Fujitsu Value Proposition for Manufacturing Industry
Enabling Digital with Connected Enterprise
Copyright 2016 FUJITSU
Digital is different things to different people
Business-model transformation
Transforming customer & user experience
Digitalizing business operations
Product leadership & innovation
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Customer Business Challenges
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Manufacturing Customers
After Sales
Industrie 4.0 & Industrial Internet
Product Lifecycle
Management / Resource &
Development
Reduce Inventory
Reduce Lead-time
Improved Sales & Operations
Delivery
Differentiation / Shorten Time-to-Market
Transform / expand Product to Service
New Sales Channels / B2B and B2C
Sales
Minimized production downtime
Increased manufacturing automation
Cost / Sourcing control
Production / Replenishment
Increased partner collaboration
Shorter Time to Market
Extended revenue stream
Preventive maintenance
Control of Installed Base
Better business planning with Analytics
Artificial Intelligence (AI)
Workforce safety
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Industrie 4.0 and Industrial Internet
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Industrie 4.0 – 4th Industrial revolution Industrie 4.0 is the extension of industrial digitalization to
the Internet of Things (IoT) in manufacturing Industrie 4.0 constitutes an evolution and an integration into
IoT of previously separate IT- application areas in automation (MES, PLC) and administration (ERP, SCM) – today, such concepts are often called Industrie 3.0 (3rd industrial revolution, since 1970)
Stakeholder group ”Plattform Industrie 4.0” consists about 70 members, 50 of which are industrial companies. Companies are individually selected and become members by invitation only. FUJITSU has been a member since last June
Industrial Internet Consortium Has been coined as a name by the Industrial Internet
Consortium (IIC), founded in 2014 This industry consortium was founded by 10 US members
and follows their charter of enabling the industrial application of the Internet of Things (IoT)
“Industrial” means anything that is the basis of a business. The IIC wants to enable solutions in energy, health, transport and other sectors, not just in manufacturing
The IIC has now more than 250 members, most of which are IT or OT companies
FUJITSU is in the 9 member steering committee
Fujitsu is also Manufacturer
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Industry 4.0 and Industrial Internet
Industrial loT Solutions
Wearables, Devices, Sensors
Cloud, Infrastructure, Networks
IoT Platform
Applications
Smart Utilities & Smart Field Services
Smart Automotive
Smart Manufacturing
Smart Healthcare
Smart Agriculture
Smart Transport & Smart City
Smart Financial Services
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Digital Transformation: ”The Connected Enterprise”
Leverages the convergence of Information Technology and Operational Technology to enable smart, connected operations and significantly improve operations effectiveness and reduce operating cost
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IT & OT seamlessly working together
The seamless integration between Information Technology & Operational Technology is the key for successful Connected Enterprise implementation.
④ Data Accumulation
① Physical Devices & Controllers
② Connectivity
③ Edge Computing
⑤ Data Abstraction ⑥ Application
⑦ Collaboration & Processes
IoT World Forum Reference Model
OT Event Based Data in Motion Real Time
IT Query Based Data at Rest Non-real time
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Copyright 2016 FUJITSU
Enabling Digital: The Fujitsu Connected Enterprise in a nut shell
①
②
③
⑤
⑥
OT Fujitsu GlobeRanger iMotion
Connected Asset
Semantic (ISO 15926 Data Model)
Industrial Operational Intelligence
Predictive Maintenance and Service
Manufacturing Analytics &
Manufacturing Performance Management
Asset Tracking & Visibility
Semantic (ANSI/ISA 95)
Simplified Work Management
MFG Execution Quality Inspection
& Control
Connected Workers
Connected Manufacturing
Other Industrial M2M
④
IT
⑦
Fujitsu Ubiquitousware
3rd party
sensors
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What does it mean for Manufacturing Operations
Machine Data (Industrial M2M)
Material Movements (RFID)
Workplace Safety data (location, human wearables)
Business Data
Business Networks (Aka, AIN) and System of Records ERP EAM SCM QM CRM
Plant/Fied
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Fujitsu Connected Asset Connected Logistics & Warehouse Assets
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What does GlobeRanger Offer in Smart Asset Management? Understanding your Business and Asset Management
Fujitsu GlobeRanger Solution
In what areas of the business does asset shrinkage occur? Why? How much is that costing the company per year?
