World-Class Shop Floor Management

Lead by TRUE OEE

FORCAM, Inc.

250 E. Fifth Street, 15th Floor

Cincinnati, OH 45202

(513) 878-2780

info@forcam.com

www.forcam.com

White Paper

Availability Performance Quality

TRUE OEE

TRUE OEE 3

Planned versus Actual 4

Recipe for Success 5

CIP Organization 6

CIP Communication 7

Shop Floor Control Panel 8

Factory 2.0 9

SFM Technology 10

About FORCAM 12

Customers’ Success Stories 15

Contents

© FORCAM 2013 www.forcam.com Lead by True OEE 2

TRUE OEE

FORCAM provides an innovative production software technology (Factory Framework™) and

consults on state-of-the-art Shop Floor Management. World-class companies from diverse

manufacturing sectors like automotive, machinery, aerospace, medical engineering and

packaging are utilizing FORCAM’s Shop Floor Management solution. It enables companies to

measure performance of their machines and plants in real-time to quickly recognize and

correct errors and waste, and to continuously optimize their productivity.

Shop Floor Management principles are the

foundation for “True OEE” 1. Leadership Principle Shop Floor Management is a top-down process. Management must be trained to incorporate

the CIP culture and to lead by OEE.

© FORCAM 2013 www.forcam.com Lead by True OEE 3

2. Management Tool ERP systems are not suited to support the CIP organization. Real time ERP data

combined with machine data is required to visualize the real status of the shop floor and to

calculate a TRUE OEE. Planned vs. Actual Performance Analysis is the key element of

Shop Floor Management.

Planned vs. Actual

The Lean Philosophy empowers the shop floor operator. The operator needs to know what

the supply chain (ERP) expects from him such as when to start an order/operation and

what target must be fulfiled.

Planned vs. Actual performance information in real time will give the operator immediate

feedback about the current performance of his manufacturing workplace in order to take

immediate measures in the case of a deviation from target.

How do you measure your shop floor performance today?

- Are there deviations between your planned setup versus actual setup times?

- Are there deviations between your planned cycle versus actual cycle times?

- How do you track and measure planned quantity deviations from actual quantity yield?

True OEE is driven by Planned vs. Actual

performance information collected in real time

© FORCAM 2013 www.forcam.com Lead by True OEE 4

Recipe for Success

With the help of FORCAM, elite companies have been able to increase productivity measured

with TRUE OEE by up to 20% within the first year.

The Recipe for Success - holistic Shop Floor Management that effectively combines the most

advanced Shop Floor Management System with the Lean Management philosophy.

A Recipe for Success in Shop Floor Management:

Measuring TRUE OEE - what you cannot measure you cannot improve

Adopting Lean Management principles and leading by OEE

Creating a Continuous Improvement Process (CIP) culture with closed-loop communication

Delivering the right information to right people at the right time

Delivering planned vs. actual performance information real-time to shop floor operators

Establishing a PDCA (Plan-Do-Check-Act) cycle with actions and measures

Setting regular TRUE OEE goals for continuous improvement

FORCAM Guarantees 10% Increase in Productivity

© FORCAM 2013 www.forcam.com Lead by True OEE 5

CIP Organization

All manufacturing roles are supported by advanced shop floor management

technology with no exceptions, from the machine operator to maintenance to

the plant manager.

Advanced Shop Floor Management (SFM)

technology must support all organizational roles

within the CIP Organization.

© FORCAM 2013 www.forcam.com Lead by True OEE 6

Continuous Improvement Process (CIP) Organization

CIP Communication

Advanced Shop Floor Management (SFM) technology

offers closed loop CIP communication by delivering the

right information to the right role at the right time

Periodic CIP Meetings, weekly and monthly, will utilize real time Shop Floor

data to monitor, analyze, and set goals and targets for:

Stoppages / Downtimes

Production Flow

Organization

Quality

Tools Optimizations

Logistics

Worker Orders / Routing

Current Turnaround / Productivity Values

© FORCAM 2013 www.forcam.com Lead by True OEE 7

Shop Floor Control Panel

(Sample from Audi)

© FORCAM 2013 www.forcam.com Lead by True OEE 8

Factory 2.0

Measuring and optimizing the performance

of manufacturing plants anywhere, anytime

The real-time information provided by FORCAM can be accessed through mobile gadgets including smartphones and tablets.

iFactory mobile application is now available.

Planning and Production are now synchronized

“Today, companies need resource efficiency in processes and in manufacturing.”

FORCAM’s Chairman, Franz Gruber, states. Everything has to intertwine in a way that errors and waste can be recognized immediately and eliminated sustainably.

