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Overview session on selecting and implementing three critical technologies: Industrial Voice and Data Networks supporting mobile devices and radios; High Frequency RFID for tracking materials, products and assets; and Mobile HMI technologies supporting PanelView Plus 6 and FactoryTalk View SE.
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Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
PUBLIC INFORMATION
Innovations in Industrial Mobility TechnologyMotorola Solutions
Innovations in Industrial Mobility Technology
JIM HILTON | MANUFACTURING WW PRINCIPAL
FinishedGoods
Manufacture & Assembly DeliveryPacking ShippingReceiving SCADA
Quality Control Service
PROCESS Food & Beverage
CPG - Soft goods (i.e., Soaps)Pharmaceutical and medicinePaper, print, and publishing
Chemical, plastics, and rubberTextiles and apparel
DISCRETETransportation equipment
CPG - Hard goods (i.e...Toys)Industrial & electrical equipment Computer & electronic products
Furniture & office equipmentMedical equipment
DEFINING THE MANUFACTURING ENTERPRISE
40%of annual profits can be lost due to unplanned downtime
54%of US manufacturers say they lack a unified view of their plant floor information
PLANT & FACTORY
- “Manufacturing Transparency, Turning Visibility into Value,” Aberdeen Group
- “The Hidden Cost of Downtime: A Strategy for Improving Return on Assets,” Maintenance Technology
5
ENHANCE OPERATOR EXPERIENCEENABLE MOBILITY
Motorola ET1 - Client -
PanelView™ Plus 6- Server - VNC Pocket
Cloud
Unit Counts Receive, Act and Acknowledge Alarms Review Historical Trends
Free operators from stationary clients yet still provide quick information
6
ENHANCE OPERATOR EXPERIENCEENABLE MOBILITY
Motorola ET1 PanelView™ Plus 6
FactoryTalk® View SEVNC Pocket Cloud
Vmware View
Enable mobile operators to be proactive instead of reacting to alarms Autonomous Maintenance Retrieve Manuals, Drawing and Procedures from anywhere
Free operators from stationary clients yet still provide quick information
FactoryTalk View SE
For the Operators Monitoring process to keep production running
Identifying relationships to optimize the process
Operator
For the Production Manager Schedule, track production activity
Way production is running, ways to improve
Production
For the Engineering / Maintenance Manager Keeping plant running
Predictive maintenance, asset optimization
Engineering
For the Quality Manager How product was made, ensure compliance
Ways to improve product and yield
Quality
For the Executive Costs, schedules, production output Financial indicators, sustainability
Plant Mgmt.
The Pressure to Improve ProductivityWhat keeps manufacturers up at night ?
MOBILE OPERATOR“It has been unbelievable! The concept is fabulous. Operators take this with them and are immediately aware of alarms and can begin to investigate. What would have taken 2 operators now only takes one.”
Major Cheese Manufacturer10/2012
Mobile HMI Benefits# of Operators Per Shift# of Shifts Per Day# of Workdays Per WeekFully Burdened Cost Per FTE % of Operators Using Mobile HMI
Hours Worked per FTEHourly Labor Cost
Annual Expansion/Relocation Savings# of New HMI Stations Planned for Next 5 Years$ Average Cost of New Fixed HMI Hardware & Installation# of HMI Station Moves Planned for Next 5 Years$ Average Cost of Relocating an HMI Station% of New HMI Stations Eliminated by Mobile HMI% of Relocated HMI Stations Eliminated by Mobile HMI
$$ Saved
Response Time Improvement - Downtime & Scrap# of Process Alarms Per Operator Per Shift# Avg Response Time Minutes without Mobile HMI# Response Time Minutes with Mobile HMI
Downtime Savings % of Process Alarms Resulting in Downtime$ Downtime Cost Per Minute# of Downtime Minutes Per Alarm without Mobile HMI% of Downtime Saved with Faster Response
$$ SavedProduct Scrap Savings
% of Alarms Resulting in Scrap Product$ Product Scrap Cost Per Alarm% of Scrap Saved with Faster Response
$$ Saved
Data Entry Labor Savings# of Operator Rounds Per Operator Per Shift# of Data Entry Minutes to Record Round Data
Average Payback
< 3 months without WLAN
< 8 months with WLAN
PACKAGINGWORLD www.Packworld.comJanuary 2014 Issue
WIP (using RFID)TDM is able to use RFID to report vehicle receipt, production progress and shipping updates back to Ford in real time.
• Real Time Tracking Realized• “Precise” Visibility• Complete & Consistent data collection
• Real-time data and visibility streamline operations and decrease downtime
• Operators can focus solely on labor tasks with significantly less multitasking and data entry
• Plant-floor operations are much more fluid with reliable automated data capture
“The application makes decisions and directs traffic flow based on the information in the system, and it’s hands-off, so our operators aren’t riffling through paper, trying to see where things go and needing to make decisions. It’s all very visual,”
MOBILE MAINTENANCE IMPACT“The ET1/Mobile HMI is an excellent complement to our existing use of fixed local and networked based HMI. Putting the information in the hands of the craftsman working on the machine saves both time and resources. The ability to provide a graphical HMI interface as well as accessing work orders, parts lists, and manuals will allow us to reduce downtime and increase productivity. The uses of this device is only limited by your imagination.”
