Make Every Operator an Expert - GE Automation & Controls · report”... A Business Process is... ... HMI ERP PLM Legacy Apps Using existing systems, layer on top SOA – Service

Work Process Management

Make Every Operator an Expert

2 /GE /

Agenda

9:00 – 9:30 Welcome and Breakfast Refreshments

9:30 – 10:30 Work Process Definition and ContextIndustrial Strength Work Process Management

10:30 – 10:45 Break

10:45 – 11:45 Production Work Processes Examples

11:45 – 12:00 Who we are and our solutions

12:00 – 1:30 Lunch

3 /GE /

The Age of Turbulence

Reset Assumptions

Risk, Asset Values, Commodity Prices, Exchange

Rates, Supply Networks

Financial Discipline

Projects That Deliver Positive Cash Flow < 6 months

Visibility

The Only Weapon Against Volatility

Adaptability

Masters of Change Will Win

Opportunity

““““I guess I should warn you, if I turn out to I guess I should warn you, if I turn out to I guess I should warn you, if I turn out to I guess I should warn you, if I turn out to

be particularly clear, you've probably be particularly clear, you've probably be particularly clear, you've probably be particularly clear, you've probably misunderstood what I've saidmisunderstood what I've saidmisunderstood what I've saidmisunderstood what I've said””””

----Alan GreenspanAlan GreenspanAlan GreenspanAlan GreenspanFormer US Federal Reserve ChairmanFormer US Federal Reserve ChairmanFormer US Federal Reserve ChairmanFormer US Federal Reserve Chairman

4 /GE /

Agile To Learn and Drive ChangeDrive Sustainable Business Value Through Work Process

ComplexityComplexityComplexityComplexityLowLowLowLow

HighHighHighHigh

Bu

sin

ess

Bu

sin

ess

Bu

sin

ess

Bu

sin

ess

Va

lue

Va

lue

Va

lue

Va

lue

Hig

hH

igh

Hig

hH

igh

What might happen?

What is happening?

Why did it happen?

ReportingReportingReportingReportingWhat happened?

Co

ntr

ollers

hip

Op

era

tio

ns

Excell

en

ce

Gro

wth

Hindsight ForesightCurrent

AnalysisAnalysisAnalysisAnalysis

MonitoringMonitoringMonitoringMonitoring

PredictivePredictivePredictivePredictiveAnalyticsAnalyticsAnalyticsAnalytics

ScheduleOptimization

Alerts

Dashboards MaterialOptimization

History

ProcessOptimization

Work

Pro

cess

Work

Pro

cess

Work

Pro

cess

Work

Pro

cess

Optimiza

tion

Optimiza

tion

Optimiza

tion

Optimiza

tion

4

5 /GE /

Work Process Definitionand Context

Challenges our businesses face...

7 /GE /

A Process is...A Process is...A Process is...A Process is...A method of dealing with in a routine way; "I'll handle that one"; "process a

loan"; "process the applicants“; “I will clean the equipment”

Procedure: a particular course of action intended to achieve a result; "the

procedure of obtaining a driver's license"; “submitting my expense

report”...

A Business Process is...A Business Process is...A Business Process is...A Business Process is...A business process is a set of coordinated tasks and activities, conducted

by both people and equipment, that will lead to accomplishing a specific

organizational goal.

Business Process Management is...Business Process Management is...Business Process Management is...Business Process Management is...Business Process Management (BPM) is a systematic approach to

managing and improving business processes.

Process Definition

8 /GE /

A Business ProcessExpense Reimbursement

Submit Expense

Report

9 /GE /

Traditional Business Process Management

Level 4

Level 1

Level 2

Level 3

Business Planning

& LogisticsPlant Production Scheduling,

Operational Management, etc

Manufacturing

Operations ManagementDispatching Production, Detailed Production

Scheduling, Quality Assurance, ...

DiscreteControl

BatchControl

ContinuousControl 1 - Sensing the production process, manipulating

the production process

2 - Monitoring, supervisory control and automated control of the production process

3 - Workflow / recipe control, stepping the process through states to produce the desired end products. Maintaining records and optimizing the production process.

Time FrameShifts, hours, minutes, seconds

4 - Establishing the basic plant schedule -production, material use, delivery, and shipping. Determining inventory levels.

