ABDW17-Lightning Talks track-Manufacturing Process Traceability with Apache Apex

Manufacturing Process TraceabilityWith Apache ApexRoshan Kulkarni, Mindstix Software Labs

© Mindstix Labs 2017

Product RecallsToyota Motor CompanyMarch 30th 2017, ~2.9 Mn Vehicles, Faulty Airbags

Ford Motor CompanyMarch 29th 2017, ~440K Vehicles, Coolant Leaks, Fire Risks

NissanMarch 25th 2017, ~56K Vehicles, Power Steering Fluid Leak

Hyundai MotorsMarch 16th 2017, ~1 Mn Vehicles, Seat Belt Glitch

Why Recalls?

Product ConcernsManufacturing Defects, Safety Issues, Customer Endangerment

Legal ImplicationsStronger Consumer Protection Laws, Federal Investigations

Voluntary RecallsPerceived Exposure to Liabilities, Brand Credibility At Stake

Cascading Effects of A Global Supply ChainComplex BOMs, Nature of Global Sourcing


Deep Financial Impact of Recalls

The Real Costs of Recall

Cost of Reverse Logistics

Direct Repair Costs

Cost of Litigation

and Settlement

Loss of Brand ValueSafe

Disposal of Faulty Parts

Replace’nt Units

Customer Comp’sn

or Full Refunds

Lost SalesEvery year, warranties and recalls cost the

global automobile

industry nearly $40

Billion…


A Stark Reality Across VerticalsVerticals Examples

Automobile 2016Takata Airbags, 100 Million Units, $1+ Billion in Settlements

Food and Beverage 2007Peanut Corp, 3200 Products, 500+ Million Units

Pharmaceuticals 2010Johnson and Johnson, 43 OTC Drugs, $900 Million in Lost Sales

Consumer Electronics 2016Samsung Electronics, Galaxy Note 7, $5 Billion in Costs

Toys 2007Mattel, 19 Million Units


What’s Needed – Manufacturing Traceability

Establish Product Lineage

• Pin Liability to Specific Suppliers and Sources

• Shift The Financial Impact of a Recall

• Narrow-cast the Impact of Product Recalls

Track Production Variables

• Root Cause Analysis of Reported Defects

• Drive Continuous Process Improvements

• Regulatory Compliance and Vendor Qualification

Generate Real-Time Alerts

• Pre-emptively Catch Production Misses

• Risk Assessment and Pre-emptive Recalls

1000’s of SKUs, 100’s of Processes, 100’s of Production Lines


Product Lineage – Bill of MaterialTracking Genealogy

For Each Unit or BatchPlastic HousingSKU #4323

Printed DialSKU #19283

Electronic ModuleSKU #4738

Glass CasingSKU #37629

Push ButtonSKU #4638

LCD DisplaySKU #80927

Screw AssemblySKU #5638

Printed Circuit BoardSKU #8830

Surface Mount ChipSKU #383784

25 uF CapacitorSKU #123412

Surface Mount ConnectorSKU #5733

Supplier:Jacksonville Parts Co.

Consignment:CR213123

Bin Number:1231231

Consignment Date:July 25th 2015

Order Number:638239

Part Serial Number:539131

Part Name:Speedometer and Odometer

SKU:8372932

Lot Number:1241312312

Assembly Date:22nd December 2015

Assembled At:Chakan, Unit 2Assembly Line #6

Assembly Line Employee:Mr. John Doe

Assembly Line Supervisor:Mrs. Jane Doe

Final Assembly Sub-Assembly Souring InformationProduction Summary


Product Lineage – Material Inward

Supply Consignments

SupplyCrates

VQAProcess

Bin Allocations

Main Store

Tagging Consignment Numbers, Supplier POs to Bins

DOL Material


AmbientParametersLine Supervisor Production

Batching

Production Process Variables

SKU1 SKU2 SKU3 SKU4

IncidentReporting

Staged Feeder

Bins

Staged Feeder

Bins

Staged Feeder

Bins

SKU5

Output Bins

Staged Feeder

Bins

People Process

ToolsQC Testbed Test Reports

Assembly Line


Shop Floor Events§ Ingress SKUs§ Egress SKU

§ Ambient Parameters§ Deployed Personnel

§ Deployed Tooling and Assets§ Tool Configuration§ Process Parameters

§ Testbed Parameters§ Testbed Reports

§ Incident Reporting, Near-Misses§ Batch Quarantine§ Tool Quarantine

Real-time Insights§ SKU Compatibility§ Stage Skip Alerts

§ Flow Rate and Violations§ FIFO Violations

§ Ensure Sufficient Test Sampling§ Notify Boundary Conditions§ Tool Overuse

§ Quarantine Violations§ Personnel x Product Matrix

§ Shelf Life Violation

Events and Real-time Insights

Audit and Archival§ Lineage§ Production Parameters


Platform Expectations§ Capture Asynchronous Events - High Volume, Unordered

§ Guarantee Reliability of Event Delivery

§ Windowing of Events Into Production Batches (Event Time Based)

§ Generate Insights in Real-time

§ Large Scale Persistence - Linear Scaling of Storage

§ Operational Ease and Workflow Updates


Event Processing FlowMQTT

Connector

(Enrichment)Sensor =>

Production Line

Window Aggregation(Event Time)

Dedup RF Tags

Persistent Store(HDFS)

Filter for SKU Compatibility

Filter for Quarantine

Batches

DashboardAlerts

DashboardAlerts

JDBC Lookup

JDBC Lookup

(Enrichment)Bin Tag =>

Sourcing Info


Thank YouRoshan Kulkarni

Founder and CEO, Mindstix Software Labs

[email protected]

ABDW17-Lightning Talks track-Manufacturing Process Traceability with Apache Apex

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