International Food Processor10/2012
Mobile Maintenance Benefits# of Maintenance Technicians Per Shift
# of Shifts Per Day
# of Workdays Per Week
# of Workweeks Per Year
Fully Burdened Cost Per FTE
% of Maintenance Techs Using Mobile HMI
Hours Worked per FTE
Hourly Labor Cost
Troubleshooting Time Improvement# of Maintenance Troubleshooting Events Per Shift
# Avg Troubleshooting Minutes without Mobile HMI
# Avg Troubleshooting Minutes with Mobile HMI
# of Technicians Involved Per Event without Mobile HMI
# of Technicians Involved Per Event with Mobile HMI
$ Downtime Cost Per Hour
$$ Saved
Data Entry Labor Savings# of Work Orders Per Maintenance Tech Per Shift
# of Data Entry Minutes to Record All Work Order Data at Shift End
$$ Saved
Average Payback< 4 months w/ existing WLAN
< 10 months with new WLAN investment
DRIVING EFFICIENCY on the Shop FloorBusiness Need (Line Side Inventory)
1. Large Elimination of paper based procedures2. Real-time Inventory Control
ROI Factors• Real-time control of 1200 orders per day, 15% increase in output• 1.8 million more shipments with 2200 fewer man hours• Less miss-shipment coupled with 98% inventory accuracy• Inventory levels declined by 121,000 cases
Business Need (Traceability & Quality) 1. Risk Mitigation2. Raw Material Lot Tracking / Unbroken Chain of Possession3. Product History & Genealogy4. Process Conditions, Movement & Status5. Isolate Impact of Process Variability
“We needed a solution that would allow us to comply with the FDA mandate, but at the same time, not disrupt the manufacturing processes we already had in place,” said Rick DePinto, IT manager for Ce De Candy. “The Motorola enterprise mobility solution met our firm timing and budget requirements, increased our productivity, and improved data quality and process efficiencies, while providing the superior ruggedness that is essential in our warehouse environment.”
Solution• Motorola Handheld devices & infrastructure• Manufacturing-driven control of inventory• Traceability – from “cradle to grave”
Driving Traceability in Produce
Project: To trace tomatoes and other produce using RFID. Tags will be placed on produce boxes and pallets
In the event of a recall, the state wants to be able to trace a product to the farm of origin and identity where inventories were sent, all within a few minutes.
Hawaii Dept of Agriculture1. Improve Quality and Freshness
2. Trace Product to Farm of Origin
3. Identify all Distribution Routes
Track & Trace (Traceability)
Asset Tracking (RFID Tray Tracking)Using trays with embedded RFID Chips and retro-fitting old trays with RFID Chips
• Inside the ‘Four Walls’ • Track inventory within warehouse• Store batch data like expiration date
• Outside the ‘Four Walls’• Minimize Tray Loss• Track and charge customers that
lose trays for trays’ cost
• When using ‘Full Tray Product’• Inventory transport and delivery trucks faster• Automatic ordering based on counts
WARNING Line 6! E-stop Pressed
Marquee Manager Gateway for:• OPC • ODBC• RSLinx • FactoryTalk View SE• RSView32
• FirstPAGE Server• FirstPAGE Alarm Manager Server• Marquee Manager Server
FirstPAGE Alarm Manager Gateway for:• OPC • ODBC• RSLinx • FactoryTalk View SE• RSView32
MOTOTRBO Radios
The SolutionSoftware Bridge from Plant Floor alarms & events to mobile devices and two-way radios
STAFF COMMUNICATIONSALARMS AND ALERTS
WARNING Line 6! E-stop pressed
OPTIMIZING ACROSS THE ENTERPRISE
Real Time AlertsEnterprise Wide ImprovementsService, Productivity, Efficiency, Inventory,
…more
• Service Alerts• Order Submission• Inventory Allocation• Delivery Notification• Management Alerts• Competitive Activity
• Pricing Updates• Inventory Visibility• Service Directives• Collections Notes• Promotion Approvals• More…….
From and To all Mobile Users
77%correlation between profitability and inventory turns
10%of the inventory value is the typical cost of carrying inventoryWAREHOUSE
& DC
- “Demand-Driven Inventory Optimization and Replenishment: Creating a More Efficient Supply Chain,” by Robert A. Davis, 2013
- “Inventory Optimization: Show Me the Money,” Supply Chain Management Review, July 19, 2011
NEW INNOVATIONS
More capable devices and networks…Smaller: New categories of mobile devices are
now possible to connect entire workforces
Digital: Combined voice and data applications, with movement towards IP for interoperability
Wearable: Superior ergonomics drive productivity, accuracy and data capture for traceability
Modular: Hardware serving your micro-niche
Browser-Driven: Flexible OS and UI capabilities
RFID-Enabled: Passive data collection for visibility
Service-Based: New procurement and pricing models ease burden and mitigate IT risks
Touch-Centric: Expanding capabilities data input and rich visual rendering in touch-centric devices
PAGE 21
UPGRADE INBOUND HANDLING OPERATIONS
• Speed up the flow• De-skill the workforce• Execute perfectly• Drive out waste
PROJECTED FIVE-YEAR GROWTH OF MULTIMODAL
VOICE AND SCREEN GUIDANCE BY 2018.
%
EFFIENCY in Yard and InfrastructureBusiness Need (Trailer Tracking)
1. Large production facility with many trailers, yards, and dock doors2. Resource intensive management involving all manual processes3. Lack of real-time, actionable information for assets in the yard4. Increasing distribution costs need mitigating strategy
ROI Factors• Facilitate yard process redesign• Drive yard operational efficiency• