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Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved. Rev 5058-CO900E

PUBLIC INFORMATION

AMS India Conference

Production Control and IT Session

Bill Sarver

Sr. Consultant – Global Accounts, Automotive, Rockwell Automation

December 11, 2013

Building a Better Automotive Enterprise

Manufacturing Velocity in the Globally Connected Enterprise

• Infrastructure

• Information Visibility

• Workforce Productivity

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved. PUBLIC INFORMATION

Rockwell Automation - At A Glance

Fiscal 2012 Sales

$6.26 billion

Employees

21,000

World Headquarters

Milwaukee, WI USA

Market

80+ countries

Emerging Markets

22% of total sales

Trading Symbol

ROK

2

World’s largest company dedicated to industrial automation and information

Top 100 Innovative

Companies

Most Sustainable

Companies


Automaker’s Challenges

Profitability

150% More Energy

More Water

30%

40% More Vehicles

80% More Steel

150

~ $2200

54.5 mpg by 2025

Vehicles / min Average

refresh

Auto Emissions

By 2020

PAT (per car)

Fuel

Economy

Consumer

Demand New

Markets

2.2 years

40% Increased

Options


Manufacturing Velocity

Bill of Design

Bill of Process

Automation Specification


Building a Better Automotive Enterprise

5

• Infrastructure

• Information Visibility

•Workforce Productivity

Deliver the right products, at the right time and

with the right quality

Manufacturing Velocity Connected Enterprise


2004

Automotive Industry Business Drivers

Global Market Drivers •Developing Country Wealth

•Consumers Require Quality & Variety

•Reduced Time to Market

Industry Drivers •Vehicle Speed to Market

•Zero Defects

•Outsourcing - Tier 0.5

•Regulatory Compliance Manufacturing Drivers •Lean / Agile & Flexible Manufacturing

•“3 Day Car” - customer order to delivery

•Continuous Cost Reductions

•Integrated Supply

•Improved Plant Uptime

•Optimized Manufacturing

•Personnel Skill Mgmt & Capabilities

India - Automotive Industry Issues

Industry business drivers & challenges have forced market focus :

Principles of Quality

Migration to Contemporary Automation Architectures

Lean Manufacturing Concepts

IT & Automation Integration

Supply Chain Management

Project Management

Education & Training

Safety

Product Development

R&D

Symptoms of Non-Competitive Manufacturing

“ What do you do when you are capacity constrained?

“ How do you share production schedules with your partners and suppliers?

38%

32%

30%

28%

14%

4%

4%

Outsource

Work overtime

Re-allocate production

Lose sales

Build more factories

Doesn't ’ happen

Don ’ t know

Percent of 50 global manufacturing companies responding

62%

16%

14%

12%

8%

Manually

Extranets

Don ’ t know

EDI

Real-time updates

(multiple responses accepted)

Forrester Research, July 2000

Situation at Manufacturing Companies

Rapid Deployme

nt

Non-Stop Operations

Integrated Supply Chain

Optimize Manufacturin

g Capacity

Business Process

Improvement

Reduce Inventory

Costs

Increase Manufacturing

Flexibility

Performance Analysis

Order Management

Early Warning Systems

Part Traceability

Reduce Cost

Increase

Capacity

Improve

Quality

Improve Speed to Market

Bottom Line…

….improve Delivery, Quality, Time to Market

12

Response to Business Drivers

Driving Integration of Control and Information

Business Enterprise Systems

Energy

Efficiency

Safety /

Security Standards /

Regulatory

Compliance The Factory

Suppliers

Supply Chain

Integration

Cost /

Quality

Customer

Demand/Feedback

Flexible

Manufacturing

13

Enterprise &

Supply Chain

Manufacturing

Islands of Information

and Disconnects?

Purchasing

Product

Design

Production

Synchronous

Material Flow

Scheduling

Production

Control

Order

Sequencing

Routing

Maintenance

Asset

Resource

Management

Quality

Production

Performance

Results

Traceability

Genealogy

Materials Sales & Distribution MRP Quality

Maintenance Human Resources Workflow Financials

• Machining

• Forming

• Fabrication

• Finishing

• Material Handling

• Packaging

Information & execution gap between plant floor,

enterprise, and supply chain

Vertical Integration

14

Leverage Investments in ERP

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

Manufacturing Analysis

Quality Management

Plant Scheduling

Production Sequencing

Shop-Floor Control

Labor Management

Maintenance Execution

Work Instructions

Source: AMR Research 2000

Percentage of Respondents

“What’s missing after ERP implementations?”


