Epicor Mattec MES Frank McLoughlin Vice President Business Solutions Group Epicor International 2017 Epicor Software Corporation 1
Agenda Agenda: What is Industry 4.0? Manufacturing Imperatives Epicor & Industry 4.0 Current Status Next Steps 2
What is Industry 4.0? 3
Evolution of Industry 4.0 4
Design Principles of Industry 4.0 Interoperability (IoT) Information Transparency (AR/VR) Technical Assistance (Analytics & BI) Decentralized Decision-Making (Automation) 5
Industry 4.0 Adoption In 2015, PwC surveyed more than 2,000 companies from 26 countries in the industrial production sectors In this global Industry 4.0 survey, onethird of the respondents said their company had already achieved advanced levels of integration and digitization, and 72 percent expected to reach that point by 2020 (see Exhibit 1). 6
Industry 4.0 Technologies Omni-channel Experience Compliance & Traceabililty Augmented Reality (AR) Internet of Things (IoT) Data privacy / Encryption Collaboration Cloud, Extensibility & Microservices Mobility Multilevel Customer Interaction & Profiling Manufacturing Intelligence Data Discovery & Algorithms Additive Manufacturing (3D Printing) Blockchain & Cryptocurrency Geolocation Big Data & Analytics 7
Industry 4.0 & ERP Touchpoints PLM & CAD MES ERP Automated Collection Logistics Suppliers & Customers MES Predictive Maintenance 8
Manufacturing Imperatives 9
Critical Manufacturing Imperatives More than half of the manufacturers that responded categorized their growth strategies as either aggressive or very aggressive to achieve profitability. How can we achieve and sustain profitability over time? 43% of all respondents reported that the primary motivation for foreign investments is to capitalize on lower cost manufacturing opportunities. How can we drive productivity up while keeping costs down across our global manufacturing facilities? It is not just about performance and efficiency; investments into new manufacturing technologies are also a way to enhance agility, flexibility, and speed to market when designing and launching new products and services. How can we ensure that our technology investments will support new technology initiatives such as IoT, mobility, big data and analytics? Maintaining the status quo does not drive growth. Manufacturers will need to do something different in order to win market share in today s environment. Many are focusing on value-added services, entering new geographic markets or adjacent market segments. How can we ensure quality and consistency across our manufacturing processes as we move into new geographies? Source: KPMG Global Manufacturing Outlook 2016 10
Manufacturers: Set Your Course for Growth Ensure and Increase Profitability Get the visibility and accessibility to data that you need to understand what is going on in your business at any time, from any device. Leverage Technology for Growth Now and in the Future Allow for greater and easier connectedness with open architecture and extensibility that offers users a way to tap into modern technologies as they become mainstream. Drive Productivity Up and Costs Down Gain efficiencies with capabilities that make it easier to manage rework and other manufacturing activities; and empower employees by providing real-time access to the shop floor. Open New Opportunities for Growth Grow your business by adding new services and products to your portfolio and extend your reach by selling into new segments and geographies. 11
Epicor & Industry 4.0 Today 12
Industry 4.0 Technologies Supported by Epicor Mattec Internet of Things (IoT) Data privacy / Encryption Epicor Commerce Connect Omni-channel Experience Epicor Social Enterprise Collaboration Epicor Cloud Cloud, ERP Extensibility and Microservices Epicor Mobile Framework Mobility Electronic Compliance Platform Compliance & Traceability Mobile CRM Multilevel Customer Interaction & Profiling Geolocation Mattec Manufacturing Intelligence Epicor Data Discovery Data Discovery Augmented Reality (AR) Additive Manufacturing (3D Printing) Epicor Data Analytics Big Data & Analytics Covered Partner Next Gen Blockchain & Cryptocurrency 13
What is Epicor Mattec MES? The product originated in Cincinnati, Ohio, only becoming part of Epicor late 2012. It is a real-time data collection system using Windows Server and SQL database. Monitors machine times, down times, critical machine processes, labor usage and material consumption. It is a very powerful tool to help the customers find what is not working efficiently in their manufacturing operation. Over 1,000 customers worldwide. 14
