how to make 99.9% uptime a realityno… · how to make 99.9% uptime a reality joe carelli vice...

HOW TO MAKE 99.9% UPTIME A REALITY

JOE CARELLI

VICE PRESIDENT/GENERAL MANAGER

LIFECYCLE SERVICES

November 12, 2019

Honeywell Confidential - ©2019 by Honeywell International Inc. All rights reserved.@Intelligrated

PRESENTER

Joe Carelli

Vice President/General Manager, Lifecycle Services

Joe has more than 30 years of experience in both government and industry international

environments. In his current role, he leads the sales and operations teams of the aftermarket

business, balancing the needs and expectations of customers and the business to achieve

profitable sales and deliver growth.

Prior to joining Honeywell Intelligrated, he served as a regional general manager for GE’s

Subsea Systems business in Africa. Prior to that, he served as the managing director for GE

Energy in Central Asia and was vice president of sales for GE’s nuclear business in Europe.

Joe’s career spans work as a field engineer, a staff engineer and a maintenance manager for

nuclear reactors, all in New York. In addition, he was seconded to the U.S. embassy in Vienna,

Austria, where he served as a diplomat on the staff of the U.S. ambassador to the U.N.,

managing a technical support program to the International Atomic Energy Agency.

Joe earned an associate’s degree in mechanical technology from S.U.N.Y. Farmingdale, a

bachelor’s degree in mechanical engineering from Polytechnic University of N.Y., and an

M.B.A. from the University of Phoenix.

1How to Make 99.9% Uptime a Reality

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WHAT’S STANDING BETWEEN YOU AND YOUR OPERATIONAL GOALS?

2 2

What is your most critical need?

THROUGHPUT

Save millions with an

incremental increase in cases

per shift (it takes more than

speeding up the sorter).

PRODUCTIVITY

Eliminate manual handling and

save millions with a fully

automated package flow. flow.

TRAILER FLOOR SPACE

Save millions by optimizing

trailer loading for a fully

balanced operation.

LABOR

Save millions on recruiting,

training and productivity by

cutting attrition.

SHIPPING & RECEIVING

Timing usage of truck bays is

critical to efficiency and hitting

delivery windows.

IN-STOCK AT THE POS

Everything depends on

ensuring item availability

at the point of sale.

How to Make 99.9% Uptime a Reality



POLLING QUESTION

What’s your most critical operational need?

• Throughput

• Productivity

• Trailer floor space

• Labor

• Shipping and receiving

• In-stock at the POS

• Other



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What are your challenges?

SUPPLY CHAIN EXECUTIVE

I have to drive down my cost-per-

case shipped across the entire

network now!

I need a way to compare system

uptime and productivity across my

network.

Can I gain enough efficiency across

the enterprise to avoid the CAPEX

of a new distribution center?

OPERATIONS MANAGER

How do I deal with ever-

increasing production targets?

How do I eliminate bottlenecks

and optimize the flow balance

through the building?

Could I get visibility to

production data to help me

drive productivity?

MAINTENANCE MANAGER

How do I get all the planned

maintenance done with shorter

and shorter maintenance

windows?

In such a tight labor market, I

barely get people trained before

I lose them to attrition.

Where do I go for technical help

when I get into a bind?



Honeywell Confidential - ©2019 by Honeywell International Inc. All rights reserved.

ORGANIZATIONS THAT ADOPT A DATA-DRIVEN LIFECYCLE APPROACH ARE POSITIONED TO WIN.


Honeywell Confidential - ©2019 by Honeywell International Inc. All rights reserved.@Intelligrated 6

FREQUENT

DISRUPTIONS

FEWER

DISRUPTIONS

NO

DISRUPTIONS

• Data analysis is automated

• Predictive maintenance is

optimized

• Unplanned downtime is

eliminated

• Data provides insights

• Maintenance is part of operation

• Actionable insights drive

productivity

• Data is inaccessible

• Equipment is run to failure

• Downtime inhibits production

MAKE THE JOURNEY TO PREDICTABILITY




POLLING QUESTION

Where are you on this journey to predictability?

