250 east 5th st., cincinnati, oh 45202 factoryframework… · state-of-the-art shop floor...

State-Of-The-Art Shop Floor Management

FORCAM, Inc. 250 East 5th St., Cincinnati, OH 45202

513-878-2780

www.forcam.com

FactoryFramework Advanced Shop Floor Management Mohamed Abuali Director Delivery Operations

http://www.forcam.com/index.php?id=209&L=209&id=261&tx_ttnews[tt_news]=164&cHash=168e44df771906d5bb88122ba4a21694

FORCAM 2014 Page 2

Presentation Agenda

FORCAM Introduction

Shop Floor Management with Factory Framework

Technical Capabilities Machine Data Collection Order Data Collection with SAP Integration Personnel Data Management SFM OEE Performance Reporting and Visualization Additional SAP Integration Functionalities

Configuration Capabilities with Live Demonstration

Project Plan and SFM Workshop

Summary and Conclusions

FORCAM 2014 Page 3

FORCAMs Passion

FORCAM provides proven manufacturing solutions to

Continuously Improve Productivity

To be the global solutions provider of the best-in-class Manufacturing Execution

Systems

FORCAM 2014 Page 4

FORCAM - History

Shareholder SAP Founder Dietmar Hopp

Web Technology SFM Evaluations

Founding FORCAM USA

Global Roll-Out (> 90 Plants)

Stamping Plants

Productivity + 20% within 12 months

SAP Spin Off

Research Partnership

Innovation Award

15,000 Monitored Assets

Release 5.0

+ 12% Efficiency Increase

within 6 Months

Machine-Connector 400 Heterogeneous Machines

Press Plants Asset worth

US$ 2.5 Billion

Founding FORCAM UK

SME Business

+ 25% increased operating

time and availability of all facilities

New Plant Mnchsmnster

Press Plant Leipzig & China

Frost & Sullivan

2014 Award

http://www.elektroauto-nachrichten.de/category/elektroauto-hersteller/audi/http://www.weirminerals.com/http://www.frustgefahr.de/mercedes_logo.jpghttp://www.elektroauto-nachrichten.de/category/elektroauto-hersteller/audi/

FORCAM 2014 Page 6

FORCAM International Presence

Head Office Germany

Friedrichshafen

FORCAM Ltd United Kingdom

Cheshire

FORCAM Inc. Americas

Cincinnati, OH, USA

Team Hungary

Team Switzerland

Benelux

Team France

Team China

Team India

Team Malaysia

Team South Africa

Team Poland

FORCAM 2014 Page 7

FORCAM Partner Network

FactoryFramework Network Over 150 MES Experts

IBM Global Partner

SAP Certified ERP Partner

IMS Center Univ. Of Cincinnati Research Partnership

TDM Systems Tool Management

Q-DAS Quality / SPC

FORSIS Industrial PCs

http://www.q-das.de/http://www.sap.com/index.epxhttp://www.q-das.de/

FORCAM 2014 Page 8

Our Customers

OEM Automobile + Automobile Suppliers

Aerospace/ Marine Aerospace Defence

Machinery

Medical Devices

Automotive

Other Industries - Minerals - Oil & Gas - Heavy Machinery - Food & Beverage - Pharmaceuticals

http://www.weirminerals.com/http://www.dieselpub.com/dp/images/news/M+H logo.jpghttp://images.google.com/imgres?imgurl=http://www.peplus.co.uk/ARBURG_logo_72_dpi_internet.jpg&imgrefurl=http://www.peplus.co.uk/last_weeks_news.htm&h=113&w=400&sz=36&tbnid=h0CycvPe4akJ:&tbnh=33&tbnw=120&hl=de&start=5&prev=/images?q=arburg+logo&svnum=10&hl=de&lr=&rls=RNWE,RNWE:2005-12,RNWE:en&sa=Ghttp://www.fissler.de/Home.1.0.html

FORCAM 2014 Page 9

AUDI

Due to Factory Framework the press plants have increased their productivity by 20 % within the first year. Investing in a new solution architecture was well worth it. Axel Bienhaus, Audi AG

FORCAM 2014 Page 10

BorgWarner

The FORCAM technology is unique and exceeded our expectations in all categories important to us - strategy, functionality, costs. J. Bischoff, BorgWarner