MES -> ERP Two Way Communication Internet of Things (IoT) Mobility ERP System MES Production Operator Mobile Interface QUALITY CONTROL MOLDING DEPT PRODUCTION CONTROL PLANT MANAGER MAINTENANCE 15
How is it done? We have different ways of communicating with the machines, from direct communication to OLE for Process Control (OPC) communication. We use a Machine Interface Unit (MIU) to collect signals from the machines as well as using OPC for the process information. Epicor Mattec System Architecture x in 1 MIU with HMI. MIU PSU MIU PSU MIU PSU MIU = Mattec Machine Interface Unit Mattec Server Shielded CAT 5/CAT 6 Ethernet Cable 3-Core SY Braided Cable for Cycle Signals PSU = Power Supply Unit Ethernet Shielded CAT 5/CAT 6 Ethernet Cables Moulding Machines Moulding Machines Moulding Machines Touch Screen HMI Panel Shop Floor PC/Tablet Network PC Shielded CAT 5/CAT 6 Ethernet Cable Up to 16 machines per TSMIU. Touch Screen HMI Panel Shop Floor PC/Tablet Touch Screen HMI Panel Shop Floor PC/Tablet 3-Core SY Braided Cable 16
Mattec & Automated Data Collection Internet of Things (IoT) Machine Monitoring Process Monitoring Energy Monitoring 17
Mattec > Integrates to Scada, Machines & Sensors Internet of Things (IoT) Machine Integration - Two way Tell the machine what to produce next How to produce the item Machine is sending us back info. Trend Analysis (Implement Nelson rules that have to do with trending and looking at recent series of data) Could be a good story Preventative/Predictive Maintenance When a container is completed call for automatic pickup 18
Mattec > Poka-yoke (Mistake Proofing) Internet of Things (IoT) Mobility Visual Checking Systems Industrial Camera Systems checking for shape / color etc. Mobile Camera systems (Camera in helmet or gloves.) Johnson Controls today makes car battery cases. Pressure test those and then it gets taken by a robot and put into a scrap bin and Mattec will count as a scrap part. Jig at end of assembly line and check that everything is good. Mattec can take pass or fail. Auto Part Qualification Based on process parameters received automatically eject a part as scrap 19
Why use Epicor Mattec MES? Know what is happening 24 hours a day, 7 days a week, 365 days per year the system doesn't take any breaks. Improve the OVERALL EFFICIENCY of your plant by: Reducing material wastage. Reduce machine down time response. Reduce labour costs. Improve QUALITY of your plant by: Monitoring Process parameters of the machines. Monitoring Variable and Attribute data of the parts. Correllating both the SPC and SQC of the process. 20
Standard Features of the system Customizable Real-time screens Plant Floor displays and Dashboards. Real-time GANNT chart production scheduling. Over 100 already written reports. Real-time OEE recording and reporting. Material Traceability. Operator tracking. Data Entry Discipline Operator can enter data with a mobile MIU tablet or handheld device. 21
HOW??? 22
Real time job data monitoring 23
Process monitoring & charting 24
SPC/SQC Automatic SPC Manual SPC Variable SQC Attribute SQC 25
HMI 26
EDA and Mattec 27
Options for the system Data Exchange should be included in every system Family Part monitoring Preventative Maintenance Statistical Analysis (SPC/SQC) Voice & Email alerts Web Setup sheets On demand Bar coding Kanban Energy Monitoring Advanced Plant Analytics Web based scoreboard 28
Why? Hard to improve if you don t know what s going on. Can t control quality when people and environment are changing machine conditions constantly. Every 1 second lost on a 20 second cycle time means a loss of one shift of production per week per machine! We find the seconds.. 29
Who is GreenMoore Enterprises? GreenMoore have been a partner of Mattec since 1989. They have installed several hundred machines in the Australia and New Zealand market. They have focused primarily in the plastics industry. Their experience with Mattec is over 50 years collectively. 30
Want to know more. Go out to the slot car track and we can answer any questions you have. Perhaps have a race around the track See if you get the best time 31
Thank you for your attendance & attention. If you always do what you always did, you ll always get what you ve always got. Henry Ford 32