Manufacturing Solutions: The Journey Terence Tan General Manager - - PowerPoint PPT Presentation

manufacturing solutions
SMART_READER_LITE
LIVE PREVIEW

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


slide-1
SLIDE 1

Manufacturing Solutions: The Journey

Terence Tan

General Manager IAM Wonderware 15th October 2014 - Holiday Inn, Glenmarie Advance Solutions Seminar: Manufacturing Intelligence – Anticipate the Unexpected by

  • ptimizing production and safeguarding your assets
slide-2
SLIDE 2

What is MES?

Manufacturing Execution Systems (MES) are computerized systems used in manufacturing. MES can provide the right information at the right time and show the manufacturing decision maker “how the current conditions on the plant floor can be optimized to improve production output. MES work in real-time to enable the control of multiple elements of the production process (e.g. inputs, personnel, machines and support services)

Source from wikipedia (http://en.wikipedia.org/wiki/Manufacturing_execution_system)

slide-3
SLIDE 3

What is MES?

slide-4
SLIDE 4

Operations & Execution Portfolio

MESA’s 11 Functions of MES

MES

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

slide-5
SLIDE 5

11 Functions of MES Fully Covered by Wonderware

ISA Model Level 2

MES

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

slide-6
SLIDE 6

Wonderware Software Solutions

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

slide-7
SLIDE 7

How to Implement?

slide-8
SLIDE 8

How to Implement? Key Factor

MES System

slide-9
SLIDE 9

How to Implement? “People”

► Project Team ► Kickoff meeting ► Details System Study ► Define Details Project Scope ► User Requirement Specification ► Project Schedule

slide-10
SLIDE 10

How to Implement? “Software Solutions”

► System Design ► Define System Specification ► Define System Architecture ► Define Project Deliverables ► Product Training ► Functional Design Specification

slide-11
SLIDE 11

How to Implement? Strategy

► Project Lifecycle ► Project Methodology – PRINCE2 ► Weekly Progress Update ► Monthly Stage Control Review ► Risk Management

slide-12
SLIDE 12

Sample of the Project Plan and Activities

slide-13
SLIDE 13

How Wonderware Help?

► Certification

▪ Wonderware Certified Support Provider ▪ Wonderware Certified Training Provider ▪ Wonderware Certified System Integrator

slide-14
SLIDE 14

How Wonderware Help?

► Customer First Program

▪ Technical Support

  • Technical Support, Online Case Management and Knowledgebase
  • Online Training Seminars, Discount on Consulting Services
  • Emergency Direct/Advanced Technical Support

▪ Software Maintenance

  • Software Maintenance Releases, Service Packs, Patches and hotfixes
  • Software version upgrades

▪ Additional Benefits

  • Wonderware Training
  • Complimentary Invitation to Customer Events
  • Dedicated Customer Portal
  • Technical Account Management Team
  • Cyber Security Readiness Workshop

▪ Optional Services

  • Customer First for Solutions
  • Customer FIRST Cyber Security Maintenance Program
  • Resident Engineer
  • Application Clone
slide-15
SLIDE 15

How Wonderware Help?

► Wonderware Developer Network

(wdn.wonderware.com)

slide-16
SLIDE 16

Slide 15

Overview of Cobega Key Factors MES Project Scope Why Wonderware?

AGENDA

slide-17
SLIDE 17

Slide 16

Overview of Cobega

Cobega Group Cobega ECCBC Daba Others

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-18
SLIDE 18

Slide 17

Overview of Cobega

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
SLIDE 19

Slide 19

3 3 PLANTS

1.200 employees

1 1 MILLION PALLETS/YEAR

50 50 HECTARES

270

MILLIONCASES/YEAR

440 SKU’S

80.700 CLIENTS

20

Brand Names

12 MILLION PEOPLE

21 PACKAGINGLINES

slide-20
SLIDE 20

Slide 20

Overview of Cobega Key Factors MES Project Scope Why Wonderware?