The FORCAM technology complements standard ERP-software on the planning level (top floor) using objective performance data coming directly from all factory assets (shop floor) – from one single machine to multiple plants worldwide. The efficiency factor of standard ERP-software is enhanced due to the real-time data capture by FORCAM. Simultaneously, FORCAM enables customers to apply the technology themselves in their company following a pilot phase.

FactoryFramework™ Shop Floor Management System

Advanced Shop Floor Management

Creates The Transparent Factory

© FORCAM 2013 www.forcam.com Lead by True OEE 9

Management OEE Dashboard

Operator Planned vs. Actual

Maintenance Pareto Hit List

Plant Manager Live Web Visualization

SFM Technology (1/2)

State-Of-The-Art Shop Floor Management

Flexible web-based connectivity of a diverse number of machine controls

FORCAM‘s Factory Framework™ solution is technologically leading Manufacturing Execution System (MES). It enables improvement processes on all levels of the production. Factory Framework™ connects, collects, and standardizes real-time data from most different machine controls. For every production level, the signals provide comparable web-based operational states of machines and plants (production, malfunctions, and downtimes).

Result: Transparent and reliable performance data – runtime, speed, quality. Additionally, Factory Framework™ connects production data with ERP data from corporate planning such as targets for orders and resources.

From the operator to the manager

All roles involved are able to

continuously optimize productivity

within their role.

Leading-edge Technology: Complex Event Processing (CEP) with Live Cache

FORCAM uses Complex Event Processing (CEP) with Live Cache, a technology used for real-time analysis of event stream from the financial sector. FORCAM combines CEP with the proven and tested MES in a rule-based approach in an optimal way.

Results:

• Fast reaction with latencies in the millisecond range and high throughput (factor is 100 times higher than in the past product generation)

• Rule-based approach enables flexible, user-defined functions

• Global deployment potential with Unicode language support and centralized server architecture

© FORCAM 2013 www.forcam.com Lead by True OEE 10

SFM Technology (2/2)

Overall Equipment Effectiveness (OEE) is Optimized

OEE - Overall Equipment Effectiveness

Shop Floor Management (SFM) is a strategy designed for the continuous optimization of the plant availability by eliminating errors and waste. The most important key figure to measure the performance is the OEE – Overall Equipment Effectiveness.

As key performance indicator, OEE results from three performance data which FORCAM monitors and visualizes in real-time, and therefore available anywhere and at any time:

How long has it been producing?

How fast has it produced?

How well has it produced?

OEE is the most important key figure (KPI) to implement the SFM strategy.

OEE is the measure for the added value of a machine.

OEE visualizes exactly which machine and process losses can be minimized.

OEE - Three crucial performance metrics: Availability, Productivity, Quality

OEE

TimeQ 4 Q 3 Q 2 Q 1

Point of the symbiosis

Lean Management Organisation

and technology

© FORCAM 2013 www.forcam.com Lead by True OEE 11

FORCAM – At a Glance

FORCAM Guarantees up to

20 % Higher Productivity in Factories in

Less Than 1 Year

MARKET Discrete Manufacturing Industries

- Automotive

- Aerospace & Defense

- Medical Devices

- Machinery

- Oil & Gas

PRODUCT Shop Floor Management System

TECHNOLOGY Leading-Edge Manufacturing Execution System FactoryFramework™

CUSTOMERS Vertical Market Segments (Automotive/Aerospace/Medical)

Select Customers include: Audi, BMW, Daimler, BorgWarner, MTU Aero Engines, Mann+Hummel, P&H Mining, WEIR Minerals

IMPACT > Significant improvements in productivity (up to 20%)

> Accelerated Return on Investment (ROI 1 Year)

> Optimized Return on Capital Employed (ROCE)

> Improved transparency leading to lower costs

> Higher energy and resource efficiency

MANAGEMENT > Former SAP Executive founded FORCAM in 2001

> SAP co-founder, Dietmar Hopp is a FORCAM stakeholder

SELECT PARTNERS > SAP

> IBM | TDM Systems | Q-DAS

> IMS Center, University of Cincinnati (Prof. Jay Lee)

> Massachusetts Institute of Technology - MIT (Prof. Bühler)

© FORCAM 2013 www.forcam.com Lead by True OEE 12

2001 + Foundation (SAP Spin-off to close the gap between Top-Floor and Shop-Floor )

+ Development of the first web-based Thin-Client production software

2002 + Daimler Powertrain Plants – development partnership to deploy thin-client web

technology to the shop-floor.

