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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
Honeywell Confidential - ©2019 by Honeywell International Inc. All rights reserved.@Intelligrated
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
Honeywell Confidential - ©2019 by Honeywell International Inc. All rights reserved.@Intelligrated
POLLING QUESTION
What’s your most critical operational need?
• Throughput
• Productivity
• Trailer floor space
• Labor
• Shipping and receiving
• In-stock at the POS
• Other
3How to Make 99.9% Uptime a Reality
Honeywell Confidential - ©2019 by Honeywell International Inc. All rights reserved.@Intelligrated 4 4
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?
How to Make 99.9% Uptime a Reality
Honeywell Confidential - ©2019 by Honeywell International Inc. All rights reserved.
ORGANIZATIONS THAT ADOPT A DATA-DRIVEN LIFECYCLE APPROACH ARE POSITIONED TO WIN.
5How to Make 99.9% Uptime a Reality
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
How to Make 99.9% Uptime a Reality
Honeywell Confidential - ©2019 by Honeywell International Inc. All rights reserved.@Intelligrated
POLLING QUESTION
Where are you on this journey to predictability?
• Frequent disruptions
• Few disruptions
• No disruptions
7How to Make 99.9% Uptime a Reality
Honeywell Confidential - ©2019 by Honeywell International Inc. All rights reserved.@Intelligrated
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.
How to Make 99.9% Uptime a Reality
Honeywell Confidential - ©2019 by Honeywell International Inc. All rights reserved.@Intelligrated
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
How to Make 99.9% Uptime a Reality
Honeywell Confidential - ©2019 by Honeywell International Inc. All rights reserved.@Intelligrated
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
How to Make 99.9% Uptime a Reality
CASE STUDY:
HOW MUCH DOWNTIME WOULD THIS EVENT CAUSE IN YOUR FACILITY?
11How to Make 99.9% Uptime a Reality
Honeywell Confidential - ©2019 by Honeywell International Inc. All rights reserved.@Intelligrated
POLLING QUESTION
Are you using operational data to drive productivity
in real time during production?
• Yes
• No
• I’m not sure / don’t know
12How to Make 99.9% Uptime a Reality
Honeywell Confidential - ©2019 by Honeywell International Inc. All rights reserved.@Intelligrated 13
DATA DRIVES OUTCOMES
CREATE
DATA
STRATEGY ESTABLISH
BUILDING
BLOCKS
IMPLEMENT
THE PLAN DELIVER
OUTCOMES
DEFINE
OUTCOMES
How to Make 99.9% Uptime a Reality
Honeywell Confidential - ©2019 by Honeywell International Inc. All rights reserved.@Intelligrated 14
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?
How to Make 99.9% Uptime a Reality
Honeywell Confidential - ©2019 by Honeywell International Inc. All rights reserved.@Intelligrated 15
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
How to Make 99.9% Uptime a Reality
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