Autoplant Systems India Pvt. Ltd. Our focus: JIT Execution. autoplant

Transcription

1 Autoplant Systems India Pvt. Ltd. Our focus: JIT Execution

2 Who is Autoplant? OUR TEAM

3 The Team The team comes with a wealth of experience Hiten Varia Suresh Sachdev Led the global operations for i2. He was executive vice president of global customer operations and chief customer officer for over 16 years. He plays the role of advisor, mentor and guide to the Autoplant team Prabhu Natarajan Venky Nayar Led the South East Asia/ANZ region for i2. Venky worked across multiple roles in sales, presales and strategy consulting with clients in Asia and USA. He brings over 15 years of experience in the supply chain planning and optimization space Suresh took over as country manager for i2 in India. He was instrumental in signing up clients like Tata Steel, Essar Steel, Grasim & Reliance. He brings his twin passions of logistics and technology to Autoplant Uma Rajan Led the Asia Pacific region for i2, well experienced in negotiating complex global deals with customers & partners for software, services, hosting and business process outsourcing She has significant exposure to cross-border investing, venture capital and incubating new companies where she developed the overall strategy. She also worked with JWT as Account Director and handled Unilever

4 Innovations Systematic S&OP process in the cement industry First order manage ment system where cement customers (dealers) can directly place orders Tracking of vehicles till final delivery at the customer site to understand and improve customer services Using RFID technolog y to control plant turnaroun d time Proof of delivery to reduce cash to cash cycles Using RFID / GPS for automated Inventory managem ent Complete plant automation paperless & unmanned In-house Product Developm ent of Hardware

5 Our Success Some of our Indian Clients International Clients Our experience so far... Successfully implemented RFID based automation in over 25 cement plants Automated weighbridges of major manufacturers from cement, steel and metals industries Successfully automated mining operations

6 Customized Solution for Various Industries Cement Mining Container Terminals Metal Processing Retail Pharmacy Automotive Cold Chain

7 Our Vision Collaboration Framework for information sharing for customers, suppliers & transporters Sensor Driven Online tracking of all trucks, drivers, plant equipment & warehouses Single workflow driven solution Automated Unmanned & paperless with exception based monitoring only Optimized Intelligent decision making capabilities at each stage to balance multiple objectives

8 How does it all fit together? Autoplant is building an Automation Framework to simplify and automate regular tasks in factory operations

9 The Automation Framework Machine Data Automation Framework from Autoplant SAP & other systems Truck GPS data RFID data from plant stages Weighbridge data Sensor data Machine status from PLC Order & EGP data from SAP Trip status updates to ERP & SMS messages Freight cost updates

10 The Automation Framework Machine Data Automation Framework from Autoplant SAP & other systems Suite of standard cement functionalities Automated mining operations Order capture and assignment Transporter collaboration workflow Inbound & outbound truck movement Replenishment workflows Backhauling workflows Freight cost and POD Access control workflows

11 Components of the Framework Actionable Items LED Display Alerts/SMS PLC control Signals/barrier Dashboards Vendor Perf. Physical actions to be taken based on output Business Intelligence Trip logic Sequencing Queuing Backhauling Assignment Freight cost Business logic to make automated decisions Transaction Management Order Capture Order Assign Truck/Driver master POD Auction Registration Transactions to complement ERP systems Hardware Control Autoplant Controllers Remote database Local processors Local hardware for distributed intelligence Data Acquisition GPS RFID Sensors ERP PLC Data collection from internal & external systems

12 Open Cloud Based Approach Plant updates from RFID, PLC & sensors Truck status though GPS Transaction updates from ERP Cloud based Automation Framework Supplier & Customer updates through internet Data to ERP & external systems Instructions to PLC & plant hardware Performance Management Automated Workflows

13 Who uses Autoplant Framework? External Entities Customer for order updates Suppliers - for dispatch updates Transporter - for assigned order updates Major Users Logistics planners Raw material planners Transporter coordinators Customers & transporters Yard personnel Plant Functions Mining operations Logistics Packer operations Security Warehouse operations Instrumentation Plant maintenance Who accesses the output Drivers & transporter rep. Tally checker Security Mining coordinator Finance/accounts payable QC/raw material coordinators

14 How do we differentiate ourselves? Autoplant controllers: give us more control over the solution and the ability to create an offering tailored to every customer s requirement Hardware strategy: a well defined hardware approach differentiates us from the small RFID operators Packaged software: separates us from the SI and our detailed workflows are better than generic ERP approaches Domain knowledge: separates us from the automation players as well as the weighbridge operators

15 A Vision for the Future Unmanned Operations No need for operators & Supervisors Complete Visibility Truck distance travelled, waiting time, asset utilization etc. Paperless Operations Eliminating redundant & unnecessary documentation Smooth Operation Close coordination with suppliers, transporters and drivers Safe Environment Drivers do not have to get down at any stage, Minimum Human intervention

16 Continuous blurring the planexecution gap NOW FUTURE Instant update Plan Execution Plan Execution Gap between plan and execution will be much lesser Instant response

17 Workflow automation Now Large teams execute largely repetitive worflows Paperwork required for verification and accuracy Errors, delays, malpractices tend to creep in Enablers Network of sensors placed at various locations Mobile and other wireless communication Sophisticated algorithms to mimic business rules Future Unmanned & paperless Most standard decisions taken based on standard rules Real time exception highlighting Workflow examples: - Customer order to payment workflow - Security & validation procedures for trucks & drivers - Access control in a plant environment - Backhauling workflow - Supplier dispatch to GRN workflow

18 Typical Workflows Available Mines Control Workflow track extracted material and equipment efficiency Automated weighbridge capture weight and automate loaders (bag, bulk) Order Capture customer order with delivery date & source confirmation Vendor collaboration order assignment and truck confirmation Inbound material workflow track material from dispatch to unloading Outbound material workflow track truck from confirmation to delivery Container terminal workflow track containers within terminal/depot Others freight cost workflow, backhauling workflow, access control workflow, packer scheduling workflow

19 Thank You!