, to Collect Moving Average, the Context X of View Sample Details & Recorded Data Individual, Materials, Configure Sample When Equipment, p/np/c/u/dpmo Plan Execution the and Characteristics Operations Mgt. Should be Collected Additional Sample Request Generation Feedback Define Select from and of Attach Multiple Control Characteristics Rule Frequency Violations Types: (Variable Time, & Qty, Attribute) Event, etc. Manual Define Attach Statistical or Automatic Multiple Specification Process Sample Frequency Overrides Control Collection Additional Operator Data Collection Types to (SPC) a (e.g. Sample Cause, Plan Comments)

20 Benefits Using Wonderware MES Software Quality improvements reported in survey are achieved through Specification and BOM Enforcement not yet impacted by use of MES/Quality Survey results are publicly available: Tech Validate Results

21 Value of Benefits Benefits from MES/MOM grow over time 10X Reduced Operating Costs Increase Volume and/or Margins at Same Cost Increase Market Share and/or Pursue New Markets Average Payback 12 Months on 1X Benefits Platform for Continuous Improvement Supports Collaboration Provides supply chain visibility 3X 1X Lower WIP and Finished Goods Inventory Reduced Waste/Scrap Reduced Rework Reduced Maintenance Costs Faster New Product Introductions Shortened Time to Market for Innovation Customer Audits Requirements Traceability and Genealogy Reduced Indirect Labor Costs Shortened Cycle Times Improved Quality/Reduced Variability Reduced Cost of Regulatory Compliance 3 to 12 mos. 12 to 36 mos. 3 years + Source: AMR Research Report: MES Provides Long-Term Revenue and Market Benefits Beyond Easy-to-Quantify Operational Cost Savings

22 Wonderware MES Software Broad MES functional coverage Production, Inventory and Quality operations Performance measuring and tracking Highly configurable standard software Fast adaption to customer process/business rules Ready to use user interface clients, reports and tools Scalability to enable step by step implementations Increase functionality or size as required or needed Reduces project scopes, risks, shorter time to value Build on a Platform for shop floor integration Superior shop floor automation integration and real time execution Standardization and reusability of production equipment centric MES functionality

23 Platform Approach to MES/MOM Transactional Capture Production Events,Work Order, Spec & Setpoint Download Adaptability, Abstraction, Data Harmonization & Standardization Communication Device integration HMI s Barcode - RFID Real-Time

24 Level 0, 1 & 2 Control Level 3 Manufacturing Execution System Level 4 Business Planning & Logistics Wonderware Manufacturing Operations Management ERP PLM EAM SCM Wonderware Enterprise Integrator (WEI) Production & Performance Applications Work Order Execution Track and Trace, BOM, Specs, Procedures, Inventory, In-line Quality, OEE Real time data processing Harmonization and Storage Event detection, Adaptability, Communication Batch Continuous Discrete 3 rd Party

25 Enterprise Integration Business Applications: EAI Apps. (BizTalk, Web Sphere, WebMethods, MII, PI, etc.) leveraging open system and standard technology 3 rd Party Finite Scheduling/ Optimization File or Query Message exchange Standard Interface connector Wonderware Enterprise Integration Application: Wonderware Enterprise Integrator (WEI) Wonderware MES Applications: API APIs provide native calls to applications, as well as support for industry standards ( e.g. BatchML, S95/B2MML, MIMOSA, etc.)

26 Wonderware Enterprise Integrator Designed for Plant Business Continuity Reliable message transportation Message history and store & forward buffering Configuration, administration, status monitoring and manual recovery actions via a secure web-based user interface

27 Level 4 Business Planning & Logistics Wonderware Manufacturing Operations Management With Workflow Level 3 Manufacturing Execution System Level 0, 1 & 2 Control ERP PLM EAM SCM Wonderware Enterprise Integrator (WEI) Production & Performance Applications Work Order Execution Track and Trace, BOM, Specs, Procedures, Inventory, In-line Quality, OEE Real time data processing Harmonization and Storage Event detection, Adaptability, Communication Batch Continuous Discrete 3 rd Party

