Building Blocks to a Connected Real-Time Digital Enterprise

Transcription

1 Building Blocks to a Connected Real-Time Digital Enterprise Conrad Leiva Oct, 2017

2 Agenda Goals of a Digital Thread for a Connected Real-Time Digital Enterprise Building Blocks for a Digital Thread Connecting the Dots How does the Digital Thread look like? Yesterday, Today, Tomorrow

3 We have made some progress right? 3

4 Engineering has always been very supportive of Manufacturing Engineering Department Yesterday Operations Shop Floor 4

5 Especially when we needed changes Engineering Department Operations Shop Floor 5

6 Physical Flow through the Plant...

7 Business Processes supporting Production

8 Most Information Flows on Paper between Departments

9 Automation and Integration began in 70 s Today

10 But is not a Digital Thread All day s and phone calls to try to communicate changes accurately

11 The Journey to the Model-Based Enterprise From 2D to 3D

12 We are in the transition from MBD to MBE

13 DoD adds Digital Thread as Acquisition Requirement

14 Now on the Journey to a Digital Thread Tomorrow Supplier Communications Customer Communications

15 ibaset is a Recognized MES/PLE Leader in Complex Discrete Manufacturing

16 ibaset s Solution = Product Lifecycle Execution A key piece required for companies striving for The Connected Real-time Digital Enterprise

17 The Digital Thread for the entire Product Lifecycle Product Realization Processes

18 The Digital Thread for the entire Product Lifecycle Program Management Customer Requirements PLM Program and Project Management Product Engineering Product Design DESIGN Change and Configuration Management Quality / Regulatory Process & Inspection Quality Requirements Production and Inventory Scheduling, Procurement ERP Procurement & Contracts Production Schedule PLAN Supplier Management Manufacturing SOLUMINA integrates to PLM and ERP to realize a fully integrated enterprise. SOLUMINA adds Execution Service, MRO

19 The Digital Thread for the entire Product Lifecycle Program Management Customer Requirements Program and Project Management Product Engineering Product Design DESIGN SOLUMINA Product Lifecycle Execution Quality / Regulatory = Process Control, Inspection, Deviation Handling, History, Corrective Action Production and Inventory Scheduling, Procurement Process & Inspection Quality Requirements Procurement & Contracts Change and Configuration Management Production Schedule PLAN Supplier Management Supplier Quality Processes Definition Source & Receiving Inspection Identify & Resolve Issues Manufacturing Manufacturing Process Definition Manufacturing EXECUTE Identify & Resolve Issues Service, MRO Services Process Definition Depot and Field Service Service Scheduling Identify & Resolve Issues 21

20 Controlled Closed-Loop Change Processes Program Management Product Engineering Customer Requirements CHANGE PROCESS Product Design Program and Project Management Change and Configuration Management Quality / Regulatory Production and Inventory Scheduling, Procurement Process & Inspection Quality Requirements Procurement & Contracts Production Schedule Closed-loop Change Control Processes Supplier Management Supplier Quality Processes Definition Source & Receiving Inspection Identify & Resolve Issues Continuous Improvement Manufacturing Manufacturing Process Definition Manufacturing Identify & Resolve Issues Service, MRO Services Process Definition Depot and Field Service Service Scheduling Identify & Resolve Issues 22

21 The Digital Thread needs Product Lifecycle Execution Program Management Customer Requirements Program and Project Management Today Product Engineering Product Design SOLUMINA Product Lifecycle Execution Quality / Regulatory = Process Control, Inspection, Deviation Handling, History, Corrective Action Production and Inventory Scheduling, Procurement Supplier Management Manufacturing Service, MRO Process & Inspection Quality Requirements Procurement & Contracts Supplier Quality Planning Supplier Quality Processes Definition Mfg Manufacturing Process Definition Task Planning Services Process Definition MRO Task Planning Service Scheduling Change and Configuration Management Production Schedule Source Quality Execution Source & Receiving Inspection Identify & Resolve Issues Mfg Task Execution Receiving Quality Execution Mfg Quality Execution Manufacturing Identify & Resolve Issues 23 Depot and Field Service MRO Identify & Resolve Task Issues Execution

22 SOLUMINA supports your Digital Thread.. NOW! Product Design PLM Product Definition Inspection & Test Planning Inspection/Test Definition Mfg Task Planning Service Task Planning SOLUMINA PLE Mfg Process Definition Service Process Definition Supplier Quality Execution Mfg Task Execution Service Task Execution As-Inspected Records As-Built Records As-Serviced Records