FORCAM 2014 Page 11

In just 6 months Factory Framework has given

us a 12% efficiency increase. Tony Locke MD, Weir Minerals

Weir Group

FORCAM 2014 Page 12

Productivity: Audi (Stamping)

+20% within 12 Months

Weir Minerals +12% within 6 Months

Technology and Scalability: From Machining Job Shops with 10+ Machines To Multi-Plant Shop Floor Management with 14,000 Machines

Connectivity: MTU Aero Engines: Shop Floor Management with

400 Machine Tools (25 Various CNC Controls / PLCs)

Seamless ERP Integration with Multiple Sites: FORCAM complements SAP ERP ideally.

Overall Impact on Customers

http://www.weirminerals.com/

FORCAM 2014 Page 13

FORCAMs Approach Advanced Shop Floor Management

If you cannot measure it, you cannot improve it. Lord Kelvin

Continuous process improvement with PDCA

Reliable performance measurement and metrics

Shop floor transparency based on real-time, objective data collection

FORCAM 2014 Page 14

Continuous Improvement Process at AUDI

Factory Framework delivered a 20% increase in overall productivity: Within the first 12 months at AUDI Within the first 3 months at SEW Euro-Drive

Target state

Actual state

Plan

Do

Check

Act PDCA

+20% AUDI and SEW

FORCAM 2014 Page 15

Presentation Agenda

FORCAM Introduction






FORCAM 2014 Page 16

Architecture for Fully-Integrated OEE System

FORCAM 2014 Page 17

Factory Framework - Modular Functionality

Factory Framework

ERP Adapter

Alerting

Process Data (Traceability)

Visualization

Machine Data Connection

SFM Performance Analysis & Reporting

Personnel Data

Production Data Mgmt (PDM+DNC)

Order Data Management Dynamic Scheduling

PLM Adapter

TDM Adapter

PLM TDM PP CO MM HR PM

CAQ Adapter

CAQ

FORCAM 2014 Page 18

Factory Framework - Interface View

Heterogenous PLC integration: Fanuc Siemens Mazak MTConnect ...

Web- Portal Rights

Management Global access

Poke Yoke Ergonomic

(Touch) Easy access

SAP ERP Baan QAD Windshield Siemens

PLM Catia

ERP PDM

Worker Client

Machine Connection

Office Client

FORCAM 2014 Page 19

Seamless Integration with SAP ERP

PP CO MM

HR PM QM

ERP Portal / BO

Shop Floor Management

Shop Floor Realtime Event-oriented Detail & Mass Data Innovation Best Practice Solution

. .

Enterprise Transactional Booking-oriented Asynchroneous Processes Stability Platform

Performance

Shop Floor Enterprise

FORCAM + SAP

task sharing, independent operation, optimized costs,

riks-free investment

VIDEO LINK Seamless Integration with SAP

http://www.sap.com/index.epxhttp://www.sap.com/index.epxSAP01_EN_OrderManagement.aviSAP01_EN_OrderManagement.aviSAP01_EN_OrderManagement.aviSAP01_EN_OrderManagement.avi

FORCAM 2014 Page 20

Certified SAP Integration

FORCAM 2014 Page 21

CIP Organization: Role-based User Administration and Reporting

Factory personnel Work order/ work instruction

Maintenance Maintenance order Hit lists

Machine

Plant Manager Overall plant performance

Forman Production planning

Industrial Engineering Production data act vs. planned

FORCAM's Shop Floor Management technology supports all organizational roles within the CIP-organization.

VIDEO LINK SFM / OEE Reporting

Office Client 2- Report.aviOffice Client 2- Report.aviOffice Client 2- Report.aviOffice Client 2- Report.avi

FORCAM 2014 Page 22

Presentation Agenda

FORCAM Introduction






FORCAM 2014 Page 23

SFM Reporting, Analysis & Visualization

Machine Data Collection (MDC) with Heterogeneous Adapters

Machine Data Collection (MDC) for Heterogeneous Controls/PLCs

Ethernet (Works LAN)

Plugin Modbus over

TCP/IP

Plugin OPC / OPC-UA

Client

Plugin Siemens

RFC 1006

Plugin Siemens

TCP/IP native

Rockwell Allen

Bradley

FANUC

Omron

OKUMA

Mitsubishi

Siemens

810/840D

PLC S5/S7

Plugin

MTConnect

FactoryFramework connects to and acquires real-time data from various machine controls using a variety of readily-available protocols.