Time FrameMonths, weeks, days, shifts

Process Customer Order

Create an InvoiceSubmit an Expense Report

Returned Product

Ship Order

10 /GE /

Business Process ManagementRapid Adoption Happening Now

Significant Results from BPM

“We reduced processing time from 6 weeks to 48

hours and the associated labor by 70%.”

“We increased transaction capacity by 50% and

reduced staff and processing time by 30% each.”

• Improve conformance• Ensure compliance• Increase throughput• Reduce rework• Reduce resources

• Reduce work in progress• Improve understanding• Reduce training requirements• Reduce progress chasing• Improve ability to meet dates

11 /GE /

A Work ProcessManual Quality Check

Take Raw Material Sample

12 /GE /

We have 1000s of Work ProcessesPeople are involved in many

Receive Materials

Quality Check Raw Material

Quality Check Finish Product

Metal Detector Check

Setup M

achine

Corrective Action Product Deviation

Quarantine

Product

Package

Finish Goods

Store Product

Cor

rect

Ala

rm

Dispatch Production Order

Scrap Product

Rework Product

Check Adhesive Levels

13 /GE /

Other Types of Work ProcessesPeople are not involved

Send Order from ERP to

Production System

Correct Alarm

Send production

results to ERP

Coordinate equipmentoperation

Monitor production

metrics

Condition data for a spreadsheet

Prevent downtime

Escalate expired

work requirements

Notify supplier of

low inventory levels

Work Process ManagementIn the Production Environment

Level 4

Level 1

Level 2

Level 3

Business Planning



Manufacturing



DiscreteControl

BatchControl








RealRealRealReal----TimeTimeTimeTime BrickwallBrickwallBrickwallBrickwall

ERP <-> Production System

Production Order Completed

Backflush Inventory

Maintenance ExecutionActual Production Order Status

Production Order DispatchingEngineering and Spec

Changes

Corrective Action

Maintenance

Task Management

Digitized Work InstructionsTask Execution

Station-Level Control

Manual Data Entry

Alarm Analysis and Action

Mfg Intelligence Data

Condition Monitoring

15 /GE /

Roadblocks to Effective Work Process Management

• Maintaining and updating written SOPs is very time consuming and expensive

• Roll out and training people to use SOPs is very time consuming and expensive

• Monitoring conformance and compliance to SOPs is very time consuming and expensive

• Execution performance feedback lags and is subjective and inaccurate

• People that know the process best typically do not create the process

16 /GE /

Overcoming Roadblocks

An Industrial StrengthWork Process Management System

17 /GE /

Key elements of an effectiveWork Process Management System

• Work Processes must be able to be developed by the people who know

the process best

• Work Processes must be able to be created and deployed quickly to

solve problems and get control of a process immediately

• Work Processes must be able to be executed with very little training

• Work Processes must be able to be managed throughout the plant

with little effort

• Execution performance feedback must be real-time and accurate so

that process improvements can be implemented immediately

• Work Processes must be able to be implemented on top of existing

systems

18 /GE /

A Work Process Management System

Workflow AuthoringWorkflow AuthoringWorkflow AuthoringWorkflow Authoring

Workflow ExecutionWorkflow ExecutionWorkflow ExecutionWorkflow Execution

Task Task Task Task InboxInboxInboxInbox

Workflow Design Workflow Design Workflow Design Workflow Design and Definitionand Definitionand Definitionand Definition

Workflow Monitoring Workflow Monitoring Workflow Monitoring Workflow Monitoring and Control and Control and Control and Control

Interaction with People, Equipment and ApplicationsInteraction with People, Equipment and ApplicationsInteraction with People, Equipment and ApplicationsInteraction with People, Equipment and Applications

WorkflowWorkflowWorkflowWorkflow

Authoring Authoring Authoring Authoring

EnvironmentEnvironmentEnvironmentEnvironment

Workflow Workflow Workflow Workflow DefinitionDefinitionDefinitionDefinition


Execution EngineExecution EngineExecution EngineExecution Engine

Hosted ApplicationsHosted ApplicationsHosted ApplicationsHosted Applications

Process EquipmentProcess EquipmentProcess EquipmentProcess Equipment

Automated Automated Automated Automated WorkflowsWorkflowsWorkflowsWorkflows

Interactive WorkflowsInteractive WorkflowsInteractive WorkflowsInteractive Workflows

