Manufacturing Solutions: The Journey Terence Tan General Manager - - PowerPoint PPT Presentation
Manufacturing Solutions: The Journey Terence Tan General Manager IAM Wonderware 15 th October 2014 - Holiday Inn, Glenmarie Advance Solutions Seminar: Manufacturing Intelligence Anticipate the Unexpected by optimizing production and
Terence Tan
General Manager IAM Wonderware 15th October 2014 - Holiday Inn, Glenmarie Advance Solutions Seminar: Manufacturing Intelligence – Anticipate the Unexpected by
Source from wikipedia (http://en.wikipedia.org/wiki/Manufacturing_execution_system)
Dispatching Production Units Operations/ Detailed Scheduling Resource Allocation & Status Document Control Product Tracking & Genealogy Performance Analysis Labor Management Maintenance Management Process Management Quality Management Data Collection Acquisition
Sales & Service Management Enterprise Resource Planning Supply Chain Management Control
ISA Model Level 2
Dispatching Production Units Operations/ Detailed Scheduling Resource Allocation & Status Document Control Product Tracking & Genealogy Performance Analysis Labor Management Maintenance Management Process Management Quality Management Data Collection Acquisition
Sales & Service Management Enterprise Resource Planning Supply Chain Management Control
WW Operations Software WW Performance Software WW Enterprise Integrator Avantis WW QI Analyst System Platform ArchestrA Workflow ISA Model Level 3
Devices
(Barcode Scanner, PLCs, DCS, AB, Siemens, Omron, etc…)
ERP
InBatch
Batch Mgmt System
MES
MES Operations/Performance
IO Servers
Connectivity
InControl
Soft Logic Controllers
Web Info Server
Internet Publishing HMI/SCADA
InTouch
RT SPC/SQC Plant Historian
IndustrialSQL Server
ActiveFactory
MES System
► Project Team ► Kickoff meeting ► Details System Study ► Define Details Project Scope ► User Requirement Specification ► Project Schedule
► System Design ► Define System Specification ► Define System Architecture ► Define Project Deliverables ► Product Training ► Functional Design Specification
► Customer First Program
▪ Technical Support
▪ Software Maintenance
▪ Additional Benefits
▪ Optional Services
Slide 15
Overview of Cobega Key Factors MES Project Scope Why Wonderware?
Slide 16
COBEGA IS A COMPANY THAT BOTTLES AND DISTRIBUTES PRODUCTS FROM Cobega works to place itself among the best bottlers of the Coca-Cola system in the world and continue being a reference in the Spanish business community for its corporate policies as well as for its excellence in business administration and talent management.
Slide 17
Bottling company and distributor of Coca-Cola Company products in Catalonia, Aragon, the Balearic Islands and Canary Islands. It also holds a 30% participation in the Portuguese business and the 100% in the Iceland’s.
Cobega Group Cobega ECCBC Daba Others
Slide 19
270
Brand Names
Slide 20
Overview of Cobega Key Factors MES Project Scope Why Wonderware?
Slide 21
They called it the ICEBERG Project…
Slide 22
Slide 23
…but it has been completed
Slide 24
Work Orders planning on bottling lines (Download and Manage) Labour management OEE, MTBF, MTTR… WO Execution (Track&Trace) CIP’s, Format Changeover and TPM Integration with SAP PM Raw material consumptions Energy efficiency Quality Reporting
InTouch
Workflow
SAP CEM
Operations
Performance
Intelligence
Slide 25
System Platform 25k/12k 49 InTouch for SP
298 equipments supervised
400 PoE of CEM 91 Wonderware Workflow users 20 Intelligence Concurrent users 5 Intelligence Analytics clients
Slide 26
Production Plan Work Orders to the bottling Lines
24h
Work Order Execution
InTouch/ WOPS SAP Workflow CEM
Slide 27
Workflows in a Work Order
A - 00:00’20’’ – WO Verification
CIP done Raw Materials availability Right number of Operators available and capable to run this equipment TPM tasks already completed Line Status
Cheklist before start a WO
Line 12 – WO1 – Cola – Cans 33cl – 30.000 u.
Pending Time Running Time
Slide 28
Workflows in a Work Order
E - 00:40’00’’ – Task Management (TPM)
Line 12 – WO1 – Cola – Cans 33cl – 30.000 u. Pending tasks are shown to the operator through InTouch, including step-by-step guide All relevant information is registered: task fulfillment, time and operator There are several types of tasks
Task Management (Total Productive Maintenance)
Slide 29
WO’s trace in real time for Planners and Line Supervisors
Slide 30
KPI’s monitoring in real time by areas
Slide 31
Slide 32
Slide 33
Overview of Cobega Key Factors MES Project Scope Why Wonderware?
Slide 34
Clearly identify WHICH are they real needs Increase Assets Availability
Reduce Production Costs
Non- Conformities
Consumption
Costs
Improve Process Mgt
production tasks
Production/M aint/Quality
Integrate Info between systems
planning (Numetrix)
Treatment
Production
*SMED: Single Minute Exchange of Die
Slide 35
Increase Assets Availability
Reduce Production Costs
Non- Conformities
Consumption
Costs
Improve Process Mgt
production tasks
Production/M aint/Quality
Integrate Info between systems
planning (Numetrix)
Treatment
Production
Increase Assets Availability
Reduce Production Costs
Non- Conformities
Consumption
Costs
Improve Process Mgt
production tasks
Production/M aint/Quality
Integrate Info between systems
planning (Numetrix)
Treatment
Production
Slide 36
Reduction of Non- Conformities:
mistakes Energy Consumption
consuming without WO, CIP , Maintenance… Support to TPM
dedicates to gather info
*BOM: Bill Of Materials
Workflow
CEM
Operations
Slide 37
SKU’s
But it is even more important to “SPEAK THEIR LANGUAGE”:
The Team cannot start the project “from the scratch” We must have knowledge and experience about the Software to be used
Slide 38
Specification
Project
Specification
Project
Slide 39
Top Management & Users involved.
MES is not necessary to make bottles/cases/pallets… They were already bottling and canning before MES!!!! People Empower Factories!!!
Slide 40
Project Manager, Engineering, and IT must become ONE team Always bear in mind who is the “End User”
Production Manager Operators Plant Manager Line Supervisor TPM Manager Bottling Manager …
Slide 41
MES is a tool for Lean/TPM/6sigma… initiatives In the same way, MES is going to evolve in order to fit “new requirements”
“Plain” Reports Mobility Solution New Equipment Improved workflows …
Slide 42
Overview of Cobega Key Factors MES Project Scope Why Wonderware?
Slide 43
Slide 44
Data Acquisition System Platform and InTouch integrated in our MES Proximity of SI’s Siemens and GE proposed International SI teams CEM & Workflow WW was the only one to integrate “Energy” as part of the solution