Heidenhein

MAZAK

Makino

FORCAM Fieldbus Controller for Legacy (Non-Ethernet) Controls

(B&R / Elau / G&L / Koyo / Other)

FORCAM 2014 Page 24

Operating State Mapping Engine "Production" State

Target: Standard OEE Key Figure Examples: Definition for "Production" Operation State

Definition Production Schunk Coperion Mahle ZNF MTU

Automatic operation 1 Automatic operation 1 Automatic operation 1 Automatic operation 1

Program running 1 Program running 1 NC program start 1 Program running 1

Feed rate switch = 100% 1 Override 0 1 Override 0 0 NC ready for operation 1

Rapid traverse = 100% 1 Cycle start 1 Cycle end 0 Manual operation 0

Spindle speed = 100% 1 Warm-up bit 0 Semiautomatic

NC ready for operation 1 operation 0

Feed rate > 85% 1

NC alarm 0

Machine off 0

Program halt 0

FORCAM 2014 Page 25

Operating State Mapping Engine Fault Code" States

Alarms

Standardized Operation States

Machine-by-Machine Assignment

FORCAM 2014 Page 26

Case Study - Machine Data Collection (MDC)

MTU Aero Engines (400 Machines | 25 Heterogeneous Controls)

FORCAM 2014 Page 27

Real Time Signal Recognition and Web Visualization

VIDEO LINK Machine Data Collection with Visualization

Office Client 1- Visualize.aviOffice Client 1- Visualize.aviOffice Client 1- Visualize.aviOffice Client 1- Visualize.avi

FORCAM 2014 Page 28

Presentation Agenda

FORCAM Introduction






FORCAM 2014 Page 29

Integrating Order Data with Machine Data (ODC + MDC)

Message Timeline

06:00 14:00 22:00 06:00 22:00 00:00 00:00

Op.

- s

tart

Op.

- en

d

WP

- dow

ntim

e

Op.

- co

ntin

ue

Op.

- p

art q

ty

Op.

p

arty

qty

Pe

rs.

log

on

Per

s. L

og o

ff

OP-

sta

rt

Op.

- st

art

WP

- dow

ntim

e

Op.

- co

ntin

ue

Event-Driven Message Entry

Workplace / Machine (WP) Order / Operation (Op) Personnel (Pers)

ODC MDC

FORCAM 2014 Page 30

Order Transparency with Order and Machine Data Integration

SAP ERP

Person/Group, Quantity, Yield, Scrap, Rework

PP

Transparent Production Environment - Detailed Production Status in Real Time

Production Shop Floor

Factory Framework

FORCAM 2014 Page 31

Actual versus Target Peformance Reporting

Target/Planned Throughput

Actual Performance

Opportunity for Improvement

Actual Throughput

ERP Data

Machine Data

VIDEO LINK Order Data Management at Worker Client

VIDEO LINK Actual vs. Target Performance

Worker Client 0- Orders.aviWorker Client 0- Orders.aviWorker Client 0- Orders.aviWorker Client 0- Orders.aviWorker Client 3- Visualize.aviWorker Client 3- Visualize.aviWorker Client 3- Visualize.aviWorker Client 3- Visualize.avi

FORCAM 2014 Page 32

Presentation Agenda

FORCAM Introduction






FORCAM 2014 Page 33

Employee Order / Operation Machine(s) Booking Type

Individual Work Centers can be allocated to several machines

One to Multi-Operation

Multi-Machine Multi-Operation Group Booking

Personnel Management - Booking Types

VIDEO LINK - Personnel Management at Worker Client

Worker Client 0- Log On Off.aviWorker Client 0- Log On Off.aviWorker Client 0- Log On Off.aviWorker Client 0- Log On Off.avi