RealRealRealReal----Time SOATime SOATime SOATime SOA

ERP <-> Production System

Production Order Completed

Backflush InventoryMaintenance Execution

Actual Production Order Status

Production Order Dispatching

Engineering and Spec Changes

Corrective Action

Maintenance

Task Management

Digitized Work Instructions

Task Execution

Station-Level ControlManual Data Entry

Alarm Analysis and Action

Mfg Intelligence DataCondition Monitoring

19 /GE /

Task Inbox

My Tasks

The Task Steps

that must be worked on

Detailed

instructions and input

Graphically define a Work Process

Managing Tasks

22 /GE /

Process Feedback and Reporting

Se

cu

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Core ServicesCore ServicesCore ServicesCore Services

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Lic

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SQ

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Service ProvidersService ProvidersService ProvidersService ProvidersH

MI

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ga

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Using existing systems, layer on topSOA – Service Oriented Architecture - The Basics

RealRealRealReal----Time Services BusTime Services BusTime Services BusTime Services Bus

Data and ServicesRepository

SetupSetupSetupSetupMachineMachineMachineMachine

ProduceProduceProduceProduceProductProductProductProduct

InspectInspectInspectInspectProductProductProductProduct

PackagePackagePackagePackageProductProductProductProduct

PackagePackagePackagePackage& Ship& Ship& Ship& Ship

Production Process

UniversalClient

24 /GE /

Se

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iSOA – Core and Service Providers

RealRealRealReal----Time Services BusTime Services BusTime Services BusTime Services Bus

Core ServicesCore ServicesCore ServicesCore Services Service ProvidersService ProvidersService ProvidersService Providers

Get AlarmsGet AlarmsGet AlarmsGet Alarms

AckAckAckAck AlarmsAlarmsAlarmsAlarms

Data ItemsData ItemsData ItemsData Items

Add ItemAdd ItemAdd ItemAdd Item

Remove ItemRemove ItemRemove ItemRemove Item

TagsTagsTagsTags

DisplaysDisplaysDisplaysDisplaysAckAckAckAck AlarmsAlarmsAlarmsAlarms

Equip ModelEquip ModelEquip ModelEquip ModelProcess SegmentsProcess SegmentsProcess SegmentsProcess Segments

Operations MgmtOperations MgmtOperations MgmtOperations Mgmt

Quality MgmtQuality MgmtQuality MgmtQuality Mgmt

Production EventsProduction EventsProduction EventsProduction EventsDowntime EventsDowntime EventsDowntime EventsDowntime Events

Waste EventsWaste EventsWaste EventsWaste Events

Production OrderProduction OrderProduction OrderProduction Order

Material ConsumedMaterial ConsumedMaterial ConsumedMaterial Consumed

MaterialsMaterialsMaterialsMaterials

Order StatusOrder StatusOrder StatusOrder Status

25 /GE /

Processes Enabled by iSOAAlarm Corrective Action Example


QuarantineQuarantineQuarantineQuarantineProductProductProductProduct

ManuallyManuallyManuallyManuallyInspectInspectInspectInspect

DispositionDispositionDispositionDispositionProductProductProductProduct

CreateCreateCreateCreateDeviationDeviationDeviationDeviation

Clear for Clear for Clear for Clear for ProductionProductionProductionProduction

Corrective Action Process

26 /GE /

Example Production Work Processes

27 /GE /

Most Common Work ProcessesWork InstructionsWork InstructionsWork InstructionsWork Instructions

---- Electronic Work Instructions / SOPsElectronic Work Instructions / SOPsElectronic Work Instructions / SOPsElectronic Work Instructions / SOPs

- "Standard Work" for Lean Initiatives – “Error proofing”

- Production Set Up

- Virtual Trainer

QualityQualityQualityQuality

---- Quality Hold:Quality Hold:Quality Hold:Quality Hold: Non Conformance, Rework and QuarantineNon Conformance, Rework and QuarantineNon Conformance, Rework and QuarantineNon Conformance, Rework and Quarantine

- QA Plan & Sampling

Corrective ActionCorrective ActionCorrective ActionCorrective Action

---- Alarm Management and Corrective ActionAlarm Management and Corrective ActionAlarm Management and Corrective ActionAlarm Management and Corrective Action

