Information Technology Integration with Manufacturing
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Transcript of Information Technology Integration with Manufacturing
MW Smart FactoryInformation Technology Integration with Manufacturing
Objectives:Inform about current trends in IT technology that impacts ManufacturingShow the various levels of integration with IT in Manufacturing and show potential opportunities
Agenda:• Review of industry trends impacting IT and Manufacturing
• “Internet of Things”• RFID• Advanced Analytics
• How these trends impact Maxion Wheels• Integrating IT with Manufacturing• Where are we today and how is technology creating opportunities• What specific opportunities exist in Limeira
Objectives and Agenda
IT Integration with Manufacturing
Current Technology Trends
Current Trends
Mobile
Integration
RFID
Everything CONNECTED
IT Integration with Manufacturing
IoT
Internet of Things
6
The MEGA Trend Matrix – Global 2025IoT
Connectivity and Convergence
Network of Physical “things” around us that are connected
IoT - Example
The Nest thermostat. Wi-Fi-connected thermostat allows you to remotely adjust the temperature via your mobile device and also learns your behavioral patterns to create a temperature-setting schedule.
9
Examples of IoT
IoT – WhyValue proposition: Greater value and service will be achieved by exchanging data with other connected devices or the user / operator
IoT enables:• Better management of assets• Efficient consumption of resources• Eliminate human error• Higher efficiency and convenience for the user
IoT – Future is Now
Evolving Technologies:• Facial recognition•Retinal scanning•Gesture recognition•Wearable technology•Wireless power•RFID
How long before our entire environment is connected?Connected home Connected car
IoT – Impact to Maxion Wheels• Customer – Connected car is evolving very quickly – a
connected or smart wheel would be a great innovation• Growing pains just like the Smartphone market 5 years ago
• Manufacturing – opportunities are HUGE
• Information Technology• Being pushed to allow consumer technology at work• Need better and faster networks• Need to help leverage this to provide more value to plants
14
IoT Gateways
IoT Gateway• Rugged design• Newest technology
• WiFi, Bluetooth, WWAN (3g or LTE)• Support for legacy devices
• Serial interfaces: RS-232, RS-485, RS-422/485
Designed to aggregate, secure and relay data from sensors and equipment from a plant floor.
IT Integration with Manufacturing
Predictive Maintenance
17
Predictive Maintenance
Maintenance System - Opportunity
Reactive / Breakdown
Orders
Preventive
Schedules
Reliability & TPM
Predictive Schedules
PM/TPMOrders
Planned Corrective,Safety-Proactive,
General, …
Predictive OrdersUsage
Equi
pmen
t –
Tool
s –
Mol
ds –
Reg
ulat
ory
– Fa
cilit
ies
MES
Requestors
ReportingSystem
Inspections
Down TimeReason Codes
Plant Floor Data
Collection
Only Change Oil When Breaks
Change Oil Every 3 Months
Reliability
Analysis
Safety-Reactive Orders
Manual Entry
Manual Entry
Plan
t St
ruct
ure Change Oil
Every 6000 km
Integration
Moving to Predictive Maintenance
Reactive - Breakdown Only
Preventive
Predictive
Reliability
Analysis
33%
50%
66%
+Productivity
+Uptime
PotentialMaintenance
Savings
Maintenance Maturity Level
Plant Maint
BudgetR$
7.5M/Yr
Est. Maint.
SavingsR$
2.2M/Yr29%
*Banff-Dupont study, Reliability Analysis, 2002
IT Integration with Manufacturing
RFID
22
• Hand Written Manual• Manual Entry Manual• Barcode Scanning Manual / Automatic
• Machine Integration / Sensors Automatic• RFID Scanning Automatic
History of Data Collection and EntryRFID
Reduce laborReduce errors
Real-time
23
RFID TagsRFID is a type of automatic identification technology that transmits data in the form of a unique serial number wirelessly.
RFID is being implemented in manufacturing worldwide to act as an intelligent monitoring system that can provide track and trace functionality throughout all levels of the supply chain.