23 Goals of the Digital Thread 1. The Right Information at the Right Place at the Right Time 2. Data is only Entered Once! Automatically distributed or linked to other systems as needed 3. Every Digital Handover is Structured, Parsable and Revision Controlled 4. Downstream processes Minimize Manual Translation or Transformation 5. Downstream systems Maintain Digital Associativity for Change Management of Derived Objects

24 Product Lifecycle Execution Today For Manufacturing

25 PLM: ebom to mbom to Process Plan ebom mbom Process Plan Top Level mbom Combustion Compressor Exhaust Associativity at the object level facilitates change management Final IPA

26 PLM -> Solumina Execution Process Plan Work Plan Work Order Associativity at the object level is carried over to execution objects for work-in-process

27 Display illustrations

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29 Data Collection Inspection Data and Job Buyoff Signatures Data requirements cannot be skipped

30 Data Collection Measurement imported straight from Machines From Machine to XML to database Is this IIoT? Data that matters!

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37 Enhanced Data Flow between PLM, MES PLM MES/MOM Part-No, BOM Product/Process Definition and Design Part-No Procure Data Process 3D Views Process Plan (BOP) Process Change Management Product Characteristics Product/Process Change Management ECN ECN Status Update WO Status Update As-Built Part Genealogy Process Execution The Digital Thread is more than one threaded message! Non-conformance to Problem Problem Reporting Disposition/Deviation Approval Corrective Action Item to ECR Discrepancy Handling

38 Enhanced Data Flow between PLM, MES, ERP PLM Product/Process Definition and Design Part-No, BOM Part-No Procure Data Process 3D Views Process Plan (BOP) Product Characteristics MES/MOM Process Change Management Part-No (pass-thru) BOM (pass-thru) ECN (pass-thru) Part-No Procure Data Process Routing ERP Parts, Production Routings Product/Process Change Management ECN ECN Status Update WO Status Update As-Built Part Genealogy Process Execution Work Order Release Work Order Operation Status Work Order Operation Schedule Order Fulfillment & Scheduling Work Order Revisions Problem Reporting Non-conformance to Problem Disposition/Deviation Approval Corrective Action Item to ECR Discrepancy Handling Parts Issue to WO Operation Defects, Scrap, Returns Procurement, Inventory and Supplier Management Digital Thread happening here Automation Program, Config Run, Control Collect, Alert IIoT happening here!

39 Product Lifecycle Execution For Maintenance, Repair and Overhaul

40 Enhanced Data Flow between PLM, MRO PLM / Tech Pubs MRO Task Mgt Today Product Configuration Management BOM, Configurations 3D Illustrations Maintenance Manuals Service Task Planning Maintenance Manuals, Requirements Service Bulletins Ensure no requirement is missed. Identify all resource requirements. Ensure Revision Control through Service Bulletins Change Requests, Service Bulletins

41 Service Plan Instructions from Manuals 3D Illustrations Parts from BOM for different product configurations

42 Select Services for Work Order Select Task Groups required

43 Enhanced Data Flow between PLM, MRO PLM / Tech Pubs MRO Task Mgt Product Configuration Management BOM, Configurations 3D Illustrations Maintenance Manuals Service Task Planning Maintenance Manuals, Requirements Service Bulletins Service Task Execution Change Requests, Service Bulletins Execute Service Tasks

44 Perform Service Task Assign skilled personnel

45 Perform Service Task Guide Technician with illustrated Work Instructions

46 Perform Service Task Verify equipment

47 Perform Service Task Collect data to verify unit is up to specifications

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49 Enhanced Data Flow between PLM, MRO PLM / Tech Pubs MRO Task Mgt Product Configuration Management BOM, Configurations 3D Illustrations Service Task Planning Maintenance Manuals Maintenance Manuals, Requirements Service Bulletins Special Repair Approval Service Task Execution Over & Above Scope and Special Repairs require additional approvals Change Requests, Service Bulletins Over & Above Scope Management