2003 + Kuka Robots – Seamless integration with SAP

+ Strategic partnership with IBM

2004 + Daimler Press Plants – 3 Press Plants with Assets worth 2.5 Billion Dollars

2005 + FORCAM rejects a bid by SAP AG

+ SAP co-founder Dietmar Hopp acquires a 10% share

2006 + Baden-Württemberg Innovation Award to FORCAM awarded for their vision and outstanding ability to execute for Daimler Powertrain Project

2007 + Breakthrough: Global Roll-out at Schaeffler Technologies and Mann+Hummel

(with Seamless SAP Integration)

2008 + Breakthrough: AUDI and BMW Press Plants opt for FORCAM

+ Daimler engine plant in Untertürkheim becomes Factory of the Year

2009 + AUDI stamping plants increase productivity by 20% within 12 months

+ On the way to set the TPM industry-standard in pressing plants

2010 + SEW (France) achieves a productivity increase by 20% in just 3 months

+ SAP co-founder Dietmar Hopp increases share to 17%

+ Founding of FORCAM Ltd in the United Kingdom

+ FORCAM initiates Research Partnership with Prof. Jay Lee at the Center for Intelligent Maintenance Systems (IMS) in University of Cincinnati, USA.

2011 + FORCAM’s Annual Customer Event (FIT 2011) hosted by Audi in Ingolstadt

+ WEIR Minerals (UK) reports 12% raise in efficiency in 6 months

+ New Customers in the USA: ZF, P&H Mining, Coperion, LUK Wooster

+ Installation of Service and Support Center in Hungary

2012 + FORCAM’s Annual Customer Event (FIT 2012) hosted by Daimler (Mercedez-Benz)

+ German Government awards FORCAM the SMB Innovation Award

+ ARC nominates FORCAM Customer, BorgWarner, for Best-in-class Shop Floor Management.

+ Founding of FORCAM INC. based in Cincinnati, Ohio, USA

Milestones

© FORCAM 2013 www.forcam.com Lead by True OEE 13

Management

Franz E. Gruber Founder & Chief Executive Officer (CEO)

Industrial Engineer

Since 2001: President and Chairman FORCAM

Until 2001: SAP AG

(Sales Executive, Special Functions for SAP CEO)

1989: Trainee IBM

CIM (Computer Integrated Manufacturing) Consultant

1988: Degree Fachhochschule für Technik (Advanced

Technical College), Esslingen

Dr. Mohamed AbuAli Chief Operating Officer (COO)

Manages delivery and deployment of FORCAM‘s technology

Ph.D. Industrial Engineering – University of Cincinnati

Project Management Professional (PMP)

Certified Quality Engineer (CQE)

Advisory Board

Erich Bühler

Former Daimler-Benz AG

Professor Dr. Dietmar Kilian

Corporate consultant, former SAP AG

Kurt Striedacher

Founder Kumatronik Group

Berthold Wipfler

SAP AG

© FORCAM 2012 www.forcam.com Lead by True OEE 14

Success Stories

• Daimler (Mercedes-Benz)

• Factory of the Year Award (by A.T. Kearney)

• Delivering monitoring and optimization of more than 14,000 machine tools

• Audi

• Audi Stamping Plants + 20% increase in TRUE OEE within 12 months

• Audi Components Plants + 10% increase in TRUE OEE within 12 months

• Click Here for Audi Case Study

“Due to Factory Framework, the press plants at Audi have increased productivity by 20

percent. Investing in a new software architecture was well worth it.”

Axel Bienhaus - Audi AG

• BorgWarner

• Exceeding expectations with unique shop floor management strategy

• 4.3% increase in TRUE OEE within 6 months

• Click Here for BorgWarner Case Study (presented at ARC Industry Forum 2012)

• Weir Minerals

• 12% increase in TRUE OEE within 6 months

• Click Here for Weir Minerals Case Study

FORCAM offers you a unique solution, based on the Lean Manufacturing Philosophy

of how to successfully manage and operate manufacturing facilities.

“FORCAM will bring True OEE to your company.”

With FORCAM technology, elite companies have increased productivity

by up to 20% within the first year, measured by

TRUE Overall Equipment Effectiveness (OEE).

© FORCAM 2013 www.forcam.com Lead by True OEE 15

Copyright © 2013 FORCAM Unauthorized use or reproduction of this work is in any form is prohibited

FORCAM, Inc.

250 E. Fifth Street, 15th Floor

Cincinnati, OH 45202

(513) 878-2780

info@forcam.com

www.forcam.com