TOYOTA MOTOR NORTH AMERICA
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SMART PLANT Trever White Division Information Officer Manufacturing & Engineering Business Systems Toyota Motor North America - IS TOYOTA MOTOR NORTH AMERICA IT Strategy to deliver World Class Manufacturing using IoT
Transcript of TOYOTA MOTOR NORTH AMERICA
SMART PLANT
Trever White
Division Information Officer
Manufacturing & Engineering Business Systems
Toyota Motor North America - IS
TOYOTA MOTOR NORTH AMERICA
IT Strategy to deliver World Class Manufacturing using IoT
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Corporate HQ, Plano, TX
More than 20 Sales Offices
Nearly 1,500 Toyota and Lexus Dealers
More than 30 Financial Offices
Suppliers in more than 45 States & Provinces
11 R&D Facilities
14 Manufacturing Facilities
Transitioning from
Torrance, CA; Erlanger, KY; and
New York, NY
TOYOTA IN NORTH AMERICA
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MANUFACTURING IN NORTH AMERICA
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IS ORGANIZATIONAL STRUCTURE
Business Specialization & Enablement
Enterprise Architecture
Information Security – Security, Risk Management, Compliance
IT Mgmt – Strategic Planning, Governance, Financial Management, Talent, Communication, & Innovation
Enterprise Services – End User, PMO, Service Management
Infrastructure Services – Infrastructure, Network, Cloud, Data Center, Audio Visual, Operations
Manufacturing
and
Engineering
Business
Systems
Demand &
Supply
Dealer,
Field, &
Affiliates
Finance &
Indirect
Procurement
Corporate
ServicesTelematicsAfter Sales
R&D and
Manufacturing
Site
Services
Regional &
Canadian Mfg
Engineering
Services
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Background
Very traditional separation of duties on the manufacturing floor between Production Engineering and IT
An Explosion of Digital Opportunities on the manufacturing floor, but no concerted effort to pursue
IT strategy to build capability and establish strong relationships with manufacturing members
Early successes demonstrated to gathering of Plant Presidents & CEO resulted in establishment of a formal program led by IT
Team Member
Education
Qualified
Partners
Proper
Technologies
New
Methodologies
Strong
Manufacturing
Relationships
Execution
Of Low-Risk
Trials
Program Strategies:
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Connected machines
The Internet of Things (IoT) refers
to Physical devices & objects
(including Machines) connected to
the Internet & each other for
intelligent decision making.
What is theInternet of Things?
People
Connecting people
in more relevant
valuable ways
Process
Delivering the right
information to the right
person (or machine) at
the right time
Data
Leveraging data into
more useful
information for
decision making
Person to person Person to machine Machine to PersonMachine to machine
Connecting IoT to People
P2P P2M M2PM2M
Smart Manufacturing - The intelligent real-time orchestration and
optimization of business, physical and digital processes within factories
and across the value chain.
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25 billion Connected “things” by 2020—Gartner
$1.7 trillionMarket for IoT by 2020 —IDC
Source : McKinsey
IoT Opportunities
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PROGRAM OVERVIEW
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PROGRAM OBJECTIVE & ORGANIZATION
Organization
<North America Exec Steering Committee>
MFG EVP, SVPs, IT GVP, Toyota Way SVP
<Global Exec Steering Committee>
<IT PMO>
<Working Team>
<AIT4Mfg Program Leads>
1 BUSINESS & 1 IT EXEC LEAD
<Business PMO>
Objective: Improve
Manufacturing Quality and
Productivity by embracing
and enabling the Toyota
Production System through
the delivery of significant IT
contribution incorporating
the principals & strategies of
IOT.
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I. PEOPLE DEVELOPMENT – VOICE OF GROUP LEADER
Integrated & automated tools to reduce Plant Floor administrative burden allowing
more time on Quality, Productivity, Safety, & Team Member Development.
More time hereLess time here
1. Group Leader Portal (Mobile)
2. Automated Time Entry (Mobile app with location services)
3. Automated Call-In System & TM Rotational Assignment
Key Activities:
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Strategy Benefit
Reduce burden during morning startup: Quickly visualize available workforce for the shift Create Manpower Schedule based on versatility (Qualification,
Ergonomic constraints, history).
