Manufacturing 4.0 : How the Internet of Things in Manufacturing can BoostAsset Performance and Returns
31 July 2018
© SOURCE 2015 ABERDEEN GROUPAchieving Operational Excellence in F&B
• F&B companies are facing both low margins and high demand variability
• At the same time, F&B companies are facing top pressures to achieve OpEx: – Reduce sustainability costs (68%) – Comply with government regulatory requirements (54%) Ensure product quality and consumer
satisfaction (47%) – Maximize productivity (38%)
• F&B companies must find new ways to achieve operational excellence (OpEx)
Achieving Operational Excellence (OpEx) in Food & Beverage
Being Successful in a Challenging & Highly Complex Operating Environment
• Five metrics are distinguishing the F&B Leaders from Follower organizations:– Production Compliance– Overall Equipment Effectiveness (OEE) – On Time and Complete Shipments– Response Time to Non-Conforming Shipments– Operating Margin vs. Corporate Plan
• Leaders accomplish such superior performance by implementing capabilities and technologies that improve production efficiency, product quality and sustainability
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Leaders Ultimately Outperform Planned Margin Goals by +9%
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Maturity Class Mean Class Performance
F&B Leaders
Top 30% of F&B aggregate performance scorers
99% Production compliance89% Overall equipment effectiveness (OEE)98% On time and complete shipments3.7 Hours response time to non-conforming shipments+9% Operating margin vs. corporate plan
F&B Followers
Bottom 70% of F&B aggregate performance scorers
92% Production Compliance74% Overall Equipment Effectiveness (OEE)86% On Time and Complete Shipments23.2 Hours Response Time to Nonconforming Shipments-5%. Operating Margin vs. Corporate Plan
© SOURCE 2015 ABERDEEN GROUPAchieving Operational Excellence inF&B
Pune Digital Factory Journey
GE Brilliant Factory
L E A N
A D V A N C E D
A D D I T I V E
D I G I T A L
Lean Continuous improvement
Dig
itally
Ena
bled
Opt
imiz
atio
n
B A S I C
B R I G H T
B R I L L I A N T
6© 2017 General Electric Company - All rights reserved 6
Brilliant Factory … The Concept
Integrating Digital Technology and Lean to improve productivity
77© 2017 General Electric Company - All rights reserved 7
• Strong focus to drive Digital maturity in 10
out of 24 sites in India
• All Brilliant Factories leverage a common
digital stack and solution suite
• Create bespoke solutions per the plant need
Key Takeaways
Lean Maturity
Digital Maturity
3
4
5
3 4 5
MMF
GEBEL / WGE X
Sanand
Pallavaram
Coimbatore
Padappai
Vadodara
Durgapur
WGE -K
Brilliant Factory Framework – Combination of Lean and Digital
Current state assessment
Gap Analysis
Build Custom App
Leverage Brilliant Factory
Solutions
Digital IndustrialMap Digital tools Site deployment
Test & fix for Operationalizatio
n
Industrial
Plant KPIs
Set up IT/OT Network
Infrastructure
Connect Machines / Sensors
How do We Make a Factory Brilliant … The Approach
99© 2017 General Electric Company - All rights reserved 9
Pallavaram
July 31, 20189
Oracle + Proficy
Proficy PfMD QDAS
Oracle + ASCP
Proficy PlantApps
Oracle
Proficy PfMD
Maximo
PLM Integration
Scheduler
Scheduler
CBM / APM (Selective)
Oracle
Anark + NX Proficy + TMS
Oracle OTM
WIP Tracker
ASCP
eAndon
TBD
iSupplier
MOS + RevX
Brilliant Factory Gap Assessment
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Pallavaram
Low
Medium
High
Impact
eAndon
GEOS
Material Optimization analytics
Condition based monitoring
RevX
Shop Floor Scheduler
IT-OT Network SegregationSkill Matrix tool
Time to ValueHighMedium
Low
Effort
Takt Tracker
Time to Value driven approach for Brilliant Factory
Warehouse Visibility
Brilliant Factory Gap Assessment
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Ecosystem / Innovation
Condition based maintenance
RFID WIP TrackingMaterial Optimization Suite
PLC
SCADA
ProficyMES
Component Manufacturing Finishing AssemblySourcing
Oracle ERP
Proficy Historian
AnalyticsApplication
PREDIX PaaS
Predix Machi
ne
GEOS
PREDIX PaaS
RevX
In-progress
Enterprise Systems
HorizontalProducts
Custom Apps
Stock to Dock Tool
eAndon
Shop Floor Scheduler
Data Science POCs
Warehouse Visibility
Skill Matrix
Takt Tracker
Outcome Based Tools and Building blocks
Brilliant Factory Building Blocks
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• Each plant developing it’s own digital applications
• No common platform for deployment of application
• Eg: Andon on MES systems
Where we were?
• Common solution stack for key areas across factories
• Common platform/mechanism for solution development
• Eg: eAndon on cloud
Where we are?
• User Persona led single pane applications
• Integrated suite of applications
• Eg: Andon system integrated with other solutions
Where we are going?0-2 years 2-4 years
• Publish reference architecture guidelines for
Platform, S/W design, IT Network and Security
• Identify current solutions with potential to scale
• Build/Buy solutions in Whitespaces
How did we do it?Digital Solution
Plant Team:
Focus on ERP, MES and other local systems
Articulate pain areas and needs
Provide feedback to solutions team on value
Digital-Ops PartnershipDigital Team
Build solutions basis plant needs
Deploy solutions and track value
Modify solution blocks basis plant feedback
Our Approach to Creating the Digital Stack for a Brilliant Factory
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Digital Stack – Our Approach and Learnings
• Strong partnership with AME, Lean to identify opportunities for Digital
• Follow a MVP approach and pilot early with solutions
• Don’t develop solutions in isolation … have anchor plants
• Selectively, create bespoke solutions per the plant need
• Define standards and technology guidelines to help scale existing
applications
“Digital tools are simply critical for us to be able to deliver manufacturing of the future.”
— Nate Arnold Vice President, CIO Services Global Operations, GE Power
GE Experience Implementing the Digital Platform Through our Supply Chain
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