- Exception Management

- HACCP Monitoring Procedures

- Troubleshooting Trees: Equipment Repair & In-Process Product Repair

MiddlewareMiddlewareMiddlewareMiddleware

- Production Specification & Recipe Management

- Industrial Middleware

Most Popular

Most Popular

Most Popular

28 /GE /

Simple Work Process

One User, One Location

Pressing the Button triggers a

Workflow

Sample System

Provide details for completing the step

Get operator input to confirm

actions

Ask Operator to validate manual

steps

Use HMI Displays

for Operator

interaction

Operator can

change setpoints

through HMI

32 /GE /

HMI display is providing real-time feedback

The target flowrate has

been reached

The step will not

continue until all manual checks

have been validated

New input requirements for

this step

We moved to the

next step

Each step can deliver unique

instructions

Keeping track of

how long the workflow has taken so far

Many types of media can help complete steps

Final validation and comments

Electronic signature

of the person performing the work

Control is returned to the

HMI

Sample System

38 /GE /

Electronic Work InstructionsCovers a lot of level 2

Level 4

Level 1

Level 2

Level 3

Business Planning

& LogisticsPlant Production Scheduling,Operational Management, etc

Manufacturing



DiscreteControl

BatchControl








Digitized Work Instructions

Task ExecutionStation-Level Control

Manual Data Entry

39 /GE /

Moderate Complexity Work Process

Many Users, Many Locations

40 /GE /

Product QuarantineBased on real customer quarantine process

Work Process

1. Operational staff identify quality suspect product

2. Product put into quarantine

3. QA staff requested to review and decide action

4. Operational staff process action (Release, Rework or Scrap)

5. Finance notified if scrap amount significant

Current manual process

• Creates huge paperwork processing burden

• Costs the company as delays/losses in process causing the product to get too near to it’s expiry date:- Rejected/low sell price/fine from supermarkets- Unnecessary scrap

41 /GE /

People involved in the Work Process

UsernameUsernameUsernameUsername Job roleJob roleJob roleJob role

Paul Wynne Finance Manager

Sue Smith Product Stream Shift Manager: Shift 1

James Hall Product Stream Shift Manager: Shift 2

Tom Caesar Product Quality Co-ordinator

42 /GE /

Sue Smith –Product Stream Shift Manager (Shift 1) Logs in

43 /GE /

At Log in there are currently no

Workflows pending for Sue

Person logged in identified at top

of screen

Controls for display options and manually

starting new Tasks

at bottom

44 /GE /

Sue observes product issue on bottling line

and decides to initiate

the Quarantine workflow

45 /GE /

Steps of Quarantine

Workflow associated with

this user

New Quarantine initiated – No unique identifier until confirmed with

“Submit” button

Time since Workflow

started. Warning mails/messages can

be generated if runs

too long

Form to be Completed by

PSSM i.e. Sue

Work instructions, Standard

Operating Procedures (SOPs)

and other documents can

be linked and displayed at each step in Workflow

46 /GE /

Standard Operating

Procedures (Word

document) displayed within Workflow

47 /GE /

Top level details entered through

pull-downs as better for later

analysis

Current step highlighted in turquoise and by

progress bar

All fields must be completed before possible

to move on – including free comment fields

PSSM selects period of manufacture for

which product must be Quarantined

48 /GE /

Completion of previous

step highlighted with

tick mark, and current

step highlighted for execution.

Stop / Start, User and

other step details

stored to database for

later reporting.(Hover mouse over

step to see details)

After submit of previous

step, Workflow is confirmed and given

unique identifier

List of pallets manufactured

during selection Quarantine

period. PSSM asked to confirm

quarantine of these pallets.

49 /GE /

Next step completed and

system informs that an e-mail

has been sent to Tom Caesar

(Product Quality Coordinator PQC) for further processing.

No current task actions for Sue

Smith (hence blank form)

Product Quality Coordinator (Tom Caesar) receives e-mail that Workflow

is waiting for him and logs in …

51 /GE /

Tom Caesar –Product Quality

Coordinator Logs in

52 /GE /

Person logged in

Pending activity for Tom Caesar immediately highlighted at login

Steps of Quarantine

Workflow associated with

this userForm recalls quarantine details entered by PSSM.

PQC examines quarantined pallets and can review, edit, comment and verifies details

for quarantine.