25 mins savings per Group Leader per shift =
$5.5M per year in time savings
TM unplanned
absence
TM restriction (ergo, medical, skill)TM calls
dedicated number
G/L reviews Absence ReportG/L loan & borrow T/M
Absence Report
Pre-scheduled TM rotation
Team Member Rotation Application (TMRA)Auto Call-In (ACS)
AC
S
Man
po
wer
Sc
hed
ule
r
I. PEOPLE DEVELOPMENT – VOICE OF GROUP LEADER
Example:
Automated Call In
& Team Member
Rotational
Assignment
System
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II. OPERATIONS – PLANT VISUALIZATION
Network connected plant equipment enabling visualization of process operating
conditions stored in Industrial Big Data share (IIOT) for Analytics.
Industrial Big Data
Production EfficiencyManually Problem Solving
ReportsDashboardsAndons
Key Activities Purpose - Benefit
Real Time Andon Visualized process level status for immediate action.
Production Control Monitoring System Shop level vehicle progress visibility (ex. Buffer, OA, OR, DT).
Electronic Performance Analysis Moment by Moment visualization (ex. line call, downtime).
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Strategy IoT Component Benefit
Real-time production information for shop leaders to visualize
and respond immediately to downtime, Andon pulls, and stop
by pitch.
Reading PLC sensor data
for near real time visibility
& decision making
Estimated $3M per shift in elimination of
downtime across North America when fully
deployed based on initial deployment results
Example: Electronic Productivity Analysis Board - Moment by Moment
Line Stops – worst machine per period will be yellow. Machine with most stops fore entire timeframe will have yellow title color.
Downtime – worst machine per period will be red. Machine with worst downtime per period will have red title color.
Line Calls - worst machine per period
will be blue. Machine with the most
calls for the entire timeframe will have a
blue title color.
Production Problems easily identified hour by hour
Difficult to see issues in timely manner.
II. OPERATIONS – PLANT VISUALIZATION
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III. MAINTENANCE
Computerized Maintenance Management System (CMMS) - Real time & historical data collection from
Plant equipment, meters, gauges into CMMS with Mobile enabling proactive, preventative, &
predictive maintenance.
Predictive MaintenanceDowntime
Sending maintenance request
for Monday. I’m predicting I’ll
need my oil changed.
Got it.
Thanks,
BOT10!
Increased Operational Availability
ReactiveFix AFTER it breaks
PlannedFix BEFORE it breaks
PredictiveMAINTAIN not break it
PredictiveREFINE & avoid breaks
PredictiveEnhance & Sustain
Inventory reduction & increased repair speed. Cycle / Event based maintenance.
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III. MAINTENANCE
Description - Purpose IoT Component Benefit
Improve Plant OA through an integrated real-time mobile notification and
dispatch system (TOAD).
1.Simple 3 Signal Trigger per Machine (Fault/Call/Continuous)
2.Detail Fault Request
Real time PLC / Machine
integration & notification
Reduction of 40k mins per
month (MTTR) = $6M per
year in labor savings.
Example: CMMS Mobile (TOAD - Toyota Operation Availability Device)
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IV. QUALITY
Electronically record & visualize vehicle quality inspection
results. Provide real-time condition feedback to inspection
TM using mobile and PC (IoT) solutions.
Electronic Quality DataOutflow of Defects
Key Activities Purpose - Benefit
Inspection Control System Common inspection platform providing integrated part & process traceability.
eContainmentCapture vehicle containment & inspection results real time in plant, yard, and at ports preventing
flow out of defects to customer.
Smart Hand Sander IOT SensorUtilize motion sensor in Paint Sander to capture movement providing feedback on good or no
good movement. Expanding to many other areas.
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IV. QUALITY
Description - Purpose IoT Component Benefit
Capture measurement data for Critical Fitting Points enabling:
1)Visibility to OK vs No Good condition
2)Real time data analysis and reporting
3)Shift workload from data handling to problem solving
Machine integration
providing immediate
measurement feedback.
Use of Mobile to audit.
Reduction of 20 mins per vehicle audit &
quality flowout avoidance= $1.8M per
year savings & avoidance
Example: TMCS - Toyota Measurement Collection & Vision System
Mobile (iPhone/iPad)
Capability to capture
measurement data
anywhere.Real time data analysis and
reporting capability by process.
What happened?