50 Enhanced Data Flow between PLM, MRO, ERP PLM / Tech Pubs MRO Task Mgt ERP Today Product Configuration Management BOM, Configurations 3D Illustrations Maintenance Manuals Service Task Planning Service Sales Order Work Order Release Contracts, Service Orders Work Order Operation Status Maintenance Manuals, Requirements Service Bulletins Special Repair Approval Service Task Execution Work Order Operation Schedule Work Order Scope Revisions Parts Management, Inventory Product/Parts Performance Parts Requirement Revisions Change Requests, Service Bulletins Corrective Action Item to ECR Over & Above Scope Management Parts Issue to WO Operation Supplier Management Tomorrow

51 Enhanced Data Flow between PLM, MRO, ERP PLM / Tech Pubs MRO Task Mgt ERP Product Configuration Management BOM, Configurations 3D Illustrations Maintenance Manuals Service Task Planning Service Sales Order Work Order Release Contracts, Service Orders Work Order Operation Status Maintenance Manuals, Requirements Service Bulletins Special Repair Approval Service Task Execution Work Order Operation Schedule Work Order Scope Revisions Parts Management, Inventory Product/Parts Performance Parts Requirement Revisions Change Requests, Service Bulletins Corrective Action Item to ECR Over & Above Scope Management Parts Issue to WO Operation Supplier Management Ensure parts are where needed. Not too many, not too few.

52 Enhanced Data Flow between PLM, MRO, ERP PLM / Tech Pubs MRO Task Mgt ERP Product Configuration Management BOM, Configurations 3D Illustrations Maintenance Manuals Service Task Planning Service Sales Order Work Order Release Contracts, Service Orders Work Order Operation Status Maintenance Manuals, Requirements Service Bulletins Special Repair Approval Service Task Execution Work Order Operation Schedule Work Order Scope Revisions Parts Management, Inventory Product/Parts Performance Parts Requirement Revisions Change Requests, Service Bulletins Corrective Action Item to ECR Over & Above Scope Management Parts Issue to WO Operation Supplier Management Feedback to Engineering for Product Performance Improvement

53 Update As-Maintained Data

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55 Product Lifecycle Execution For Supply Chain Quality Management

56 The Digital Thread from Engineering, Planning to Suppliers Supplier Communications Customer Communications

57 The Digital Thread with Suppliers

58 Taking Enterprise Quality Management to the Next Level Read ibaset s White Paper at Today Tomorrow

59 What is Your Digital Thread Adoption Score? Product Design Product Definition Inspection & Test Planning Inspection/Test Definition Mfg Task Planning Service Task Planning Mfg Process Definition Service Process Definition Supplier Quality Execution Mfg Task Execution Service Task Execution As-Inspected Records As-Built Records As-Serviced Records

60 Where Are We Today on the Digital Thread? Source: State of the Digital Thread, ibaset, 2017

61 Questions? Resources

62 COMPLEX made SIMPLE THANK YOU

63 Confidential 2017 The statements contained in this document include forward looking statements including statements regarding the Company s expected future financial position, results of operations, business strategy, budgets, projected costs, capital expenditures, products, competitive positions, growth opportunities, plans, business and product goals and objectives for future operations, as well as statements that include words such as anticipate, if, believe, plan, estimate, expect, intend, may, could, should, will, and other similar expressions are forward-looking statements. These forward-looking statements are made subject to certain risks and uncertainties, which could cause actual results to differ materially from those presented. Readers are cautioned not to place undue reliance on these forward-looking statements, which speak only to the date such data was presented. The Company undertakes no obligation to publicly revise these forward-looking statements to reflect events or circumstances that arise after the posting this data in this document or presentation. Factors that may cause actual results to differ materially from those in the forward-looking statements include, without limitation, reduction in demand or as a result of current economic and market conditions; customer acceptance of pricing; delays in delivery or increases in costs, including transportation costs, of raw materials or sourced products and labor or changes in or unavailability of quality suppliers; exchange rate fluctuations, changes in foreign import tariffs and monetary policies and other changes in the regulatory climate in the foreign countries in which we operate and/or sell products; delays in manufacturing and delivery schedules; bankruptcy of or loss of major dealers, retail customers or suppliers; customer acceptance of, changes in the costs of, or delays in the development of new products; introduction of new products by, or more favorable product pricing offered by, our competitors; product liability or other litigation, warranty claims or returns of products; the effectiveness of the cost reduction programs implemented globally, including the successful implementation of procurement and sourcing initiatives; changes mandated by federal, state and other regulation, including health, safety or environmental legislation; and other risks. Many of these factors are outside of the Company s control.