RFID
24
RFID (Radio Frequency Identification)
RFID Wireless Receiver
RFID Tag
Receiver
Receiver
RFID Attached to PalletsTrack Movement
Track Location
Track wheel shipments
• Real Time Inventory• Automated Scanning• Location Tracking• Production Confirmation• Data Integrity• Warranty
RFID
IT Integration with Manufacturing
Advanced AnalyticsDeep Learning
26
• Complex analysis of data• Correlating inputs to outcomesWhich inputs result in the best outcome
• When to use:• In highly complex activities• Where there are many variables• Where it is difficult to correlate inputs to
outcomes
• A form of Artificial Intelligence• Goal: Create smart machines or operators
What is Deep Learning
Automate Complex Activities – Preserve Knowledge – Improve – Replicate
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Everyday Uses
Automate Complex Activities – Preserve Knowledge – Improve – Replicate
Apple Siri
IT Integration with Manufacturing
Value to Maxion Wheels
34
IT Integration with Manufacturing Landscape
Standard
MW Maturity Level
Market Trends
CloudSaaS
Data & Analytics
EmergingHigh Demand
Basic
Predictive MaintRealtime Inventory
Prod PlanningRFID
Network / WiFiConnected
SensorAI /Deep Learning
• PLC• Machine Integration• Sensors
(ERP)
35
Where we are today
Advanced (ERP)
CloudSaaS
Data & Analytics
Emerging
Basic
Predictive MaintRealtime Inventory
Predictive MaintRealtime Inventory
Prod PlanningRFID / PFDCRFID / PFDCNetwork / WiFiConnected
SensorAI /Deep Learning
• PLC• Machine Integration• Sensors
PLC Networks
Plant Floor WiFi
Vision Systems
Andon’s
37
Where we are today
Advanced (ERP)
CloudSaaS
Data & Analytics
Emerging
Basic
Predictive MaintRealtime Inventory
Prod PlanningRFID
AI /Deep LearningNetwork / Wifi
Sense / Monitoring
PLC
• PLC• Machine Integration• Sensors
Plant Floor Data Collection (PFDC): Inventory Management, production
reporting
(Czech, Turkey, Dello, GUA/SAN)
Plant Maintenance-mostly break/fixProduction Planning-Turkey
ERP Integration-Scanners, Data collection systems.
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Integration Cycle – Technology Impact
Collect
Sense
Analyze
Act
Become awareMachine cycled, temp higher
Communicate and store dataCasting database
What does this mean?Ask questions, draw conclusions
Take action to improve / correctChange casting settings
Network capable sensorsWiFi, RFID, PLC Integration
ConnectivityWiFi, Bluetooth, Gateway
Data Warehouse
Predictive Analytics, Deep Learning
Technology
Collect
Sense
Analyze
Alerting, Mobile, Displays
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Integration Cycle – Apply to Manufacturing Processes
Collect
Sense
Analyze
Act
Network capable sensorsWIFI, RFID, PLC Integration
ConnectivityWIFI, Bluetooth, Gateway
Data Warehouse
Predictive Analytics, Deep Learning
Technology
Collect
Sense
Analyze
Alerting, Mobile, Display
Preventative MaintenancePredictive Maintenance
Control complex process with large amount of variables (Casting)
Automate Inventory Management and
production reporting
Use Cases
Opportunities for Limeira?
IT Integration with Manufacturing
Discussion
Discussion
Mobile
Integration
RFID
IT Integration with Manufacturing
Thank you!
“Bad news — the scale is threatening to cut off our
access to the fridge…’
The evolution of electronics“These “smart, connected products”—made possible by vast
improvements in processing power and device miniaturization and by the network benefits of ubiquitous wireless connectivity—have
unleashed a new era of competition.”
Cloud ComputingConnectivity Big Data & AnalyticsSensors & Actuators
Internet of Things1933
First room thermostat introduced
1971AlohaNet is first public wireless packet data network
1998John Masey, Chief Scientist at SGI presents a paper titled “Big Data…and the Next Wave of Infrastress”
1999Cloud computing is introduced to the enterprise
2010The IoT and interconnectivity create novel possibilities for electronics
Internet of Things in ManufacturingGLOBAL OPERATIONS
I can see my production line status and recommend adjustments to better manage operational cost.
I know when to deploy the right resources for predictive maintenance.
I gain insight into usage patterns from multiple customers and track equipment deterioration.
MANUFACTURING PLANT
Identify and correct quality issues. Inventory Management
Remotely Manage Equipment
Monitor production flow in near-real time
GLOBAL FACILITY INSIGHT
Condition-based maintenance. Predictive maintenance
THIRD-PARTY LOGISTICS
Provide cross-channel visibility into inventories.
CUSTOMER SITE
Transmits operational information to the partner (e.g. OEM) and to field service engineers
Managers
R&D
Plant Floor
47
Where Do We See Advance integration or automation Delivering Value?
• Lower Cost Data Collection• Real-time Monitoring, Alerting and Control• Machine status and parameters• Product specifications• Inventory Tracking
• Predictive Maintenance – condition, cycle, • Lower Maintenance Cost (10%-50%)• Higher Uptime
• Deep Learning for Manufacturing• Making better wheels more consistently
Where do we see value? Where do you see value?
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Where Do We See Advance integration or automation Delivering Value?
• Process Understanding and Optimization• Failure Reduction, Quality Improvement• Supply or Demand Chain Optimization• Productivity or Resource Optimization• Increased Predictability of Supply Chains and Customer
Demand• Automated Maintenance• Other?
49
0s
Smart Bullets
“Tests suggest that increasing a target's distance actually improves the the projectile's accuracy by giving it more time to adjust its flight path”
More Data = Better Results