Operations Management- A Vital Link in SMART Manufacturing Strategy
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Transcript of Operations Management- A Vital Link in SMART Manufacturing Strategy
A Vital Link in Smart Manufacturing StrategyOPERATIONS MANAGEMENTAseem Sinha,
M A Baliga
Prateek Srivastava
Disclaimer
Any statement, opinion, prediction, comment, or observation made in this presentation/publication
are those of the presenter/author only and in no condition should be construed necessarily
representing the policy and intent of Reliance Industries Ltd. (RIL).
The information presented herein are of the presenter/author’s own and in no way RIL attracts any
liability for any inconsistency or irregularity in terms of the accuracy completeness, veracity, or truth
of the content of the presentation/publication. In addition, RIL shall not be liable for any copyright
infringement and misrepresentation for the presented content as the content is presumed in good
faith to be a creation of presenter’s/author’s own mind.
The scope of this presentation/publication is strictly for knowledge sharing purposes and not
necessarily to provide any advice or recommendation to the audience/readers. Any endorsement,
recommendation, suggestion, or advice made by the presenter/author shall be in his personal
capacity and not in professional capacity as an employee of RIL. Any person acting on such
endorsement, recommendation, suggestion, or advice will himself/herself be responsible for any
injury/damage.
Agenda
• Introduction
• Smart Manufacturing
• Operations Management
• Reliance Journey towards Smart Manufacturing
• Summary
Reliance Industries Limited - Overview
Reliance Industries Limited
RIL Financials:
• Revenue $ 62.2 Billion
• PBDIT $ 7.4 Billion
• Net Profit $ 3.8 Billion
• Exports $ 32.5 Billion
RIL ranked 114th in the Fortune Global
500 list of the World’s Largest
Corporations in terms of revenues, and
was ranked 155th in terms of profits.
This is the 11th consecutive year that RIL
has featured in the Fortune Global 500
list
India’s largest private sector enterprise
Reliance Industries Limited
Source- Website RIL annual report-(2014-15)
Integration from Textiles to Crude Oil
• Largest refining capacity at any single location
• Largest producer of Polyester Fibre and Yarn
• 5th largest producer of Paraxylene (PX)
• 5th largest producer of Polypropylene (PP)
• 8th largest producer of Mono Ethylene Glycol
• Fully Integrated Operations
• Among the lowest operating costs in
industry
• 100% utilization rate through the cycle
• Focus on high growth India Market
TextilesFibers &
Chemicals
Polymers, Fibers
& Chemicals
Refining &
PetrochemOil & Gas Other Ventures
Naroda Patalganga Hazira Jamnagar Panna Mukta
KG Basin
Yemen
• Retail
• 4G telecom
• Others
Smart Manufacturing
Reduce reactive monitoring and convergence of key IT trends
6
Smart process manufacturing is an
integrated, knowledge-enabled, model-
rich enterprise in which all operating
actions are determined and executed
proactively applying the best possible
information and
supported by a rich
set of actionable
performance metrics.
1st -Revolution
Industrial Revolution
Started in 18th century
2nd -
Revolution
Electrically powered mass production
3rd Revolution
Introduction of Electronics,
Robotics
Information Technology
4th Revolution
Harnessing power of data.
Big Data,
Predictive Analytics
Artificial Intelligence
Smart Manufacturing - Approach
Moving the Needle via Ecosystem Optimization
7
• Focus on functional excellence at the
site level
• Technology driven approach that can
create ‘islands’ within an organization
• KPI’s & procedures tailored to
individual facility’s needs &
preferences
• Operational Excellence across the
enterprise and the ecosystem
• Create ecosystem wide data
visibility & action criteria
• Drive consistent KPI’s across the
organization
…to true enterprise wide
optimization of people & processesMoving from traditional approach
by project/site/unit…
Enterprise wide
optimization
Site
Functional
Excellence
Demand
driven mgmt.
of
Ecosystem
Pillars of Smart Manufacturing
A key driver in Smart Manufacturing
8
In Smart environment people are knowledgeable, well-trained, empowered, connected and able to
improve systems performance
Smart processes are capable of intelligent actions and responses
Smart Manufacturing incorporates Real-time, On-line predictive Models to eliminate process upset
and equipment failure before it happens
People
DataProcess
Why Operations management is a Smart Manufacturing component
Best practice, workflow and people
9
Areas Attributes
Smarter Business and Engineering
• Analysis and capture of Operating performance in an
information model
• Verification that planning and operating targets are
inside Safety Reliability and Efficiency Zone
Smarter Operator
• Real time On-line predictive models
• Control and monitoring Zone definition given to Control
System and Operator
• Operator focus on process exceptions and production
management
• Fully competent, equipped & empowered and
connected
Smarter Process Execution
• Workflow to download Task (targets & Limits )
• Execution by control and optimization (model based)
• Exception/deviation monitoring & situation awareness
1
2
3
Reliance Smart Manufacturing Vision
Manufacturing Operations - Enabled through integrated Digital
platforms
• Robust technical architecture
• Nimble & real time data management
• Strong analytics capability
• World class process architecture
Which is continuously monitored & proactively governed
through best in class practices
Reliance Smart Manufacturing Initiatives
Programmatic approach towards Smart Manufacturing
11
Operations
Management
Operator
Competency
Manufacturing
Information
Intelligence System
• Integrated limit repository
• Operating instructions
• Operations management
• Operations logbook
• Interlock bypass
management
• Develop, implement &
maintain High Fidelity,
Operator Training
Simulator for every plant,
at all sites
• Information integration
• Role-based KPIs
• Dashboards
• Monitoring
• Collaboration
• Safe operations
• Standard work processes
• Improved situational
awareness &
communication
• Enhance Operator
Competency
• Increase productivity
• Improved unit
operations
• Energy savings
• Standardization
• Visibility
• Agility
Smart
Operator
Round
Wireless
Transmitters
Data
Reconciliation
Model
Online/Offline
Models and
Simulators
Real
Time
Optimizers
Robotics for
confined
space work
Asset
Performance
Management
Risk
Based
Inspections
Advance
Process
Control
Drones for
Remote
Inspections
Summary
12
• Transformative time for industry driven by Technology
Trends - Cloud, IIoT, Mobility, Predictive Analytics, Connectivity
• Managing dynamic & constrained environment shall
require Smart Manufacturing and Work Process
Transformation
• Digitization is the way forward for manufacturing industry
Reliance Industries Ltd.
Digital Transformation driving Smart Manufacturing