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K St t i f Di t M f tK St t i f Di t M f tKey Strategies for Discrete ManufacturersKey Strategies for Discrete Manufacturers
Meeting the Challenges of Rapidly SurgingMeeting the Challenges of Rapidly SurgingMeeting the Challenges of Rapidly Surging Meeting the Challenges of Rapidly Surging Resource, Material and Energy CostsResource, Material and Energy Costs
Jim CaieVice President
ARC Advisory GroupARC Tokyo Forum
July 16 2008
This presentation is copyrighted by ARC Advisory Group (ARC). The information is proprietary to ARC and it may be not be reproduced without prior permission from ARC.
[email protected] 16, 2008
Today’s Game Changers for Discrete ManufacturersToday’s Game Changers for Discrete Manufacturers
Rapid Surge in Energy Costs has Greatly increased Cost of Doing Business
P l
Business Drivers
Fierce Global CompetitionDynamic Customer Requirements
• People• Equipment• Material• Operations
Shrinking Product Life Spans
Global Markets, Supply ChainsTechnological Advancements
High Energy Costsp• Logistics• Etc.
C i R thi ki th i B i
High Resource & Material Costs
New RequirementsCompanies are Rethinking their Basic Product and Manufacturing Strategies• Relentless Cost Reduction Everywhere• Optimal Use of All Resources
Reduced Overall Costs & DowntimeReduced Energy & Material CostsOptimized, Validated Mfg Designs
Flawless Execution
New Requirements
p
Challenge is Changing Quickly to Adapt to this New Environment
Flawless ExecutionReal-time, Actionable Information
Empowered Knowledgeable PeopleBest Practice Focus
Common Scalable Systems
2© ARC Advisory Group
to this New Environment Common, Scalable SystemsCollaborative Production Systems
Smart Applications
Agenda
Discrete Manufacturers Can Effectively & Efficiently Adapt to this New EnvironmentDiscrete Manufacturers Can Effectively & Efficiently Adapt to this New Environment
Rethink, Enhance and Leverage
Automation and Control Systems
Operations Management (MES) Systems
Use of Digital Manufacturing Tools
3© ARC Advisory Group
Collaborative Production Systems (CPS) ModelCollaborative Production Systems (CPS) Model
Enterprise/Business Operations
Operations M t
Operations Management
Inbound Supply Chain
Customer Relationship
Management Systems
Management (MES)
Automation &PLM & Digital
Shipping,Outbound SC
Product/Plant Design & Eng
AutomationSystems
Automation & Controls
PLM & Digital Manufacturing
4© ARC Advisory Group
ARC has Established a Research Community in Each Domain
Automation & ControlsAutomation & Controls
Challenges for Cost ReductionEngineering Costs Deployment & Support CostsControls Component (Material) CostsEnergy UsageEnergy Usage Safety Related Costs
Opportunities to Achieve Cost ReductionsGlobal, Open, Common Controls Architecture
Intelligent, Integrated Platform for Multiple Control Applications
5© ARC Advisory Group
Safer Automation at Lower Costs
Eight Strategies to Achieve a Global, Open, Common Controls ArchitectureEight Strategies to Achieve a Global, Open, Common Controls Architecture
Leadership Driving Common
• Establish Global Common Vision
• Drive Initiatives to Implement Vision
• Empower Competent Groups to Execute Initiatives
Stability in the Controls Architecture
• Leverage advantages of reusing validated designs across the company for 3 – 5 years
• Bundle new technology/practices together and thoroughly validate prior to deploymentand thoroughly validate prior to deployment
• Standardize on a Single PLC Supplier
Commonizing Software Designs