28 Wonderware Skelta BPM Industrial BPM Software Wonderware Skelta BPM 2014 is advanced business process management (BPM) and workflow software to manage activity flows that include people and/or systems inside or outside of an organization. (across all domains such as Production, Maintenance or Quality ) Sophisticated Human Workflow and Task Management, Calendar Management and Task Escalation Seamlessly Embedded into Wonderware Applications (MES and System Platform!) and 3 rd Party Applications e.g. Workflows automatically triggered by Platform or MES events A workflow can fully interact with Wonderware MES BPM enables standardization of processes

29 Wonderware MES Software Strategy and Investment

30 Drivers of Modernization in MES/MOM Application Modernization The convergence that s occurring around desktop and mobile computing must be device neutral (e.g. desktop PCs, panels, tablets, phones, etc.) Model Driven MES/MOM approach Expanding operational and collaboration boundaries to coordinate people and applications across the organization in an intelligent, effective and governed manner

31 The Evolution of the User Interface Device Neutrality the Convergence of Desktop and Mobile Computing Apple Inc.

32 Model-Driven Operations Management What is Model-Driven all About?? Wonderware Skelta BPM and integration with App. Business Rules Configuration: Add new machine Add new line Change KPIs Add new product Etc. Application Model Example Application Models App. User Interfaces Runtime: Record downtime event Edit a downtime event Start/complete orders Record scrap Etc. Wonderware MES, InBatch and Recipe Manager Plus and third party applications delivers a model-driven application framework that enables customers to use application models to standardize MES/MOM processes/procedures with adaptability to meet specific business needs and objectives when rolled out to as multiple plants or as enterprise MOM standards.

33 Model-Driven Operations Management Example Skelta BPM Workflow Form for Configuring Line Classes Standard form provided with MES for configuring Line Classes Form is extensible within Forms Designer Form button is linked to workflow Form adopt data from multiple data sources and allow for composite scenarios (e.g. MES, Recipe Manager and Galaxy)

34 Model-Driven Operations Management Example Workflow process for Configuring Line Classes Map data from the form into transaction arguments Send notification if error is encountered Execute (2) transactions to save configuration data in MES Check to see if Line requires automatic data collection (e.g. check-box on form) Create Line Template object in Galaxy Send notification if error is encountered Standard Business Rule for Creating Line Classes

35 Model-Driven Operations Management Example Workflow for Configuring Line Classes Extending standard business rule to meet solution specific needs Extended Business Rule for Creating Line Classes

36 Manufacturing Operations Design Philosophy Architecture & Design Reusability & Scalability From Start to End Through a Platform-based Approach Integration To enable/deliver Functionality Deployment Flexibility Configurable Industry Best Practices Virtualization Infrastructure Required Object Oriented Centralized Management Historization Redundancy /Failover Facility Model Scripting Reporting Data Mining Collaboration Industry Standards Compatibility Business with Control System Vendors Integration Device Open Integration Integration Comm. Capabilities Protocols Collaborativ -PCS e Processes -Instruments Telephonic Notification Production operations Inventory operations Inline Quality operations Traceability/Genealogy Downtime/ OEE Workflows Dashboards/Intelligence User interface/mobile Event Logging Security SPC/SQC Towards Lower Total Cost of Ownership (TCO) Invensys 10/13/2014 Technology Configuration Know How Management Industry Software Expertise Deployment Regional Revision Support Control Library of Standard Templates Standardized /Non Customized

37 Related Support, Services, Training & Expo Demos Support > Premium Customer Support > MES Specific Support Group > wdn.wonderware.com tech notes Services > Project Management Services > Project Implementation Services > Endorsed System Integrators Training > MES Operations (ILT and Web-based) > MES Performance (ILT and Web-based) > MES Quality (ILT and Web-based) > Workflow Overview ILT Expo Demos > Recipe Management and Manufacturing Execution Systems (booth 4) > WonderBev Demo (booth 3) > Workflow (booth 13) > Food & Beverage Industry Wall Confidential Property of Schneider Electric 37

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