Louisiana-Pacific s Manufacturing Information Management Journey. September 22 nd, 2015

Transcription

1 Louisiana-Pacific s Manufacturing Information Management Journey September 22 nd, 2015

2 Agenda Introduction Jeffrey Wagoner LP IT Manufacturing Manager Description of Louisiana-Pacific (LP) Operations Who are we and what do we do? What is IT Manufacturing? LP s Manufacturing Information Management Journey

3 Agenda Introduction Jeffrey Wagoner LP IT Manufacturing Manager Description of Louisiana-Pacific (LP) Operations Who are we and what do we do? What is IT Manufacturing? LP s Manufacturing Information Management Journey

4 Louisiana-Pacific (LP) Operations We are a leading manufacturer and distributor of building products. Founded in 1973, today we operate approximately 25 manufacturing facilities in the U.S., Canada, and South America. One of the largest producers of OSB.

5 LP Products

6 Why IT Manufacturing? Created IT Manufacturing department in 1998 to: Bridge the gap between corporate IT and Plant Electrical & Engineering Depts. Implement MFG System Standardization Consult with plants on Manufacturing Information requirements Install, Configure, and Maintain MFG Applications on MFG Servers Provide Hands-on Training for Specific MFG Applications IT Standards Enforcement IT MFG Mission Statement: To provide the tools and knowledge to transform operational and manufacturing data into information and knowledge in order to support prompt and intelligent decision making at all levels in the enterprise to help drive efficiency, quality and performance across LP s manufacturing operations.

7 Agenda Introduction Jeffrey Wagoner LP IT Manufacturing Manager Description of Louisiana-Pacific (LP) Operations Who are we and what do we do? What is IT Manufacturing? LP s Manufacturing Information Management Journey

8 LP s Manufacturing Information Management Journey

9 No Standardization At the time, we had over 105 plants in 10+ business lines No standardization within the Company, within a Business, or even within a region. Every plant did things differently. Saw the need for standardizing how we looked at MFG data, from how we Gather/Track It, Report It, and Understand It! Less than 5% of our plants had a Historian. 3 different Historian vendors.

10 LP s Manufacturing Information Management Journey

11 Started Using Wonderware s Historian Toolset Started using InSQL v7 Started to use Active Factory v3.2.1 as a reporting tool Explored the power of the toolset and it s potential

12 LP s Manufacturing Information Management Journey

13 Standardized on Wonderware s Historian Toolset Replaced all existing Historians with Wonderware s InSQL Historian Moved all plants to using Active Factory (Historian Client) Expanded functionality over time to create reporting systems

14 Some of the Realized Benefits of Historian Client Process Efficiencies Process Problem Solving & Troubleshooting Environmental Various E.P.A. Reporting Preventive Maintenance Predictive Maintenance Dashboards Various Reporting o Natural Gas Consumptions o Downtime o Raw Material Usage o Tank Telemetry o Panel Weights o Product Quality o Production Reporting

15 LP s Manufacturing Information Management Journey

16 Standardized on Wonderware s QI Analyst for Process Data Analysis Moved to utilizing QI Analyst as primary Statistical Process Control (SPC) software to conduct analysis of Historian Data Provided the ability to see properties of each board as it is made against Targets as well as Upper and Lower Spec and Control Limits. Operators now make process changes when the process is out of control rather than snap gut reactions Analyzed the actual data in the Historian No duplicate data

17 LP s Manufacturing Information Management Journey

18 Production, Process and Downtime Tracking & Reporting System Our Needs: Expand LP Wonderware software applications and reporting capabilities while maintaining our current investment Develop an automated reporting system to replace our current Daily Production report and provide a new Daily Process report Develop a Down time tracking system with the ability to compile, track and filter downtime by area, shift, crew, line speed and Product To reduce the time needed to gather and compile information on a daily basis for reporting purposes. SPC Data Ability to pull QI data into reports Access and sort data based on product, shift/crew, operator

19 Production, Process and Downtime Tracking & Reporting System Our Solution: Partnered with Wonderware and Consulting Services group to design a Production, Process, and Down Time Tracking & Reporting System that utilizes the following: Existing investment in WW Historian and QI Analyst App Server Info Server MP (Manufacturing Performance) Services MS SQL Reporting Services SharePoint Services ASP.NET

20 Production, Process and Downtime Tracking & Reporting System Realized Benefits: Reduction in labor hours required in tracking data and creating reports - Reduced over 1000 hours annually spent tracking data and creating the reports by hand per plant Elimination of error factor over 98% of data is pulled directly from process tags into the reports Information at our fingertips Instant access to real time reporting for analysis Broader access of the information to business team Information is rolled up to corporate reporting as well as available via web to drill down for specifics

21 Production, Process and Downtime Tracking & Reporting System Realized Benefits Continued: Accurate accounting of all downtime to the second with the ability to compile, track and filter downtime by area, shift, crew, line speed and product Production report drill down metrics Having the data to accurately manage people and hold them accountable Automated Report Generation KPI Reporting

22 Production Report Example

23 Operator Downtime Screen

24 Replace Operator Downtime Logbooks

25 Drilldown Metrics

26 LP s Manufacturing Information Management Journey

27 Going Mobile! Hist. Client and QI Analyst on Tablets Standardized on Windows based Tablets for mobile needs In addition to running Work Orders and other plant software, have the ability to run Historian Client and QI Analyst Ability to replace round sheets and enter data directly into the system rather than write things down and key them back in when you get to the office

28 LP s Manufacturing Information Management Journey

29 SmartGlance - Data at your Mobile Fingertips! Know what is happening within your plant when you re not at your desk Access information from home without getting onto the corporate network Ability to see report generated data Not only see Historian tag data, but trend it and trigger user specific Alerts! STRONG User acceptance / adoption. Quick and easy to use!

30 SmartGlance - Data at your Mobile Fingertips!

31 SmartGlance - Data at your Mobile Fingertips! Some Challenges we have run into: Not all positions in our plants have company supplied Cell Phones. Cell Phone Coverage can be spotty, specially in specific spots in some plants Wi-Fi not always available Cell Phones not allowed on some plant floors

32 SmartGlance - Data at your Mobile Fingertips! Some user quotes: Great resource to help monitor the process! The information is helpful being so accessible to help make real time decisions and adjustments! I love the App and the alert levels that can be set. This is an awesome tool. I like seeing what is going on at the mill but don t like to call in and bug my guys so this tool covers that need. I like having the quick glance of the previous day s production. I think it s a great tool, being able to check operations at any given time is a definite pro along with the ability to specify set points for immediate notifications for certain events that are critical. Every Manager and Supervisor needs to have this app!

33 Where to Next? The Journey Continues

34 Questions?