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V. LOGISTICSDeploy electronic systems utilizing Internet enabled logistics tracking sensors & tools to provide real time part
visualization preventing parts shortage and supporting JIT delivery (ex. RFID, GPS, Scanning).
Less time here
Date: 7/16/14
Time: 9:13:38 PM MF&VM: Event Identification
TimeZone: EST
NE SE MW West
Weather 1 0 1 1
● Snow 1 0 0 0
● Storm 0 2 0 1
● Tornado 0 0 1 0
IconLocation
EventNE SE MW West
Natural Disaster 0 0 0 1
● Tsunami 0 0 0 0
● EarthQuake 0 0 0 1
IconLocation
EventNE SE MW West
Traffic 15 15 9 27
● Accident 5 12 3 5
● Construction 10 3 6 22
IconLocation
Event
NE SE MW West
Traffic 0 1 0 1
● Misc 0 1 0 1
IconLocation
Event
Region
RSS Feed WEATHER
RSS Feed CONSTRUCTION
RSS Feed XXXXXXXX
Date: 7/17/14
Time: 8:27:18 AM MF&VM: Supply Chain_Supplier View
TimeZone: EST
Region
NE Tire & Rubber NE Level 1 Snow Emergency John P Jones 456-951-7852 [email protected] J Doe Ron Round
Boston Stamping NE Blizzard Conditions J Hancock 456-578-9843 [email protected] Bill Boston Tonia Press
InjectionSNOW NE Ice FS Key 456-152-7414 [email protected] Joe Allan Nick Board
TEA Fabric NE No Power P Reverere 456-945-8888 [email protected] Mary Gary Earl Camerson
Toyota Buyer Contact Toyota PC ContactRegion Reason Contact Cell eMailIcon Supplier
Streering WheelsRUs NE Level 3 Snow Emergency Bill Mary 456-951-7852 [email protected] J Doe Ron Round
Slit Steel, Inc NE Blizzard Conditions John Allan 456-578-9843 [email protected] Bill Boston Tonia Press
GlassCO W Flooding Anne Glass 456-152-7414 [email protected] Allan Nick Board
AlumALL W Limited Power Bill Can 456-945-8888 [email protected] Mary Gary Earl Camerson
Icon Supplier Region Reason Contact Cell eMail Toyota Buyer Contact Toyota PC Contact
NE SE MW West
Not Opperational 4 0 16 15
4 0 3 0
0 0 2 2
0 6 11 13
IconSupplier
Down
Operation, Limited
Operational, 100%
Date: 7/16/14
Time: 9:13:38 PM MF&VM: Supply Chain
TimeZone: EST
Seperation Ctr: # of # of # of
KSC Manifests Skids Parts
On-Time: 549 6,503 5,802
Late: Arrived: 12 14 177
Late: Not Arrived: 5 21 180
Total: 566 6,538 6,159
Seperation Ctr: # of # of # of
PSC Manifests Skids Parts
On-Time: 549 6,503 5,802
Late: Arrived: 21 14 177
Late: Not Arrived: 5 21 180
Total: 575 6,538 6,159
Cross Dock# of # of # of
WCD Manifests Skids Parts
On-Time: 549 6,503 5,802
Late: Arrived: 21 14 177
Late: Not Arrived: 5 21 180
Total: 575 6,538 6,159
Cross Dock # of # of # of
MCD Manifests Skids Parts
On-Time: 549 6,503 5,802
Late: Arrived: 21 14 177
Late: Not Arrived: 5 21 180
Total: 575 6,538 6,159
Cross Dock # of # of # of
SCD Manifests Skids Parts
On-Time: 549 6,503 5,802
Late: Arrived: 21 14 177
Late: Not Arrived: 5 21 180
Total: 575 6,538 6,159
Cross Dock # of # of # of
CCD Manifests Skids Parts
On-Time: 549 6,503 5,802
Late: Arrived: 21 14 177
Late: Not Arrived: 5 21 180
Total: 575 6,538 6,159
Cross Dock # of # of # of
RCD Manifests Skids Parts
On-Time: 549 6,503 5,802
Late: Arrived: 21 14 177
Late: Not Arrived: 5 21 180
Total: 575 6,538 6,159
Cross Dock # of # of # of
DCD Manifests Skids Parts
On-Time: 549 6,503 5,802
Late: Arrived: 21 14 177
Late: Not Arrived: 5 21 180
Total: 575 6,538 6,159
Cross Dock # of # of # of
KCD Manifests Skids Parts
On-Time: 549 6,503 5,802
Late: Arrived: 21 14 177
Late: Not Arrived: 5 21 180
Total: 575 6,538 6,159
Region
Supplier
Information NE SE MW West
Operational, 100% 111 243 131 68
Operation, Limited 67 15 2 2
Down 3 0 0 0
Total: 181 258 133 70
# of Suppliers
NAMC
Information K I MS TX
Operational, 100% 1 1 1
Operation, Limited 1
Down
Total: 1 1 1 1
NAMCs NAMC
Information WV AL B1] B2 B2
Operational, 100% 0 1 1 1 1
Operation, Limited 0 0 0 0 0
Down 1 0 0 0 0
Total: 1 1 1 1 1
NAMCs (Unit Plants)
Can Ship
Can’t Ship
Parts Logistics Monitoring
Supplier Crossdock Plant ReturnsLineside
Logistics Big Data Vehicle Part Delivery Control Tower
Separation
Center
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V. LOGISTICS
Description - Purpose IoT Component Benefit
Provide 100% visibility of all parts orders tied to trailers in the
yard. Provide timely and accurate communication of trailer
moves between dock workers and shunt drivers.