Real-time alerts for security breaches within defined boundaries. Reduced lost/stolen assets (often multi-million €).
Is there real-time visibility of all assets at any given time, and who has them? How can you optimise your assets in different parts of its business?
Real time visibility of exact location of assets including chain of custody to ensure assets are signed out (and in) to/from specific individuals.
How do you ensure that the right employees are handling certain assets having undertaken the relevant training?
Know what each individual is entitled to check out according to role and training.
How does asset stocktaking occur? Optimization of asset usage based on actual usage rather than advised holdings. Automatic recording of moving of assets through gates.
How do you manage servicing the assets to ensure this is conducted at the right time and in the right location for this to happen?
Real-time alerts for asset recall for servicing /maintenance. Can record the servicing and repair history for every item tracked.
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GE Turbine
Warehouse Optimization and Tool Tracking
Business Challenges:
Need better accountability of inventory for manufacturing and shipping processes
Fix lack of location accuracy of inventory
Sub-optimal process of finding missing or misplaced inventory
Optimize tool tracking and accountability
iMotion-Based Solution:
All inventory is RFID tagged on receipt at the dock door
All zones, aisles, shelf sections and bins tagged with location RFID tags
All forklifts enabled with wireless RFID reader & antennas
Solution tracks inventory from receipt to put-away to pick to consumption
Tool check-out window, personnel doors and dock doors instrumented with readers
Business Benefits:
Real time visibility of all inventory in the warehouse
Significant reduction of “misplaced” inventory
Better view of the velocity of inventory IN and OUT of the warehouse
Full passive, electronic tracking of tools with alerting for late check-ins
Company Overview:
GE Turbine is the world’s largest supplier of gas turbines and is a subsidiary of General Electric (GE); A Digital Industrial Company
which transforms industry with software-defined machines and solutions that are connected, responsive and predictive.
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Daisy Brands iMotion Increases Inventory Velocity and Operational Efficiency
Company Overview:
Daisy Brands is the largest producer of sour cream in the U.S. At its 50,000 sq. ft. facility in Dallas, the company uses a
flexible warehouse management system that allows forklift drivers to make inventory decisions and update the system.
Business Challenges:
Comply with retailer mandate.
Generate internal efficiencies with mandate-driven RFID investment.
iMotion-based Solution:
140 cases of sour cream loaded onto a pallet. Bar-coded SKU used to generate RFID label
which is applied to the shrink-wrapped pallet.
RFID tag number and SKU number linked and stored in database.
Forklift readers read RFID tag number on pallet which is displayed on vehicle-mount
computer screen. Driver inputs inventory movement information into system through
touch-screen – ending location and reason for move.
iMotion links WMS to RFID readers on forklifts, barcode scanners and RFID printers.
Shipment validated against ERP system, shipping memos, and invoices generated.
Business Benefits:
Greater operational efficiency – truck loading time reduced by two-thirds with elimination
of data entry and recording tasks.
Greater visibility into product inventory by type and location. Elimination of paperwork,
phone calls, e-mails and faxes to determine product availability.
Shipping errors prevented through immediate notification.
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Fujitsu Connected Asset Predictive Maintenance & Service
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Actionable insights into operations
Industrial Operational Intelligence
Microsoft-SAP Innovation Awards Winning Solution
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Predict Act
Source: Gartner
Sensor Data
Business Data
Environmental
Data
Pattern
and
Root
Cause
Analysis Pre
dic
tions
• Create work order
• Change product specs
• Alter maintenance
schedule
• Preposition spare parts
• …
Sense
Predictive Maintenance
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$50 billion total assets
Enhance operations and maintenance by combining information technology (IT) with operational technology (OT):
Boost productivity,
Improve asset reliability
Gain real-time visibility into all aspects of operations
Customer case – One of largest Utilities in NA
Improved Operational Efficiency Manual hours saving estimated at thousands of hours per year Reduced Operational Risk Risk avoiding benefits estimated at multiple million USD
Reduced Operational and Maintenance Cost Transforming from preventive to predictive maintenance
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Customer case - Aircraft maintenance
Scheduled aircraft maintenance Scheduled maintenance
Maintenance tasks and retrofit tasks
Required parts and materials Part authenticity, life cycle, condition, provider
Required tools Up to date calibration
Required technicians Calendars, up to date certifications
Shop floor space Integrations
Work assignments Parts Tools HR system Premises
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Fujitsu Connected Manufacturing Asset Tracking and Visibility
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Manufacturing (Work-in-Progress)
What do we offer? • Real Time WIP: Problem solving before they occur. Real-time visibility with alerts at every stage of the WIP to enable
immediate corrective action. Post-mortum is too late. Paperwork is too slow, labour intensive and inefficient. Can drive productivity by at least 30%.