2007


Converged Factory Information

Finance

Sales

Plant

Supply Chain

Product Development

Today’s Challenge

Capabilities to Enable

• Ethernet connectivity

• Best practice DMZ traversal

• CLOUD & FOG (new application models)

• Only 19% of manufacturers have effective link between plant & business KPIs

• Only 4% of factories monitor their equipment

Use Case Examples • Predictive Maintenance

• Real time Energy Optimization

• Real time Supply Chain

• Integration of customer order to plant PLC


Automotive Brands Mfg in India - 2013


9


Track/Trace

EtherNet/IP

Ethernet

Infrastructure Enabling the Globally Connected Enterprise

Ethernet Switch

Quality Error Proofing Materials Production

Enterprise ERP System

Easily access real-time data to make better decisions

and improve your manufacturing operations


Applications

20


Functions evolve into Applications Architecture standards define Platforms

21

Order management Serial No. Generation Build Sheet/Manifest Printing/Broadcast Sequence Display(HMI)/Broadcast Barcode Printing Number Punching/Etching Store/Retrieve/Dispatch Production Booking

Barcode Scanner/RFID Read Take-In/Take Out Data Collection Unit / Lot Genealogy WIP Tracking History Reporting

Quality Inspection Display Quality Data Collection Audit Quality Alert Quality Disposition Rework History Card Operator Qualification Quality Metrics Quality Analysis CAPA (8-D)

Part Pick (PP) Part Pick Guidance (PPG) Part Pick Validation (PPV) Part Scan Validation (PSV) Equipment Error Proofing (EP) Torque Tool (TT) Work Instruction (WI)

Equipment Monitoring OEE Calculation Machine Performance Production Performance Andon (LCD) Alerts (Andon, E-mail, SMS) Reporting Dashboard

... More….

Production Order Management

Genealogy, Track & Trace

Functions Applications

Error Proofing

Quality Management

Performance Management

Material Management Operational Intelligence Business System Integration

Architecture Platforms Ford specific

Production

System Integration

Application Servers

Data Collection & Pre-Processing

Data Collection

Clients

Smart Phones

Controllers

LCD Andon

Historical

Data Mart

Database:

MSSQL

• Oracle

Application Server

IBM WebSphere

• JBOSS

Data Collection

• Live Data

• OPC

OLDI

DXD

Clients • Laptops

• PC

Mobile Clients • Tablets

• Android

• iPhone

Plant Floor Devices • Controllers

Rockwell

Siemens

• LCD Andon Displays

Copyright © 2012 Rockwell Automation, Inc. All rights reserved.


Better manage and control the order

process to achieve more efficient and

profitable operations

Key values:

• Real-time coordination of production plan across plant-wide production processes

• Provides visiblity into production status and shop-floor inventory

• Lean Manufacturing and Production

Inventory

Supports Build to Stock or Demand

Work Order Management

Materials Flow and Complex Routings (rework/repair)

Track External Supplier and Outsourced Activity

Synchronization with Finite Scheduling Demands

Order Visibility WIP Inventory Cycle time Yield



Order Enforcement Across a S95-based Production Model

Route/Processing Sequence Enforcement

BOM/BOO Integration and validation with ERP/PDM/PLM

Broadcast Lot Hold and Control Part Specific Work/Setup

Instructions Lot/Part/Unit level data

collection Checklists to enforce setup Detailed Status by Order Integrated Non Conformance

and ECO Processing


Genealogy / Track and Trace

Better understand and document how a

product is manufactured for quality, safety

and continuous improvement initiatives

Key values:

• A complete contextual image of unit and lot level activity for customer and industry compliance

• Decision support framework for process and part analytics for continuous improvement

Tracking Capturing and tracking critical events and

data of a unit or assembly to… Machine/Operation Direct and Rework Labor Operator/Crew Real-time Work In Process Visibility

Trace Capturing critical process values and

associating them to a given unit or assembly TREAD act compliance

Genealogy Capturing all item Identification associated

with producing a given unit or assembly Consumption/Raw Material Lot/Serial


Material Control & Reporting Units (vehicle or components) Lots (Batch) Carriers and Fixtures Kitting and Racks

Operation-based Routes Equipment and Tooling Capture Process-centric reporting

Parts with multi-level BOMs Real-Time Genealogy

Manual Operations Work/Safety Instruction Enforcement Checklists & Test Definitions

Speed up recall decisions with significant accuracy and reduce overhead compared to paper-based systems

Genealogy / Track and Trace


Error Proofing

Indicate which parts are to be used for production

Ensure critical processes are done

Provide operators with correct work instruction Enforcement and Confirmation

Provide operator guidance

Operator Quality Alerts

SPC events

Interface to Automation Layer

Key values:

• Historical log of critical events

• Mistakeproof Unit Assembly

• Streamline processing activities

• Lean Activity Support

Better manage and enforce product

requirements within a complex process for

improved quality and reduced costs.


Features of Error Proofing

Operator Guidance

Pick Light with confirmation

Part Verification Array

Component Validation

Record unit assembly

Component usage

Serial or Part Number

Sequence and Route

Critical Process Validation

Torque/duration/temperature

Test and Inspection

Work Instructions/Drawing Enforced

Improve quality while reducing the

costs associated with production or

assembly errors


Operator Console with Work Instruction Example

28

Configurable

Line, Station Operator

Privileges

Certification Level

Button Functions Configurable


Work Instruction Example Screen


Quality Management

Contextual quality assurance

Order, Part, Customer, Specification

Electronic instructions for quality procedures

Supplier to customer coverage

Yield and First Time Thru Visibility

Parametric test for SPC/SQC analytics

Standard codes for Pareto charting

SPC rules/triggers for event notification

Compliance history for performance to specifications

Key values:

• Historical log of critical events

• Regualtory complinace – Tread ACT

• Unit to order qulaity analysis

• Continuous Improve program support

– Lean/TPM/TQM support, ISO,QS

Manage key quality characteristics

throughout the process for improved

profitability


Quality Management

Root-cause analysis through seamless access to production history records

Non-Conformance Management Non-conformance tracking (NCR/NCM) Corrective and preventive action

(CAPA/CAR) Supplier corrective action requests

(SCAR).

Operator Certifications

Business system integration

Product and customer-base process specifications

Automated data collection and event capture

Historical record of time-based parameters

Environmental and energy usage collections

Improve tracking and compliance of

quality control processes over a wide

range of products


Example: Quality Inspection Display


Performance Management: Production Monitoring

Equipment Monitoring

Real Time Production and Machine Status

ANDON

Communicates Plant, Equipment status.

Real Time Annunciation.

Maintenance Communications.

Reporting & Dashboards

Enables Plant operations visibility”

KPI’s Dash boards to monitor operations

Genealogy / Tracing reporting

Production Reporting

Communicate the Plant Info to all, Visibility into

the line, have the capability of real time reports

and Dashboards


Material Management

Digital Part Pick Kitting

Smaller line side storage footprint.

Reduced material store level.

Improved productivity because multiple pickers are

allowed.

Better kitting accuracy.

A paperless light directed fulfillment system.

Kanban / JIT Just In Time material replenishment triggers e-Kanban integrated with operation complete, digital part pick or “pull events” at:

Kitting areas

Line Side (Error-Proofing)

“Market Place”

Work Stations

Configurable attributes:

Kanban quantities: (i.e. reorder point, minimum stock, or package quantity)

Minimum on-hand quantity

Manage Material Flow throughout the

process for improved profitability


Shipping and Sequencing

Sequencing at Line Start Re-Sequence Order to Build to Reverse

Truck load

Rack Loading

Shipping Requirements

Reverse Load Truck LIFO

Print Labels ANSI B10

Direct Operator to load properly

Sequencing in Shipping Physically re-position racks

Use BTS & Pull From Stock to Fill Order/Truck Sequence

Use of Barcode to create “Shipper” label

Key values: • Reduce sequencing and shipping

handling costs up to 35%

• Reduce supply chain inventory up to 15%

• Improve on-time shipments up to10%

• Reduce shipping errors up to 50%

• Eliminate second source or manual

shipping costs up to 30%

Improve operational efficiencies and

reduce costs through better sequencing

and on-time shipments


Shipping station creates individual serial

number for tracking, assembles order

data and verifies the order is correct

before shipment

Shipping checklist

Record context that the order was

assembled correctly for shipment

Wireless handheld support, allows

operators to work anywhere in the

shipping area

Shipping and Sequencing

Harmonize the production and

shipping processes to reduce

costs and improve customer

satisfaction


Vehicle Design Design for global footprint,

Localized suppliers

Suppliers Just in time,

Flexible

Manufacturing On demand production,

In line quality control

Dealership Inventory management,

Real-time profit / cost

Consumer Configuration Real-time consumer customization

On-Vehicle Real-time diagnostics,

Warranty reports DESIGN TO DEALER

Automotive CONNECTED ENTERPRISE

Information Visibility

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.

Information Visibility Business Intelligence – Sharepoint Integration

38

“We believe that the value of manufacturing intelligence will only grow when software providers can integrate it with

more traditional BI to provide enterprise-wide monitoring & analysis of manufacturing performance.” – Gartner


Operations Intelligence

Key performance indicators (KPI)

OEE

Production performance

Quality metrics

First Time Through

Inventory

Work-in-Process (WIP)

Supply chain data

Safety

Finance

Maintenance

Human resources

Reporting & analysis tools

Alarm and Fault logging

Role-based operator interfaces & dashboards

Situational display at machine, line, plant & enterprise levels

Key values: • Lean Activity Support

• Process Visibility, Management Agility

• Visual Queuing Status

• TQM – TPM – CI Dashboards Optimized on Best Practices

• Spans Production, Qualtiy, Business Systems

Obtain real-time plant floor and business system data to drive and support effective operations management


Energy Management

Predict energy consumption based upon:

Weather variables and calendar

Previous behavior (baseline)

Optimize usage based upon:

Predicted consumption

Current and predicted Utility costs

Equipment availability

Current equipment configuration

Monitor buildings for correct behavior:

Predicted consumption (at a building

level)

Actual consumption

• Web based analysis, reporting and alerting

– Access to the information needed from

anywhere

– Engineering data converted into financial

information

Use your Energy usage information combined with your operating patterns to Optimize and Predict your energy costs


Energy Visualization & Targeting •Plant Electrical Infrastructure Status •Power Quality

•Distribution System Monitoring •Facility Energy Profiling

•Measurement and Targeting •Process Energy Profiling

Energy Control •Emergency Load Shedding •Peak Shaving

•Demand Management •Supervisory Generator Control

•Emergency Generation •Supervisory Cogeneration Control

•Load Curtailment

Energy Optimization •Thermal Plant Optimization •Mechanical Efficiency

•Chiller Plant Optimization •Energy Scheduling

•Ammonia Plant Optimization •Supply/Demand Matching

•Industrial HVAC

Rockwell Energy Management Solutions

Real time information & analysis gives the operators and

managers the ability to make more profitable decisions.


• Collect manufacturing performance data with AutoSuiteTM Performance Management and use that data to improve processes and generate production reports

• Execute more than 11.5 million data collection transactions per day to monitor inventory, production, budget and more

• Oversee maintenance activities through FactoryTalk AssetCentre

• Achieve real-time data reporting through Allen-Bradley® PanelView™ and FactoryTalk View software

42

Leading Automotive Supplier Automated Data Collection and Reporting Boosts Productivity

Tier 1 automotive supplier cuts development time, increases efficiency and eliminates paperwork

RE

SU

LT

S • Increased OEE and productivity by 50 percent, helping the

facility execute more than 11.5 million data collection

transactions per day to monitor inventory, production,

budget, equipment operation and more

• Reduced project development time by 50 percent, from 6

months to 3 months, as part of company’s Six Sigma

process

• Eliminated the time associated with manual paperwork

• Needed flexibility to adjust production volume at any time to meet customer demands

• Faced ongoing pressures to reduce downtime and boost productivity

• Needed an automated data collection and reporting system to replace current manual system

CHALLENGE SOLUTION


• Production Monitoring • Production Tracking • Reporting Integration Services • Plant Floor Integration • Analyzed and tracked detailed uptime,

downtime, cycle times

43

Infrastructure Implementing MES and Control Systems

RE

SU

LT

S • Increased Efficiency from 45% to 85

• Decreased reject rate (from 20 to 5 / month) yielding

$20,000 per month savings

• Improved cycle times by 28%

• Increased quality, agility and customer satisfaction

• Need to change from “batch” style production to ILVS

• Growing production mix required timely material delivery

• Existing manual tracking system had inadequate visibility

• Home grown solution Pilot was unsatisfactory

CHALLENGE SOLUTION

Tier 1 automotive door panel OEM supplier for major automotive company required to transition from batch production of door panels to in-line vehicle sequencing (ILVS) to meet the production format of its customer


