SIOP & Smart Factory Planning, Execution and Control of - - PowerPoint PPT Presentation

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SIOP & Smart Factory Planning, Execution and Control of - - PowerPoint PPT Presentation

digitalsoft SIOP & Smart Factory Planning, Execution and Control of Operations Digitalsoft digitalsoft Head Quarter Pescara, Italy +39 0871 090000 Digitalsoft Innovation Lab Innovation & Development Center Connect and Empower


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SLIDE 1

digitalsoft

SIOP & Smart Factory

Planning, Execution and Control of Operations

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SLIDE 2

Leverages digital technology as a competitive advantage in internal and external operations.

digitalsoft

Connect and Empower Businesses

We are providing smart platforms enabling digital transformation and value chain integration being agile in innovating and adapting to business needs

Digitalsoft Head Quarter Pescara, Italy +39 0871 090000 Digitalsoft Innovation Lab Innovation & Development Center Madurai, India +91 739 773 3522 Digitalsoft US Sales and Operations Atlanta, USA +1 800 755 7264 Digitalsoft China Sales and Operations Shanghai, China +86 185 2107 0660

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SLIDE 3

Processes enabled by

Strategic Planning (STRAP) Execution

Master Production Scheduling

(MPS)

Detailed Scheduling

Shop floor & Supplier Scheduling

SIOP

Operations Plan units Demand Plan Inv $

Strategy Planning

Demand Planning Customers Supply Planning Suppliers Business Planning

(BUDGET) 3

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SLIDE 4
  • Monthly Process
  • Demand Management
  • Long Term Planning
  • Load Balancing
  • Scenarios & Simulation
  • SIOP Report & Analytics

Processes enabled by Platforms

4

Process

  • Weekly Process
  • Demand Arbitration
  • Production Planning
  • Shipment Planning
  • Inventory planning
  • Constraint Checks
  • Versioning

Sales & Operation Planning Master Production Planning Strategic Business Planning

  • Material Requirement

Planning

  • Supplier scheduling
  • Supplier Collaboration

Portal

MRP Execution of Operations

Systems Your ERP

(SAP, Oracle, Infor, …)

  • Detailed Shopfloor Scheduling with

real time production progress

  • Clear to Build: components

availability monitoring

  • Execution and Control of

Manufacturing: Quality, Traceability, Visual boards & KPI, Maintenance

  • Logistic Execution: Warehouse,

Material handling & Replenishment

  • Clear to Ship: Shipment process

Sales, Inventory & Operations Planning Smart Factory

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SLIDE 5

enabling your end-to-end connected supply chain

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SLIDE 6

Leverages digital technology as a competitive advantage Smart platform enabling digital transformation and value chain integration

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SLIDE 7

7

Digitization and integration

  • f

manufacturing and supply chain processes, empowering

  • perators, supervisors and plant

managers to proactively manage the production execution process thru streamlined transactions and KPI enablement. Enabling a robust planning process to create the best supply plan based on latest demand insights, internal and external bottlenecks and targeted inventory levels. Connecting data and processes, IOT with Big Data analytics will enable a more reliable monitoring across the actors involved in the

  • perations to detect problems

early and prevent outages. Real-time interactive boards for

  • peration excellence:

OEE, Actual vs Target, Production Line Downtimes, Andon, Maintenance activities, Warehouse and Material Handling activities.

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SLIDE 8

8

Sales, Inventory and Operation Planning enables the creation of a capacity constrained production plan. The plan will become more realistic and achievable

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SLIDE 9

– Features

9

Sales, Inventory and Operation Planning

Demand Management

  • Sales Forecast management
  • Demand Planning and Arbitration

(sales forecast, customer orders, etc.)

  • Automatic demand forecast based
  • n statistical forecast / machine

learning algorithm

  • Automatic update demand plan

based on previous week past-due.

Analytics & KPI

  • SIOP dashboard and report
  • MPS dashboard planning status
  • MAPE & Bias report
  • Demand Analysis report
  • Weekly report
  • Revenue report
  • KPI: OTTR, DOS, Premium

Freight, Cycle time

ERP connector

  • Import “Master data” : Materials,

BOM

  • Import EDI, Customer Orders,...
  • Import “Actuals” : Production,

Inventory stock, Shipments,...

  • Export Production Planning to your

ERP as Ind. Requirement or Planned (input to MRP).

