Cisco Covacsis Solution IPF: Intelligent Plant Framework Vel K Product Manager Market Strategy
Manufacturing Business Challenges How can we improve production by double digit without any Asset investment? How do we reduce the operation cost of the plant? How do we align Plant operations to Business KPI? How do we improve the production bench marks without any Asset investment? How can we see the plant s financial performance in real time? How do we get a 360 degree visibility of the plant operations in real times?
Productivity Improvement : A Continuous Journey
Intelligent Plant Framework enables faster efficient, decision making by providing real-time, end-to-end business visibility of the plant
IPF Framework Supervisor CxO Real-time Analysis and Collaboration Mfg. Head Costing Team Batch Entries Manual stoppages Process variables Meters, VFD, PID, Sensors Power consumption Chemical consumption Consumables PLC / DCS / SCADA Technical downtime Run-time and cycle time Process parameters Machine performance Line Manager Plant Head HR - IR Data Discrete Devices Plant Machinery Data Analytics Data Analytics Acquisition QMS / LIMS Energy system Building mgmt. systems Planning Data Production WIP inventory Conversion Cost Data Discrete Devices Plant Machinery Mgmt. system ERP system Management system ERP system
IPF Framework CxO Mfg. Head Supervisor Line Manager Real-time Analysis and Collaboration Plant Head Data Analytics Data Analytics Acquisition Costing Team HR - IR Utilities consumption Consumables Consumption Asset utilization Availability OEE Machine Uptime Stoppage Reason Analysis Batch Cycle Time Yield and Throughput Operational Metrics Conversion Cost Floor Financial Quotient Production Opportunity Loss Financially Most Inefficient Cost of Deviation Cost of inefficiency Financial Metrics Data Discrete Devices Plant Machinery Mgmt. system ERP system
IPF Framework Supervisor CxO Real-time Analysis and Collaboration Mfg. Head Costing Team Trend Analysis Real-time plotter machine performance process parameters projected performance of the machine Cycle-time line efficiency Top reasons for downtime Comparison Overall Conversion Cost Cost of Inefficiency Relative Asset Utilization Worst performing section Overall power consumption WIP Inventory Line Manager Plant Head HR - IR Line Manager Plant Head Data Analytics Data Analytics Acquisition Top plants Highest WIP inventory Least energy efficient Cumulative economic loss Most efficient plant Best financial index Data Discrete Devices Plant Machinery Mgmt. system ERP system Manufacturing Head CxO
IoT Cloud Challenges Limited Bandwidth Latency Network Availability
Distributed FOG Computing Traditional Computing Model (Terminal/Mainframe, Client-Server, Web) IoT Computing Model Assumes Infinite Bandwidth, Zero Delay Data Center/ Cloud Endpoint Speed of Light Latency-Critical Responsiveness Required Resiliency Security Data Grows Faster Than Bandwidth Data Center/ Cloud IOX Device Assumes Limited Bandwidth, Variable Delay, and Intermittent Connectivity Assumes Limited Bandwidth, Variable Delay, and Intermittent Connectivity
Cisco Covacsis Solution Implementation Architecture Machine Serial / Ethernet I/O Cisco router With LIU Server Machine LAN / WAN BLOG Analytics Server in Data Center/Cloud Serial / Ethernet I/O Cisco Router With LIU Server
Customer Case Studies - India Leading Pharma Company 44% increase in tablet production 70% reduction in average batch turnaround time Leading Textile Company 50% increase in production rate in 9 months period 30% reduction in water consumption Increase in production of A-Grade fabric from 94% to 97.89 % Leading Chemical Company 28% increase in production of fatty acid 44% reduction in reflux emission
Improvement : A Continuous Journey Automation IPF Consultant ERP
Cisco Covacsis Solution Enable Manufacturers to Have Plant Wide Visibility of Business Impact Make Faster Decisions Stay Ahead of Competition