• Frequent disruptions

• Few disruptions

• No disruptions




Can you afford to operate your DC blindly?

8

WHY BOTHER WITH DATA?READ CONFLICTS

Observed high number

of read conflicts, which

was the largest

contributor to scanner

error percentage.

Caused by product being

placed on the conveyor

in the pick modules

upstream.

BAD GAPS

Identified an issue with

a high amount of bad

gaps between product

being inducted onto

the sorter.

Caused by the sorter

operator manually

inducting product after

the merge.

PICK MOD JAMS

Identified a transfer of

higher and increasing

amount of jams beyond

what was expected

historically.

Caused by operator not

following the process for

placing product on main

line after a pick.

NETWORK VIEW

Foster discussions

between DCs to

compare productivity

and share best

practices.

Enable data-based

discussions on root

causes and go forward

with plans across the

network.




What can you neglect and still succeed?

9

BUILDING BLOCKS FOR CRITICAL OUTCOMES

ASSET MANAGEMENT

ASSESSMENTS

DATA VISUALIZATION

AND ANALYTICS

RESIDENT TECHNICIANS

AND SUPERVISORS

FIELD ENGINEERS

ENGINEERING

CENTER OF

EXCELLENCE

TECHNICAL

ADVISORS

TRAINING

SPARE PARTS

MANAGEMENT

24/7 TECHNICAL

SUPPORT




What form of collaboration works for you?

10

DEVELOP A MAINTENANCE STRATEGY

Your DC Service Provider

24/7 TECHNICAL SUPPORT

DATA VISUALIZATION AND ANALYTICS

SITE LEADERS

RESIDENT TECHNICIANS

FIELD ENGINEERS

ENGINEERING COE

TECHNICAL ADVISORS

TRAINING

SPARE PARTS MANAGEMENT

ASSET MANAGEMENT ASSESSMENTS



CASE STUDY:

HOW MUCH DOWNTIME WOULD THIS EVENT CAUSE IN YOUR FACILITY?



POLLING QUESTION

Are you using operational data to drive productivity

in real time during production?

• Yes

• No

• I’m not sure / don’t know




DATA DRIVES OUTCOMES

CREATE

DATA

STRATEGY ESTABLISH

BUILDING

BLOCKS

IMPLEMENT

THE PLAN DELIVER

OUTCOMES

DEFINE

OUTCOMES




DEFINE

OUTCOMES

CREATE

DATA

STRATEGY

ESTABLISH

BUILDING

BLOCKS

IMPLEMENT

THE PLAN

DELIVER

OUTCOMES

DATA DRIVES TRANSPARENCY

Is it really uptime?

Throughput?

Cost per package?

Or just getting through the shift?

Do I really want the enterprise to see my productivity in real time?

Can I survive with total transparency?

Will I have to change my entire mindset?

How will conflicting metrics be resolved?

Hey, wait, that’s my building block they want to outsource!

Does that building block cost me or save me?

How will priorities change?

Why can’t we just keep doing what we’re doing?




Fundamentals

Controls

Conveyors

Palletizers

Robotics

Sortation systems

Board certification

OPERATING IN A TIGHT LABOR MARKET

Make the case

Own the pipeline

Change the narrative

Broaden the field

Visit military bases

Visit schools

Keep the cadence

Review compensation

Continue to train

Create career paths

Encourage mobility

Communicate


Recruit Train Retain


Honeywell Confidential - ©2019 by Honeywell International Inc. All rights reserved.

Conveyor &

Sortation

Systems

Fulfillment

TechnologiesLifecycle

Services

Operations &

Solutions

Development

Palletizing &

DepalletizingRobotic

Solutions

Software

Solutions

The Connected

Distribution

Center

@Intelligrated

QUESTIONS?

16How to Make 99.9% Uptime a Reality 16


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