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Vel K
Product Manager – Market Strategy
IPF: Intelligent Plant Framework
Cisco Covacsis Solution
Manufacturing Business Challenges
How can we improve
production by double
digit without any Asset
investment ?
How do we reduce the operation cost of the
plant ?
How do we align Plant operations to Business
KPI ?
How do we improve the production
bench marks
without any Asset
investment ?
How can we see the plant’s
financial performance in real time?
How do we get a 360 degree
visibility of the plant
operations in real times?
Productivity Improvement : A Continuous Journey
Intelligent Plant Framework enables faster efficient, decision making by providing real-time, end-to-end business visibility of the plant
IPF Framework
Operator
Data
Real-time
Analysis and
Collaboration
Plant
Machinery
Discrete
Devices
Mgmt.
system
ERP
system
Analytics
Operator
Supervisor
Line
Manager
Plant
Head
Costing
Team
Mfg.
Head
HR - IR
CxO
Data Acquisition
Data Analytics
•Batch Entries
•Manual stoppages
•Process variables
Operator Data
•Meters, VFD, PID, Sensors
•Power consumption
•Chemical consumption
•Consumables
Discrete Devices
•PLC / DCS / SCADA
•Technical downtime
•Run-time and cycle time
•Process parameters
•Machine performance
Plant Machinery
•QMS / LIMS
•Energy system
•Building mgmt. systems
Management system
•Planning Data
•Production
•WIP inventory
•Conversion Cost
ERP system
IPF Framework
Operator
Data
Real-time
Analysis and
Collaboration
Plant
Machinery
Discrete
Devices
Mgmt.
system
ERP
system
Analytics
Operator
Supervisor
Line
Manager
Plant
Head
Costing
Team
Mfg.
Head
HR - IR
CxO
Data Acquisition
Data Analytics
• Utilities consumption
• Consumables Consumption
• Asset utilization
• Availability
• OEE
• Machine Uptime
• Stoppage Reason Analysis
• Batch Cycle Time
• Yield and Throughput
Operational Metrics
• Conversion Cost
• Floor Financial Quotient
• Production Opportunity Loss
• Financially Most Inefficient
• Cost of Deviation
• Cost of inefficiency
Financial Metrics
IPF Framework
Operator
Data
Real-time
Analysis and
Collaboration
Plant
Machinery
Discrete
Devices
Mgmt.
system
ERP
system
Analytics
Operator
Supervisor
Line
Manager
Plant
Head
Costing
Team
Mfg.
Head
HR - IR
CxO
Data Acquisition
Data Analytics
• Trend Analysis
• Real-time plotter
• machine performance
• process parameters
• projected performance of the machine
Operator
• Cycle-time
• line efficiency
• Top reasons for downtime
• Operator Comparison
Line Manager
• Overall Conversion Cost
• Cost of Inefficiency
• Relative Asset Utilization
• Worst performing section
• Overall power consumption
• WIP Inventory
Plant Head
• Top plants
• Highest WIP inventory
• Least energy efficient
Manufacturing Head
• Cumulative economic loss
• Most efficient plant
• Best financial index
CxO
IoT Cloud Challenges
Limited Bandwidth Latency Network Availability
Distributed “FOG” Computing Traditional Computing Model
(Terminal/Mainframe, Client-Server, Web)
Assumes Infinite Bandwidth, Zero Delay
IoT Computing Model
Data Center/ Cloud
Endpoint
Assumes Limited Bandwidth, Variable Delay, and Intermittent Connectivity
Data Center/ Cloud
Device
IOX
Assumes Limited Bandwidth, Variable Delay, and Intermittent Connectivity
Speed of Light Latency-Critical
Responsiveness Required
Resiliency
Security
Data Grows Faster Than Bandwidth
Cisco – Covacsis Solution Implementation Architecture
Operator
Cisco Router
With LIU
Server
Machine
Serial /
Ethernet
I/O
Machine
Operator
Cisco router
With LIU
Server
Serial /
Ethernet
I/O
LAN / WAN BLOG Analytics Server
in
Data Center/Cloud
Customer Case Studies - India
• 44% increase in tablet production
• 70% reduction in average batch turnaround time
Leading Pharma Company
• 50% increase in production rate in 9 months period
• 30% reduction in water consumption
• Increase in production of A-Grade fabric from 94% to 97.89 %
Leading Textile Company
• 28% increase in production of fatty acid
• 44% reduction in reflux emission
Leading Chemical Company
Improvement : A Continuous Journey
IPF
Automation
ERP
Consultant
Cisco Covacsis Solution Enable Manufacturers to…
Have Plant Wide
Visibility of Business Impact
Make Faster Decisions
Stay Ahead of
Competition