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Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.
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Rockwell Automation’s Connected Enterprise RA’s Modernization journey
Mick Mancuso Director of Manufacturing Operations April, 2017
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. PUBLIC 2
Agenda
Results
IT & OT Convergence
Operations’ Priorities
About Rockwell Automation
Lessons Learned
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Leading global provider of industrial power, control and information solutions
at A GLANCE
AUTOMATION SOLUTIONS for a broad range of industries
80+ COUNTRIES
22,000 EMPLOYEES
$5.9B
Technology innovation Domain expertise Culture of integrity &
corporate responsibility
SERVING CUSTOMERS FOR
113 YRS
FISCAL 2016 SALES
3
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. PUBLIC
Rockwell Automation Products
Connection Devices
Components Control & Visualization Platforms
Solutions / ETO
Push Button & Signaling Devices
Sensors & Switches
Small Controllers
Smart Motor Controllers
Logix Family
Performance & Visualization
Variable Frequency Drives
Custom OEM Panels
LV Control Centers
MV Control Centers
PRODUCT COMPLEXITY & LEAD TIME
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About Rockwell Automation Operations
The Connected Enterprise Implementation & Transformation
387, 000 SKUS
20 YEARS AVG PRODUCT
LIFE
PRODUCT TYPES • Stock + Configure to Order • Engineered to Order
UP TO 200 SKUs PER ORDER
15 PLANTS
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RA Manufacturing Objectives
In every Rockwell Automation manufacturing plant, our core objectives are clear and they are standardized:
Safety & Security
Quality
Service
Productivity
6
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The Connected Enterprise
Time and Attendance
(Kronos)
Automation (ControlLogix)
Torque Control (Atlas Copco) Testers
(HP 3070)
Product Marking (Global Product Marking - GPM)
Automated Optical Inspection (Koh
Young)
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Process Example
8
Process 1 Process 2 Process 3
Operator 1 Operator 2 Operator 3
7 Mins 5 Mins 4 Mins
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Process Example
9
Process 1 Process 2 Process 3
Operator 1 Operator 2 Operator 3
4.5 Mins 4.5 Mins 4.5 Mins
When Process is Optimized, the next level of Productivity lies in: • Adherence to Process & Standards • Reducing Downtime • Making Decisions Quicker - Real-Time Data Matters • Eliminating Defects
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IT & OT Convergence
Production Floor
REPORTING EXECUTION APPLICATION INTEGRATION
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Reporting
Standard Reporting Data Exports • Labor Variance • Down time • Defects • Production Status • Order History • Thru put
• Indirect/Direct Labor • Order Complexity/Variance • Defects analysis • Engineering Change analysis • Work Cell Efficiency • Training – Worker Flexibility
Shop Floor Performance Management - Dept Performance - Performance Mgmt - Engineering Quality - Root Cause Analysis
- Quick Problem Solving
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Execution
Production Cell Performance Displays – Actionable Information
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Remote Dashboard Monitoring
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Printed Circuit Board Assembly Example
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PowerFlex Drive Assembly Example
Quality & Productivity Improvement – Closed Loop, Guided Manufacturing with Integrated Smart Assets
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VantagePoint Event Tracking
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Application Integration
• Engineering Changes • MIR / OCN changes SharePoint
• Labor Reporting • Kronos
• Continuous Improvement • FileMaker Training Documents
• Quality • Global Product Marking linkage
• DC Electric Tools
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. PUBLIC
Our Situation Now
We have clearer visibility into every plant’s operation
Best practices are more accurately identified and proliferated using consolidated analytics
Using real-time data, more profitable decisions are easier to make
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Safety & Security Access points and control MES vs. ad-hoc Excel solutions
Quality
Defect detection & containment Training documented & controls to stop Operator
Delivery
Fast-track process for expedites Continue to run Operation while doing ERP system
maintenance
Improvements in Objectives
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Inventory
120 days to 82 days
CapEx 30% per year in
capital avoidance Productivity ► 4% to 5% yearly productivity*
Delivery
Mid-80s to 96%
Lead Times Reduced 50%
Time to Want
82% to 98%
Quality 50% reduction in
PPM
Rockwell Automation Journey Video
THE CONNECTED ENTERPRISE Rockwell Automation Transformation
* Productivity gains offset inflation and fund investments
OES’s Vision for Our Connected Enterprise
- The Connected Supply Chain -
Analytics: The discovery and communication of meaningful patterns in data
Some Key Takeaways
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• Senior Management Sponsorship Required • Strong IT and OT Collaboration is Essential • Don’t Underestimate the Culture Change Required • Create a “Win” … Others Will Follow • Must be Tied to Business Strategy … Not a Stand Alone Initiative • Focus on Critical KPIs … Versus Data • Never Ending Journey … Close Monitoring Required
Faster Time to Market
Improved Asset Utilization $ Lower Total Cost
of Ownership Enterprise Risk Management
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