• Standardize on a Single PLC Supplier
• Create Library of Standard Templates for Hundreds of Basic Control Tasks
• Auto-generate 80%+ PLC Code for an
6© ARC Advisory Group
Application by Cutting & Pasting Templates
Eight Strategies to Achieve a Global, Open, Common Controls ArchitectureEight Strategies to Achieve a Global, Open, Common Controls Architecture
Utilizing Common, Open Networks
• Must be Robust, Proven, and Globally Supported
• Enables Competitive Choice and Easier
Deploying Lean
• Enables Competitive Choice and Easier Integration
Deploying Lean, Scalable Systems
• Utilize Same Software for both Hi-End and Low-End Devices throughout your Diverse Applications
Virtually Developing,
• Optimize Controls Performance & Value
• Systems Ready Prior to ProductionEvaluating, and Validating Control Designs
y y
• Testing is Robust
7© ARC Advisory Group
Eight Strategies to Achieve a Global, Open, Common Controls ArchitectureEight Strategies to Achieve a Global, Open, Common Controls Architecture
Deploying Common Electrical Panels
• Designs Must Meet Regulations of All Countries
• Common Look & Feel Regardless of OEM• Common Look & Feel Regardless of OEM Providing the Equipment
• Purchasing Economies of Scale
Competitively Sourcing Common Components
• Drive Down Prices with Competitively Bid, High Volume Long Term ContractsComponents High Volume Long Term Contracts
• Common Components Enable Common Hardware Designs
8© ARC Advisory Group
Competitively Sourcing Common Components Competitively Sourcing Common Components
Common Components Savings Over TimeCommon Component Cost
60
80
100
cent Uncommon
NAV l
0
20
40Perc NA Volume
Global Volumes
Panel Field Fluid Power
Components
•Capital & Material Savings are Significant
•Selecting Energy Efficient Components (Drives) can Save
9© ARC Advisory Group
g gy p ( )Significant Additional Costs over Time
An Alternative to Significantly Reduce Energy Costs in the Factory
Electric Actuators
• Replacement of Pneumatic Actuators (clamps, slides,Replacement of Pneumatic Actuators (clamps, slides, grippers, etc.) with Electrically Operated Devices.
• Supports the “Airless Plant” Concept. • Significantly reduced utility operating costg y y p g• Significant capital expenditure avoidance.
Other Potential Advantages
• Robustness & Reliability• Maintainability• Safety & Fault tolerance
10© ARC Advisory Group
Intelligent, Integrated Multi-Functional Control Platform
ARC Programmable Automation Controller (PAC) Model
Users want single point access to information
LogicLogicProcessProcess
TagsTags
MotionMotion DrivesDrives
HMI SCADA
HMI SCADA
DatabasesDatabases Development Platforms
Common Tagging and
Database
Common Configuration
Tools
Networked Multi-vendor Architecture
Multi-domain
automated systems
Multi-domain
automated systems
Multiple Control
Applications
HMIHMI
PACMulti- Domain Functionality
Multiple Control Applications
Efficient Data Exchange in a Multi-
PAC Reduces Complexity & Enables Integration
11© ARC Advisory Group
Efficient Data Exchange in a Multi-Vendor Environment
Enables Highly Distributed Systems
Integration
Expanding PAC Capabilities with Windows CE Intelligent ModulesExpanding PAC Capabilities with Windows CE Intelligent Modules
PLC
ITDatabases
Intelligent Module
PLCsWeb Viewers& HMIs
Marques
MES Applications
Facility Applications to Reduce Energy Usage
Predictive Maintenance Applications
12© ARC Advisory Group
Predictive Maintenance Applications
Motion Control Applications
Safer Automation at Lower CostSafer Automation at Lower Cost