53 /GE /

Following examination of quarantined product PQC selects those pallets for

release to distribution



tick mark, and current step highlighted for

execution.

54 /GE /

PQC selects those pallets from remaining quarantined

product (considering previous

step) to be written off or scrapped.

Another option could be Rework



tick mark, and current step highlighted for

execution.

55 /GE /

Next step completed and

system informs that an e-mail

has been sent to PSSMs.(Note: message sent to the

PSSM role rather than a

specific individual at this time)

56 /GE /

No pending tasks for Tom

Caesar (hence empty task list)

Product Stream Shift Manager (Sue Smith) receives e-mail that a Workflow is waiting for her

and logs in …

58 /GE /

Previously when Sue was

logged in, she had no pending actions, as the workflow was

waiting for the PQC (Tom) to

complete their actions.

As PQC completes actions Status of Quarantine task

updates for Sue to pending

59 /GE /

Sue is instructed to Scrap

those pallets identified by Quality Coordinator for write-

off, and then confirm (with the

Submit button) that it is done.

Note: Pallets released to distribution have their statuses

updated automatically and

have no manual action

60 /GE /

No pending tasks for Sue Smith.

Workflow for Quarantine is completed!

Finance Director is notified by e-mail that product over a threshold has

been written off. Logs in to check status ….

62 /GE /

Person logged in

Paul Wynne (Finance Director) is presented with

historic report of all

Quarantines (including the recent issue)

Report filterable (using SQL reporting)

63 /GE /

Report filtered on specific pallet

Details of Quarantine

recorded

64 /GE /

Total Pallets Quarantined

Pallets released to distribution

Total Pallets written-off

65 /GE /

Product QuarantineCovers many levels

Level 4

Level 1

Level 2

Level 3

Business Planning



Manufacturing



DiscreteControl

BatchControl








ERP <-> Production SystemInventory

Financial Records

Actual Production Order Status

Quality Quarantine

Corrective Action

Dispatch Product Orders

66 /GE /

High Complexity Work Process

Many Users, Many LocationsMany Systems

67 /GE /

Process Production OrderMixing automated and manual tasks

Task 1 Task 2 Task 3 Task 4

Set Up Machine, Download Recipe

Visually Inspect Product

Package Product Pallet and Ship

68 /GE /

Setup MachineTake the next production order, begin the setup

Task 1

Setup for Production

69 /GE /

Visual InspectionInspect and correct production issues

Task 2

Visually Inspect Product

70 /GE /

Package ProductPackage, Inspect, and Stage

Task 3

Package Product

71 /GE /

Process Production OrderMixing automated and manual tasks

Task 4

Pallet and Ship

72 /GE /

Process Production OrderCovers many levels and systems

Level 4

Level 1

Level 2

Level 3

Business Planning



Manufacturing



DiscreteControl

BatchControl








ERP <-> Production SystemActual Production Order Status

Inventory Movement

Customer Shipping

Quality Sampling

Corrective Action

Material Delivery

Production SetupQuality Sampling Trigger

Inspection Instructions

Packaging Instructions

Label Printing

73 /GE /

Our Operations ExcellencePortfolio

74 /GE /

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Proficy SOAProficy SOAProficy SOAProficy SOA

ModulesModulesModulesModules ServicesServicesServicesServices

HMIHMIHMIHMI HistorianHistorianHistorianHistorian Workflow Workflow Workflow Workflow MESMESMESMES 3333rdrdrdrd PartyPartyPartyPartyApplicationsApplicationsApplicationsApplications

Cim

plic

ity

Introducing the Proficy Operational Excellence Platform

75 /GE /

The Future…

Provide major cost savings from

simplifying and automating manual

processes, and realized big increases in

productivity

Enable the transformation of companies

from a collection of proprietary

operations into a collection of standard

plug-and-play activities.

The future of the Industrial IT

“Last year more than 50% of the mission-critical systems companies built in 2007 were SOA based, the figure will exceed 80% by 2010.”Source: Gartner Group, 2008

SOA for the Industry will:

76 /GE /

Proficy Workflow – Special Offer

Documents

Make Every Operator an Expert - GE Automation & Controls · report”... A Business Process is... ... HMI ERP PLM Legacy Apps Using existing systems, layer on top SOA – Service