Infrastructure Building a Safe & Secure Infrastructure

44

Common Vision

Single system architecture, built around industry standard networking

technologies, including EtherNet/IP

Converged Site Wide Architectures

Tested and validated design and implementation guidance

optimized for both IT and automation

Products and Solutions

Creating an ideal networking environment for both IT and controls professionals with co-

developed Stratix industrial network infrastructure portfolio and associated services

People and Process Optimization Services and education to help with successful architecture

deployment and efficient operations


Risks and threats to networked systems

Unintended

employee actions

Theft

Unauthorized actions by

employees

Unauthorized

access Denial of Service

Application of

Security patches

Unauthorized

remote access

Natural or Man-made

disasters

Sabotage

Worms and

viruses

Unaddressed security risks increase potential for disruption to system uptime and safe operation


A Vendor’s Perspective

Control System lifecycles are long (20+ years)

Products will have vulnerabilities

Security is a team sport

Vendors & Customers

IT & Engineering

Pick your teams (point don’t go it alone)

REMEMBER: Human beings are imperfect

Control System safety & security are closely linked

Control System security manages variables

Managing the security variables enhances uptime

46

UPTIME = PROFITABILITY


Two Critical Elements to Security

Technical

Non- Technical

A corporation’s risk tolerance level – often a “fuzzy gray line.”

Risk Averse

Risk Friendly

Technical

Non

Technical

Attack vector

Technical

Non

Technical

Attack vector

• How much security is enough

security?

• The amount of security is a system

should rise to meet a corporation’s

level of risk tolerance.

• In theory, the more security that is

properly designed and deployed in a

system, a lower amount of risk

should remain.


Our Approach to Industrial Security

Layered Security Model

Shield potential targets behind multiple levels of protection to reduce security risks

Defense in Depth

Use multiple security countermeasures to protect integrity of components or systems

Openness

Consideration for participation of a variety of vendors in our security solutions

Flexibility

Able to accommodate a customer’s needs, including policies & procedures

Consistency

Solutions that align with Government directives and Standards Bodies

A secure application depends on multiple layers of protection. Industrial security must be implemented as a system.

ApplicationApplication

ComputerComputer

Device Device

PhysicalPhysical

NetworkNetwork

ApplicationApplication

ComputerComputer

Device Device

PhysicalPhysical

NetworkNetwork

48

http://images.google.com/imgres?imgurl=http://upload.wikimedia.org/wikipedia/commons/thumb/4/4c/US_Department_of_Homeland_Security_Seal.svg/360px-US_Department_of_Homeland_Security_Seal.svg.png&imgrefurl=http://commons.wikimedia.org/wiki/Image:US_Department_of_Homeland_Security_Seal.svg&h=359&w=360&sz=82&hl=en&start=1&usg=__g68ZxZ1Czwnbm-C8k0D2deynJXk=&tbnid=fqr03iu-bFLMmM:&tbnh=121&tbnw=121&prev=/images?q=department+of+homeland+security&gbv=2&hl=en


Our Focus on Industrial Security

Reduce risks to safe and reliable operation …Control system architecture with layered security to

help maintain operational integrity under threat

Protect assets & information …Product and system features to help control access, tamper-proof and limit information exposure

Network

IP

protection

Data Protection

and Confidentiality

Anti-

Tamper

and

Detection

Remote

Access

Data

Protection

Role-based

Security

Supply-chain

Partners

Government and Standards Alignment …Responsible disclosure with control system solutions that follow global standards and help fulfill independent & regulatory security requirements

49

http://images.google.com/imgres?imgurl=http://upload.wikimedia.org/wikipedia/commons/thumb/4/4c/US_Department_of_Homeland_Security_Seal.svg/360px-US_Department_of_Homeland_Security_Seal.svg.png&imgrefurl=http://commons.wikimedia.org/wiki/Image:US_Department_of_Homeland_Security_Seal.svg&h=359&w=360&sz=82&hl=en&start=1&usg=__g68ZxZ1Czwnbm-C8k0D2deynJXk=&tbnid=fqr03iu-bFLMmM:&tbnh=121&tbnw=121&prev=/images?q=department+of+homeland+security&gbv=2&hl=en

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.

www.rockwellautomation.com

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