Future Automations Systems Will:Perform Many Non-Value and Repetitive
Tasks Currently Done by HumansTasks Currently Done by HumansEnable More Efficient, Safer Interaction
with People using Technology such as:
Motoman 13 axis Dual ArmMotoman 13 axis Dual Arm
• Intelligent Cooperative Robots, Sensors, Effectors & Controls
• Non-Contact Sensors for Situation Awareness & Human Tracking
Motoman 13-axis Dual-Arm Assembly Robot
Motoman 13-axis Dual-Arm Assembly Robot• Force Tactile Sensing
• Bio-Metric Sensing & Control Reliable Solutions Emerging Technologies
will Enable Improved Less• Sensing to Recognize Non-Standard Conditions
• Self Optimizing, Learning Processes, Equipment, & Tools
will Enable Improved, Less Obtrusive Safety at Lower Costs
13© ARC Advisory Group
• Wireless Information & Control
Agenda
Automation & Controls Research CommunityAutomation & Controls Research Community
User Best PracticesImplement Common Hardware, Software and Network Standards
Maximize Use of Ethernet Technologies at all Levels of Automation
Design Robust Interfaces Between Controls & IT Systems
Effectively Plan & Execute Controls Migration, Upgrades, & Reuse
Virtually Validate Controls Designs Prior to Production
Supplier RequirementsSupplier RequirementsProvide Open Standards Bases Products
Provide Cost Effective Ethernet IO Technology/ProductsProvide Cost Effective Ethernet IO Technology/Products
Provide Simpler, Cheaper, more Mobile HMIs
Provide Backward/Forward Compatible, Scalable, Maintainable, U d bl P d t
14© ARC Advisory Group
Upgradable Products
Operations Management (MES)Operations Management (MES)
Dynamic Coordination of Personnel, Equipment, Parts and Material to Effectively
and Efficiently Manufacture Products
Enterprise/Business Operations
Enterprise/Business Operations
Inbound Supply Chain
Customer Relationship
ChallengesR d i C d O i i i U f R i Hi hl
Operations Management
Systems
Operations Management
Systems
AutomationSystems
Operations Management
(MES)
Automation & Controls
PLM & Digital Manufacturing
Operations Management
(MES)
Automation & Controls
PLM & Digital Manufacturing
Shipping,Outbound SC
Product/Plant Design & Eng
Reducing Costs and Optimizing Use of Resources in a Highly Distributed & Dynamic Supply ChainMost MES Systems Not Well Integrated with Key Factors of ProductionProduction
Opportunities Effective and Efficient Cross Functional Integration and Process EnforcementCost Effective Schedule Compliance
15© ARC Advisory Group
Convergence of Automation & IT technologiesImproved Productivity, Uptime & Quality and Lower Energy Usage
Reasons for Deploying Operations Management (MES) SystemsReasons for Deploying Operations Management (MES) Systemsg ( ) yg ( ) y
Improve visibility of manufacturing information
Improve cross-domain business processes
Improve throughput
Improve operating efficiency
Improve new product introduction
Improve quality of products and services
Align production with dynamic business needs
Rationalize/eliminate legacy applications
Improve labor productivity
Improve the ability to produce more products
0 10 20 30 40 50 60 70 80 90 100
Improve the ability to produce more complex products
Software tools to take Lean to the next level
Source: ARC Manufacturers Research May 2007
16© ARC Advisory Group
MES Systems Can Help
Disparate Applications Hinder Manufacturing Excellence : the MES MessDisparate Applications Hinder Manufacturing Excellence : the MES Mess
ERP
CRM SCM
Production Definition
Production Capability
Production Plan Production Information
CRM SCM
Planning
Scheduling
Yield Accounting