AGENDA

slide-21
SLIDE 21

Slide 21

They called it the ICEBERG Project…

slide-22
SLIDE 22

Slide 22

slide-23
SLIDE 23

Slide 23

…but it has been completed

“THEHIDDENFACTORY”

slide-24
SLIDE 24

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

Scope

24h

InTouch

Workflow

SAP CEM

Operations

Performance

Intelligence

slide-25
SLIDE 25

Slide 25

System Platform 25k/12k 49 InTouch for SP

  • 36 in WW Panel PC
  • 13 for Cobega’s Workstations

298 equipments supervised

  • 92 Operations Entities
  • 98 Performance Entities

400 PoE of CEM 91 Wonderware Workflow users 20 Intelligence Concurrent users 5 Intelligence Analytics clients

Scope

slide-26
SLIDE 26

Slide 26

Production Plan Work Orders to the bottling Lines

24h

Work Order Execution

InTouch/ WOPS SAP Workflow CEM

How it works

slide-27
SLIDE 27

Slide 27

Workflow Example

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
SLIDE 28

Slide 28

Workflow Example (TPM)

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
SLIDE 29

Slide 29

WO’s trace in real time for Planners and Line Supervisors

slide-30
SLIDE 30

Slide 30

KPI’s monitoring in real time by areas

slide-31
SLIDE 31

Slide 31

slide-32
SLIDE 32

Slide 32

slide-33
SLIDE 33

Slide 33

Overview of Cobega Key Factors MES Project Scope Why Wonderware?

AGENDA

slide-34
SLIDE 34

Slide 34

  • 1. What are they looking for?

Clearly identify WHICH are they real needs Increase Assets Availability

  • Increase OEE
  • SMED

Reduce Production Costs

  • Reduction of

Non- Conformities

  • Energy

Consumption

  • Labor Costs
  • Maintenance

Costs

Improve Process Mgt

  • Support TPM
  • Coordination

production tasks

  • Coordination

Production/M aint/Quality

Integrate Info between systems

  • SAP/R3
  • Production

planning (Numetrix)

  • Wastewater

Treatment

  • Syrups

Production

*SMED: Single Minute Exchange of Die

slide-35
SLIDE 35

Slide 35

  • 2. Where is the Return On Investment?

Increase Assets Availability

  • Increase OEE
  • SMED

Reduce Production Costs

  • Reduction of

Non- Conformities

  • Energy

Consumption

  • Labor Costs
  • Maintenance

Costs

Improve Process Mgt

  • Support TPM
  • Coordination

production tasks

  • Coordination

Production/M aint/Quality

Integrate Info between systems

  • SAP/R3
  • Production

planning (Numetrix)

  • Wastewater

Treatment

  • Syrups

Production

Increase Assets Availability

  • Increase OEE
  • SMED

Reduce Production Costs

  • Reduction of

Non- Conformities

  • Energy

Consumption

  • Labor Costs
  • Maintenance

Costs

Improve Process Mgt

  • Support TPM
  • Coordination

production tasks

  • Coordination

Production/M aint/Quality

Integrate Info between systems

  • SAP/R3
  • Production

planning (Numetrix)

  • Wastewater

Treatment

  • Syrups

Production

slide-36
SLIDE 36

Slide 36

  • 2. Where is the Return On Investment

Reduction of Non- Conformities:

  • Avoid BOM

mistakes Energy Consumption

  • Assets

consuming without WO, CIP , Maintenance… Support to TPM

  • Labor hand

dedicates to gather info

*BOM: Bill Of Materials

Workflow

CEM

Operations

slide-37
SLIDE 37

Slide 37

  • 3. Avoid White Paper Syndrome

ASEPTIC

Syrup

KISTERS

HI-CONE

KAIZEN

SKU’s

TORQUE

LEAN

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
SLIDE 38

Slide 38

  • 4. Methodology

MES project

Functional Specifications and Methodology

Specification

  • 300 PoEU

Project

  • 1.000 PoEU

Specification

  • 5 alarms/equipment

Project

  • 500 alarms/equipment
slide-39
SLIDE 39

Slide 39

  • 5. Top Management

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
SLIDE 40

Slide 40

  • 6. Breaking Down Factory Barriers

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
SLIDE 41

Slide 41

  • 7. Continuous Improvement

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
SLIDE 42

Slide 42

Overview of Cobega Key Factors MES Project Scope Why Wonderware?

AGENDA

slide-43
SLIDE 43

Slide 43

slide-44
SLIDE 44

Slide 44

Why Wonderware

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

slide-45
SLIDE 45

Software Solutions for Real-Time Success