RFID, GPS tracking , GeoCoding
Yard with integrated mobile calls
Estimated $3M savings per year
in reduction of Part Expedites
Example: Yard Management System
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INDUSTRIAL BIG DATA ANALYTICS
Use Case 1: Paint Defect Analysis
Reasons for Paint defects in TMMK Lexus
ES impacting Vehicle Quality
Use Case 2/3: Warranty vs Alignment
Warranty claims compared to Mfg Quality
Defects including Alignment data and
Dealer Claim Investigation
Use Case 4: Change Point Mgmt
Correlation between Mfg change points
and Quality Defects
Use Case 5: TM Skill Gap
Correlation between Mfg Defects & Team
Member capability
1 = Vehicle WILL have defect 0 = Vehicle will NOT have defect
Rules auto-
generated
60 Million
Data
Records
Source(s)
WWW
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PROGRAM IMPACT
35 Active Projects
$23M Investment
$600M Benefit
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OUR APPROACH…RECOMMENDATIONS FOR CREATING A SUCCESSFUL IOT PROGRAM
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Focus on Core Principles… Embracing and Enabling “Lean”
TOYOTA WAY
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Pick opportunities carefully, start small
Understand current business process & capabilities
Define the ideal business process
Identify the necessary conditions and integrations
THEN….Identify the technology
Identify innovation opportunities
Build vendor partnerships and internal relationships
Build pieces and integrate incrementally
Deliver successfully, reapply and celebrate
Reflect and identify next opportunities
SEQUENCE OF STEPS:
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Provide proactive business leadership and cross-
functional architecture.
Engage plant executives on business opportunities and local
priorities.
Direct on-floor observation with Engineers
(genchi-genbutsu)
Demonstrate capabilities 1 by 1 to gain trust from skeptical
business counterparts.
Deliver actual value with a few motivated bus units. Add
functionality and plants over the time, improving iteratively.
Break down silos and bring stakeholders together.
INFORMATION SYSTEMS ROLE ON THE PLANT FLOOR
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Wired and Wireless Capabilities as
Standard for all areas of facilities
Digital Plant communication
Connecting equipment to the
network
Organization wide use of mobile
devices and a Mobile agnostic
development approach
Focus on small application
development methodology and
teams based on iterative delivery
Business Intelligence and
Analytics FrameworkPre-installed server infrastructure
TECHNOLOGICAL FRAMEWORK FOR SUCCESS
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Wired and Wireless Capabilities as
Standard for all areas of facilities
Digital Plant communication
Connecting equipment to the
network
Organization wide use of mobile
devices and a Mobile agnostic
development approach
Focus on small application
development methodology and
teams based on iterative delivery
Business Intelligence and
Analytics FrameworkPre-installed server infrastructure
TECHNOLOGICAL FRAMEWORK FOR SUCCESS
Internet of Things Agile Development
Mobile / Social AnalyticsBuild Farm, Converged
Infrastructure
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Trever White
Division Information Officer
Mfg & Engineering Business Systems
Toyota Motor North America &
MESA Executive Board Member
CONTACT INFORMATION
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THANK YOU!