Maintenance
Hundreds of Applications
OptimizationInventory
BatchContinuous Logic
S A d L i l D iCommon Data/Information
ApplicationsAPC HistorianDCS PLC
F
FF
F
Sensors, Actuators and Logical Devices
17© ARC Advisory Group
Increasing Complexity of Automation Systems
Three Pillars to Fix MES MessThree Pillars to Fix MES Mess
Infrastructure• Real-time Plant Support
Connectivity• Enterprise
Processes• Production Planningpp
• Technology Platform• Applications Platform• Business Processes• Security• Role-based Portals
p• Design & Engineering• Operations, Controls, &
Equipment• Supply Chain & External
Operationsd
g• Production Execution• Product Data Tracking• Visibility & Analytics• Quality Enforcement• Inventory Logistics
• etc. • Product Support Opsy g
• Asset Mgmt• Product Support
Operations Management
18© ARC Advisory Group
p g
Source: ARC Advisory GroupSource: ARC Advisory Group
Technologies Expanding MES CapabilitiesTechnologies Expanding MES Capabilities
Asset Tracking
• RTLS,GPS for Location Determination
• Web-based Visualization & Automatic Alerts
Intelligent, Adaptive Systems
• Watch-dogs to Avoid Errors• Watch-dogs to Avoid Errors
• Reliability Centered Manufacturing
Data Display
• Wireless and Mobile
19© ARC Advisory Group
Opportunities for MES to Significantly Reduce Energy UsageOpportunities for MES to Significantly Reduce Energy Usage
Facilities
PLC MES
FacilitiesManagement
System
Lights Heat
Realities of the Plant Floor
Efficient AGV Routings
g
Utilizing accurate, timely information in the plant and supply chain, MES can help
Efficient Supply Chain Routings
20© ARC Advisory Group
supp y c a , S ca e poptimize use of energy in the enterprise
Routings
Operations Management Research CommunityOperations Management Research Community
Top Best Practice IssuesAvoiding Being Trapped as a “Victim of Our Legacy”
Integrating Best of Internal & Commercial Systems
Effectively Leveraging IT & Mfg Engineering Resources
Utilizing Event and Role Based Systems
Utilizing Wireless for Data Collection & Display
Top Supplier RequirementsReduce Cost of MES (scalability)
Facilitate Integration in a Legacy Environment
Support More Analytical and Role-Based Systems pp y y
Provide Remote Expert Assistance
Help Standardize Mfg Data Definitions
21© ARC Advisory Group
Digital Manufacturing (DM)Digital Manufacturing (DM)
Digital Mfg is a Set of Virtual Tools that Help Mfg Engineers to Efficiently Optimize & Validate M f i D i P i P d i
Enterprise/Business Operations
Enterprise/Business Operations
Operations Operations Operations Operations
Inbound Supply Chain
Customer Relationship
Manufacturing Designs Prior to Production
Challenges Reduce the Time Required to Develop and Maintain Virtual Models
Management Systems
Management Systems
AutomationSystems
Management (MES)
Automation & Controls
PLM & Digital Mfg
Management (MES)
Automation & Controls
PLM & Digital Mfg
Shipping,Outbound SC
Product/Plant Design & Eng
Reduce the Time Required to Develop and Maintain Virtual ModelsProvide More Accessible, Accurate Data to Drive SimulationsImprove and Better Integrate the Still Emerging Set of Virtual Tools
OpportunitiesSpeed to Market with ConfidenceEfficiently Developed Models that Stay RelevantEfficiently Developed Models that Stay RelevantQuicker and More Thorough Validation Faster Production Accelerations with Improved Quality & Productivity
22© ARC Advisory Group
Virtual Training CapabilityElimination of Physical Builds for Validation
What Does Digital Manufacturing Do?What Does Digital Manufacturing Do?