FORCAM 2014 Page 34

SAP ERP

Exact Production Cost Determination

WorkdayBook on Book off

Works order 1

Works order 2 Op

Op

Sta rtOperator

Sta rtOperator

Sta rtMa chine 2

Sta rtMa chine 1

EndMa chine 1& Opera tor

EndMa chine 2& Opera tor

A B C D

Person, Group, Quantity, Yield, Scrap, Rework Overhead costs, Cost centers

PP CO

Actual-time-tracking of all activity types including multi machine operation

Production Shop Floor

Factory Framework

FORCAM 2014 Page 35

Quick Cost Transparency

Direct Analysis of Labor Costs in Production Order Display (SAP Standard)

FORCAM 2014 Page 36

Presentation Agenda

FORCAM Introduction






FORCAM 2014 Page 37

Target-Oriented Performance Measurement & Benchmarking

Group: M1 M2

Machine Performance

Plant Performance

Hall, Cell, Line, Group Performance

Multi-Plant Performance Benchmark

Plant 2 Plant 3

Machine 1 Machine 2

Plant 1

Machine 3 Machine 4 Machine 5

Group: M3 M5

Plant 1

Group: M1 M2

60,5%

TRUE OEE Target 60,5%

60,5% 49,5% 51,7%

60,5% 60,5%

66,0% 55,0%

66,0%

66,0%

72,0% 60,0% 70,0% 40,0% 55,0%

FORCAM 2014 Page 38

Web Visualization (with ANDON Capability)

Real-time web visualization of current production status worldwide via web data access with Factory Framework

Creation of one's own displays with the editor and operation of multiple views independent from each other - e.g. machine, production line or shop floor layout

Fully Configurable with a Report/Visualization Editor Display on large format screen in the production / ANDON board

FORCAM 2014 Page 39

Performance Reporting and Optimization

Transparency in real-time through detailed imaging of TPM methods to uncover bottlenecks and improvement potentials

Plant-wide transparency in real-time through web technology Coherent key figures (OEE, NEE, TEEP) Large selection of predefined reports with different views:

workplace, order, material, personnel Creation of one's own reports with the report editor

FORCAM 2014 Page 40

Reporting Dashboards and OEE KPI Cockpits

Individually Adjustable Graphic Screen All key figures that are important to you in one single overview.

Display of crucial key figures and machines Ergonomic and well-arranged Individually configurable

FORCAM 2014 Page 41

Presentation Agenda

FORCAM Introduction


Technical Capabilities Machine Data Collection Order Data Collection with SAP Integration Personnel Data Management SFM OEE Performance Reporting Additional SAP Integration Functionalities




FORCAM 2014 Page 42

SAP ERP PP CO MM HR PM QM

Bi-Directional SAP ERP Integration

Order Data Management

Booking of Order Messages Personnel Messages Statistics, Notes, Warnings

Quantities, Stoppages

3


Machine Data Collection


3

1 2

4

Master Data

Order, Op, dates, PT

Status, Quantities, Stoppages

5

VIDEO LINK SAP Work In Progress

FactoryFramework

SAP02_EN_WorkProgress.aviSAP02_EN_WorkProgress.aviSAP02_EN_WorkProgress.aviSAP02_EN_WorkProgress.avi

FORCAM 2014 Page 43

SAP ERP Integration with Corrections

SAP ERP PP CO

MM

Order Data Management

Automatic in SAP: Cancellation and New Booking

Simple and Quick corrections in FF Office Client Quantities Scrap Stoppage Reasons

Factory Framework

VIDEO LINK Corrections

SAP03_EN_OrderCorrection_Scrap.aviSAP03_EN_OrderCorrection_Scrap.aviSAP03_EN_OrderCorrection_Scrap.aviSAP03_EN_OrderCorrection_Scrap.avi

FORCAM 2014 Page 44

SAP ERP PP CO MM HR PM QM

Alert Management (with optional SAP PM integration)

Order data management

Booking

3

Machine data

Factory Framework

Process data

Control, compare, alarm, transfer

Alerting

1 1

2 Alerting, Notification

FORCAM 2014 Page 45

Presentation Agenda

FORCAM Introduction






FORCAM 2014 Page 46


Factory Framework Software Overview - LIVE

Hierarchic Configuration

Machine Data Collection (Formula Engine)