  • Export Arbitrated Demand to the

ERP

Scenario & Simulation

  • Easy way to simulate a different

what if scenarios.

  • Manage different set of constraints

by scenario

  • Execute optimizer for each

scenario

  • Compare various scenarios and

Finalize the best scenario and finish goods requirements.

  • Versioning

Inventory Planning

  • Shipment planning. You can do it

within the planning table

  • Automatic stock projection based
  • n actual stock, production,

shipment and purchased quantity

  • Target stock automatically
  • ptimized vs demand forecast and

production plan while respecting the material target stock days.

RCCP

  • Rough Cut Capacity Planning
  • Supplier Capacity management

and Analysis

  • Internal key resources check
  • Highlight and track critical

situation with aging

  • Critical issues classification report

Constraints Checks

  • SIOP streamlines the constraints

side of things.

  • External constraints (Supplier

Capacity)

  • Internal constraints (Production

line capacity and Manpower)

  • Customer Priority

Production Planning

  • Short and long term Production

planning (weekly and monthly process)

  • Automatic optimizer for Production

Plan proposal ensuring inventory targets, customer priority and internal and external constraints.

  • Flexible planning layout screen,

with integrated RCCP and Constraints check

  • Load balancing
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SLIDE 10

digitalsoft 10

Drive operational excellence by simplifying & enhancing operational backbone for speed, quality, flexibility and efficiency

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SLIDE 11
  • Detailed Shopfloor

Scheduling

  • Graphic Gantt
  • Real time production

progress updating

  • Constraints checks
  • Calendar and Capacity

management,….

Scheduling

  • Components

availability

  • Sub assembly

monitoring

  • Embedded control

inside the scheduling control by components availability

  • Quick view of critical

components / subassy

  • Interface with SAP

Clear to Build

  • Production

management & confirmation

  • Downtime

management

  • Maintenance &

Escalation

  • Labor activity

management, Skill map

  • Production Data

Collection

Manufacturing

  • PULL Strategy:

internal pull between shop floor and warehouse

  • Automatic shop floor

replenishment

  • Replenishment

activities guide and coordination (forklift, milk run, self-driving vehicles, ...)

Logistics

  • FIFO and Warehouse

management

  • Retrieval and Storage
  • perations
  • Warehouse activity

monitor & KPI

  • Kitting

Warehouse

  • Delivery order from

SAP

  • FG Stock Analysis
  • Cargo management
  • Dock booking mgmt.
  • Automatic forklift

mission

  • Labeling, Check &

Load

  • Print Docs, Post Good

Issue

Clear to Ship

  • Real-time production

vs target

  • OEE & Performance

Analytics

  • Warehouse &

Replenishment activities

  • Metrics & Key

Performance indicators

  • Cognitive Analytics

with AI / ML

Visual Mgmt

  • Traceability of

materials and components

  • Traceability of lots and

container ID

  • Traceability of
  • perations (downtime

etc.)

  • Traceability of process

data

  • End-to-End Fully

Traceability

Traceability

  • Scrap & Rework mgmt,
  • Quality Alert
  • Part checks /

inspection

  • Work instruction (SOS)

& Check list

  • Process Control &

Poka Yoke

  • SPC integration

Quality

  • Escalation process
  • Andon management
  • Kaizen
  • 5S
  • RCA
  • Gemba walk
  • Audit

Lean Mfg

  • Self-driving vehicles
  • Automatic Warehouse
  • Automatic Weight

System

  • Automatic systems for

identification, storage, palletize, wrap, ...

  • Collaboration Robot

Automation

  • Machine Data

Collection

  • Interface Machine and

Sensors / Devices (IIOT)

  • Real time interface

with SAP and Enterprise Applications

  • Integration with

Automation and Robots

Integration

11

– Features

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SLIDE 12

– Connecting Intelligence

12

Things

Connecting all physical devices and

  • bjects for data

collection.

Process

Delivering the right information to the right person at the right time.

People

Connecting people in more relevant and valuable ways.

Data

Leveraging data into more useful information for decision making.

$ $$ $$$ $$$$ 00101010010 101010001 10011

The right data at the right time to right devices, so that the right people or machine can make the right decision with automated processes and analytics insight.

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SLIDE 13

– The fully connected way of making things.