Manufacturing Planning• Definition of High-Level Manufacturing Processes• Evaluation of Capacity Requirementsp y q
Detailed Design & Analysis• Detailed Resource Modeling & Simulation• In-depth Process Definition and Validationp• Detailed Work Instructions• Thermal, Stress, & Spring-back Analysis• Digital Layout • Equipment Tool & Fixture Design• Equipment, Tool & Fixture Design• Ergonomic Simulation• Energy Usage
Validation & Virtual CommissioningValidation & Virtual Commissioning• Control Logic Validation• HMI/MES Validation• Sensor Placement Validation
Knowing the Manufacturing System Works Prior to
23© ARC Advisory Group
• Automation Integration Validation Production
Using Digital Manufacturing Tools for Controls Validation and Virtual Commissioning
PHYSICALVIRTUAL
Control Mfg Process
DE
SIG
N
DesignModeling
DLI
DAT
E
Production Simulation
Validate Control
VAL PLC HMI
24© ARC Advisory Group
OPC Client/Server
Assessing How Well Production and Controls Designs are FunctioningAssessing How Well Production and Controls Designs are Functioning
Electrical Panels in DELMIA V5 Logic Controlling the CellElectrical Panels in DELMIA V5 Logic Controlling the Cell
Human Machine InterfaceMechanical Equipment in DELMIA V5 Human Machine InterfaceMechanical Equipment in DELMIA V5
PLCPLC
Engineers Can Simultaneously Monitor Control Logic Execution, HMI Diagnostics, Functioning of
25© ARC Advisory Group
g , g , gPanel Devices, and Functioning of the Production
Processes and Equipment.
Digital Mfg Supports Asset Life Cycle ManagementDigital Mfg Supports Asset Life Cycle Management
Virtually Optimize Facility and Supply Chain Assetand Supply Chain Asset Designs and Practices Over their Life Cycles, Considering Cost, Energy Usage, Time, and Other I t t F tImportant Factors.
26© ARC Advisory Group
PLM/Digital Mfg Research CommunityPLM/Digital Mfg Research Community
User Best PracticesVirtually Optimize and Validate Designs Prior to ProductionMaximize Reuse of Virtual Models by Emphasizing CommonMaximize Reuse of Virtual Models by Emphasizing CommonIntegrate PLM Systems with ERP, SCM, EAM and MESFully Integrate DM tools• Into the Company’s design process• Across all manufacturing disciplines• Into the Information & Control architecture of the plant floor
S li R i tSupplier Requirements
Provide PLM/DM Tools that are C bl f i i d d i i h li i f d i fl• Capable of integrating product design with realities of production floor
• Capable of integrating mechanical and electrical data• Easier to use and capable of supporting large models• Capable of capturing process knowledge
27© ARC Advisory Group
• Capable of capturing process knowledge
Assist Users in Cost Justification for PLM/DM Systems
ARC’s Benchmarking Initiative for the Discrete Mfg CommunityARC’s Benchmarking Initiative for the Discrete Mfg Community
ARC Discrete Benchmarking Consortium
Member’s Role
ARC Manufacturing Clients
• Define Methods and Metrics to Focus on
• Collect the Data
• Use Reports to Compare Their Plants with Industry Abstracted Data
ARC’s Role
Consortium of Discrete
Manufacturers
• Facilitate the Process
• Maintain a Confidential Database
Manufacturers Sharing
Benchmarking Information
• Provide Comparison Reports
Benchmarking Will Help Discrete M f t R d t T d ’
28© ARC Advisory Group
Non-Clients
Manufacturers Respond to Today’s Challenges More Effectively and More Quickly
Meeting Today’s Challenges with Smart ApplicationsMeeting Today’s Challenges with Smart Applications
Enterprise/Business Operations
Enterprise/Business Operations
Operations Management
Systems
Operations Management
Systems
Operations Management
(MES)
Operations Management
(MES)Shipping,
Outbound SC
Inbound Supply Chain
Product/Plant Design & Eng
Customer Relationship
AutomationSystems
Automation & Controls
PLM & Digital Manufacturing
Automation & Controls
PLM & Digital Manufacturing
Smart Applications
Next Generation CapabilityMore Effectively and Efficiently Utilize
• PeopleA t tiBenchmarked Current &
Emerging Best Practices & Technologies
• Automation • Information• Energy & Material
Dramatically Improve Competitiveness
29© ARC Advisory Group
Thank You.Thank You.For more information, contact the author at [email protected] or visit our web pages at
www arcweb com
This presentation is copyrighted by ARC Advisory Group (ARC). The information is proprietary to ARC and it may be not be reproduced without prior permission from ARC.
www.arcweb.com