• Data Automation: Manual errors will always impact cost. Any manual element in a manufacturing process will lead to error, inefficiencies, and delay. Install sensors to monitor, filter data according to thresholds, and apply business rules to automate. Even reducing minor errors that have a big impact can lead to 95% reduction in wastage costs.
• Tool Management: $2.75m pa in labour savings (for 100 workers). Get workers focused on work not finding tools or equipment. Check in/out facility, accountability for assigned tools, real time alerts for maintenance and calibration, Labour savings of approx. 15 mins per worker per task. This applies to any sector with significant tool volume/value.
Copyright 2016 FUJITSU
Meggitt Composites Work-in-Process, IoT Sensor Monitoring and Alerting
Business Challenges:
Need better insight into each stage of the manufacturing process
Lack of visibility into the Work In Process (WIP) queue and in-stage dwell time
Need better accountability of freezer and oven controlled raw materials and
baked subassemblies
Tool tracking and asset utilization
iMotion-Based Solution:
RFID tag each part, kit or subassembly manufactured in the manufacturing
process
Install RFID infrastructure at all process steps
Track each part through the manufacturing process
Collect and report on all time and process metrics
Integrate freezer and oven sensors for lifecycle tracking
Business Benefits:
Real time visibility into the velocity of the manufacturing process
Visibility into the queue time and process time for each stage
Graphical dashboard of the entire manufacturing process to monitor, measure
and make real-time corrections
Full electronic accountability of raw material life cycle through freezer transitions
Company Overview:
Headquartered in the UK, Meggitt PLC is a global engineering group specializing in extreme environment components and smart sub-systems for
aerospace, defense and energy markets.
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NeonLite Electronic & Lighting (HK) Improvement of Production Capacity through Greater Material Traceability
Business Benefits:
Manual data capture and entry eliminated.
Single integrated system to support inbound logistics, raw materials
management, and manufacturing work-in-process.
15 to 20% increase in production capacity, 10-15% increase in revenues.
Company overview
NeonLite, maker of the Megaman brand, is one of the world’s top manufacturers of energy-saving lighting products that are distributed in more
than 80 countries worldwide.
Business Challenges:
To ensure its commitment to the environment by reducing material waste
and consumption.
Extend material visibility from raw material through the manufacturing
process to finished product.
iMotion-based Solution:
Component parts and finished goods placed in tagged trays as they move
through assembly line or into a storage warehouse.
Handhelds and portals used to read the tags at various points.
Alerts and exception reports generated when errors detected.
Interfaces with ERP Syteline warehouse software.