OEE Time Basis

User Rights Access Management

Language / Literal Editor

Web Visualization and Reporting Editor

Alerting with Auto-Reporting

FORCAM 2014 Page 47

Presentation Agenda

FORCAM Introduction






FORCAM 2014 Page 49

Factory Framework - Phased Project Plan

FactoryFramework Universal ERP Adapter

SFM Performance Analysis & Reporting

Process Data Management

Visualization

Machine Data Collection

Alerting

Personnel Data

Production Data Management + DNC

Order Data Management Detailed Scheduling

Top Floor (ERP)

Shop Floor

Phase 1 Phase 2

- Machine Data Collection - Web Visualization, Reporting - Alerting

- ERP Data (Orders/Ops)

- Personnel Data

Phase 3

- PDM/DNC

Phase 4

- Dynamic Scheduling

FORCAM 2014 Page 50

Systematic Project Plan

FORCAM 2014 Page 51

Shop Floor Management (SFM) Workshop AGENDA (8:00 AM - 5:00 PM) Shop-Floor Muda Walk (8:00 AM)

Introduction (8:30 AM)

Participants Goals of the SFM Workshop Roles & Responsibilities

FORCAM Lessons Learned and Case Studies (9:00 AM) Shop-Floor Management Solution Fundamentals & Technology (9:45 AM)

Factory Framework System Overview (30 Min) Module Requirements and Detailed Specifications

FF - Order Data Management with SAP ERP Integration (45 Min) FF Machine Data Collection (30 Min) FF - SFM Performance Reporting, Visualization, Alerting (30 Min)

LUNCH BREAK (NOON) Shop-Floor Management Solution continued (1:00 PM)

Office-Client and Worker-Client Specifications Processes, Interfaces, Usage

Shop Floor Management Reporting Dashboard Reporting/Cockpit: OEE, GANTT, Actual vs. Planned

System Administration and Rights Access Management Machine (Shop Floor) Integration Requirements (2:00 PM)

Machine Types / PLC Types / Signal Acquisition ERP (Top Floor) Integration Requirements (2:30 PM)

ERP Specifications - Orders, Operations, Bookings IT Requirements (Hardware / Server / Networks) (3:30 PM) Summary, Action Items and Next Steps (4:00 PM)

Required Attendees: Project Manager All Project Team

All Project Team

Project Team (Select)

Plant Maintenance

IT (ERP)

IT (Infrastructure) Project Manager

FORCAM 2014 Page 52

SFM Workshop - Schedule, Attendees, and Deliverables

Schedule

1 Day On-Site with 2 FORCAM Consultants

Attendees Suggested Attendees (CIP Team)

Project Leader / CIP Director / Plant Manager (Champion) Production (Lean) Manager Production Supervisor(s) IT Manager Maintenance Manager ERP Manager Production Engineers

Deliverables

1. SFM Checklist - Requirements Specification Document 2. Fixed Price Quotation 3. Project Management Plan

FORCAM 2014 Page 53

Global Template Approach (Multi-Site Project Deployments)

Shop Floor Management

(SFM) Workshop

PILOT

Pilot Site

All Sites

FORCAM 2014 Page 54

Presentation Agenda

FORCAM Introduction






FORCAM 2014 Page 55

Architecture for Fully-Integrated OEE System

FORCAM 2014 Page 56

Our Value Proposition

Top Customer References in Discrete Manufacturing State-of-the-Art Technology, Awarded by Frost & Sullivan

Server-centric J2EE Web-based Technology Architecture

Outstanding Scalable Shop Floor Management System

Seamless Universal ERP Integration with Order Data Management Real Time Machine Data Collection with Heterogeneous Adapters Performance Measurement and Reporting with OEE Personnel Data Management Alerting and Alarming Strong Configuration Capabilities

Global Delivery Team for Template-based Rollout (for Multi-Site Deployments)

FORCAM 2014 Page 57

Thanks for your attention! FORCAM, Inc. 250 E. Fifth Street, 15th Floor Cincinnati, OH 45202

(513) 878-2780

www.forcam.com
http://www.forcam.com/index.php?id=209&L=209&id=261&tx_ttnews[tt_news]=164&cHash=168e44df771906d5bb88122ba4a21694

250 east 5th st., cincinnati, oh 45202 factoryframework… · state-of-the-art shop floor...

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