13

SUPPLIERS

3D PRINTING (ADDITIVE MFG)

  • Scrap elimination
  • Mass Customization
  • Rapid Prototype

IOT / SENSORS

  • Zero default /deviation
  • Reactivity
  • Traceability
  • Predictability

ADVANCED MATERIALS

  • Smart value-added products
  • Technical differentiation
  • Connectivity

Cloud Computing

CYBER SECURITY

  • Stronger Protection for internet

based manufacturing

  • Technology products with longer life

cycles

BIG DATA

  • Making Sense out of complexity
  • Optimization & Creativity
  • Collaborative manufacturing

MANUFACTURING SYSTEM

  • Cyber-physical systems
  • Interconnected systems
  • Full coordination & automation
  • Planning of Operations
  • Execution & Control of Operations

ROBOTS / COBOTS

  • Real-time autonomy / productivity
  • Full transparency (contextualization,

comprehensiveness, collaborative robot) on data reporting

MASS CUSTOMIZATION

  • Customer and marketing intimacy
  • Flexibility
  • Perfect match of customer’s need

with mass production efficiency

  • On-demand manufacturing

Smart Factory

CUSTOMERS

INTERNET OF THINGS

  • Object tagging
  • Internet-to-object communication
  • Real-time data capture
  • Optimized stocks
  • Reduced waste

Supplier Collaboration

  • Integrated Supply Chain
  • Interconnected systems
  • Perfect coordination

LEAN LOGISTICS

  • Pull Replenishment
  • Flow optimization
  • Lower costs

SHIPMENT

  • Shipment
  • ptimization
  • Fully Traceability
  • Lower costs
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SLIDE 14

14

– Business Transformation Roadmap

Foundation Integrated & Visual Connected Flexible & Intelligence Smart Factory

1st year 2nd year 3rd & 4th year 5th year 6th & 7th year Future Factory Data Planning & Detailed Scheduling Manufacturing Logistics and Material Handling Quality Analytics

Traceability

  • f materials

Machine Data Collection Traceability

  • f process data

Intelligent Sensors Traceability

  • f operations

Device History Record E2E Fully Traceability Cyber physical systems Capacity Analysis Detailed Scheduling Scenario Planning & Simulation SIOP Clear To Build Automatic Optimized Planning Constraints Analysis MPS Weekly Planning Self-driving vehicles LeanLift integration Warehouse Automation Automatic Identification & Loading Clear To Ship Smart Supply Network Warehouse Management Unique Container ID Kitting Physical Inventory Count Batch Management Warehouse activity monitor & KPI PULL: Shop floor Replenishment Serialization Production Execution Downtimes KPI, Reports Escalation Visual Factory (Andon, Prod.Line...) FG Declaration Backflushing Mobile workforce Maintenance Rework / Repair Resource & Labor Mgmt, Skillmap Smart Maintenance e-Kanban Augmented Reality Collaboration Robot Eco-efficient system Flexible production Smart Integration with PLM Responsive Manufacturing Automated KPI, Metrics RCCP Constraints Checks Predictive Insights Data Analytics Predictive Analytics Actionable Intelligence Automatic adjustment

  • f machine

parameters Maximizing asset utilization Minimize bottlenecks Insight to product design Intelligent Products Check List and Work instruction (SOS) Part checks Scrap mgmt Process Control & Poka Yoke SPC integration Incoming Inspection Digital Quality Mgmt Quality Prediction Remote Quality Monitor Prescriptive Analytics Supply Chain Planning Collaboration Quality Notifications Closed-loop control Lean mgmt (Kaizen, Audit,...)

Phase

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SLIDE 15

Source: McKinsey Digital - Industry 4.0 How to navigate digitization of the manufacturing sector

INDICATIVE QUANTIFICATION OF VALUE DRIVERS CASE HISTORY: BENEFIT MEASURED FROM OUR PAST IMPLEMENTATIONS

3% - 5%

Manufacturing Plant Productivity YoY

10%

OTTR & Production Reliability improvement

25%

Customer Service Level improvement

5% - 10%

Inventory reduction and Yearly financial adjustment by higher accuracy

15%

Cycle Time and Downtime reduction

5% - 10%

Indirect Cost and Time reduction

5% - 10%

OEE – Overall Equipment Efficiency improvement

+5%

Enabling sales increase thru up sell and cross sell (with higher margin >50%)

is enabling up to 10% overall productivity YoY, when implemented in combination with Lean methodologies

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SLIDE 16

Thank you

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We are committed to co-create value with our Customers

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SLIDE 17

Thank you