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Fujitsu Connected Manufacturing Manufacturing Performance & Quality Management
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Business Processes - ERP
Manufacturing Operations – MES
Manufacturing Control
Manufacturing Systems – Information Sources
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Production schedule, material use, shipping and inventory levels, finance,
logistics etc
Batch management, manufacturing execution/operations
management systems, maintenance and plant performance
management systems
Real-time Logic / Batch controls and software
Intelligent Devices: Physical Process /
Sensors / Analyzers / Actuators Physical Production / Manufacturing
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Business Processes - ERP
Manufacturing Operations – MES
Manufacturing Control
Physical Production / Manufacturing
Manufacturing Systems – Information Flows
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Production planning, order requirements, product
definitions, availability, electronic work instructions,
produced and consumed material, product tracking and
tracing information
Resource requests, material definitions, product
deliveries, material availability, material lots, product
shipments, equipment assignments, maintenance
requests, maintenance progress, equipment
capabilities, maintenance schedule
Work instructions, recipes, set points,
process values, alarms, adjusted set
points, production results,
Manufacturing Operations – MES
Manufacturing Control
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Connected Manufacturing Solutions – Operator Dashboard
Real-Time Dashboard – Orders View
Simplified UI
Mobilization
Process and Quality
Enforcement
Improved Efficiency
Knowledge
management
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Food Manufacturer
Integrated manufacturing and quality management solution connects machine, processes, data and people
Customer case – Meat processing company
Improved Operational Efficiency Mobilized and paperless plants
Improved Food Safety and Quality Business Use Self Service
Reduced Operational Cost Tens of millions USD potential saving of recall/refunding
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Finnish Manufacturing Company
Thousands of log files/hour/operation across production lines Data volumes 30GB / day
Customer case – Advanced Analytics
Automated quality control Monitor / alert / react for production lines in real rime
Adhoc quality analytics Visualisation of data with self-service tools
Long term trend analysis Predictive modeling
Fujitsu Connected Workers Workforce Safety Augmented Reality
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Connected Workers
Before
ヘッドマウントディスプレイに 情報を表示
Efficient working processes thanks to mobile/wearable device and AR technology
Displayed by HND Work procedure Device condition
Complex processes
Look for information from manual
Document in a report
Real-time data-sharing
Security & Improved task accuracy
Efficiency by hands-free
After
Head Mount
Display
Real-time sharing Inspection result Device information
Wearable
Keyboard
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Workforce Management/ Health & Safety
Ensure workers safety and visualize their environment
Using the vital wrist band we can see when conditions deteriorate increasing the chance of heat stroke. Issue alerts and provide support when an accident occurs.
Monitoring workers for staff management & ensuring worker safety
Detect falls by monitoring both acceleration & barometer pressure
Avoid the chances of getting heat stroke by estimating heat stress from pulse, active mass, temperature & humidity
Lone worker monitoring
Opportunities
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Ensuring the right information available in context
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UBIQUITOUSWARE – IoT Core Module Features
sense real time the environment, motion, location and vital signs
Sensors Acceleration
Geomagnetism Barometric
Pressure Gyro Mic
HCE Low power
consumption, Analysis
algorithm
Fall Detect a fall by sensing changes in movements & barometric pressure
Posture Identify posture (standing, sitting & lying) by sensing movements in 3D
Exercise Intensity
Calculate energy consumption from movements & active mass
PDR Precise positioning by estimating moving direction & distance
Location Log
Complement & correct location data as well as stored positioning data *Precise outdoor positioning together with GPS
Heat Stress
Issue alerts based on the heat stress caused by temperature & humidity *Detect together with heart rate and temperature & humidity sensors
Physical Load
Issue overload alerts by estimating physical loads from changes in heart rate
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"UBIQUITOUSWARE" Products, Accelerating the Digitalization of Customers' Operations
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https://www.youtube.com/watch?v=1ISP3pRICuo
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Getting started - on Digital Journey
“Think big, start small; learn fast and scale quickly”
• Focussed session – up to 2 hours • Interventions- e.g. trends, art of the possible, threats &
opportunities • Outcome – common understanding, sponsorship & agreed
priorities
Executive Workshop
• In-depth session – up to half a day • Interventions – e.g. facilitated discussion, demonstrations,
concept jam • Outcome – identified opportunities for solutions
Digital Innovation Session
• Develop consistent strategy for digital – up to 4 weeks • Interventions – e.g. visioning workshop, road-mapping • Outcome – agreed approach, outcomes, initiatives and
milestones
Digital Vision and Roadmap
• Real-life application of digital – up to 3 months • Interventions – e.g. day in the life, hackathon, agile
solutions integration • Outcome – business case for the solution
Proof of Concept and Value
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Why Fujitsu?
Framework and method to help customers drive yield from the Digital Transformation with own IP like GlobeRanger and RunMyProcess
Lean tools help our customers rethink current supply chain and reduce costs
Innovation driven company with availability of smart solutions and patents
End-to-end service – from business process to applications and infrastructure layer
Fujitsu being a long term global partner with strong Nordic presence
Fujitsu is also Manufacturer
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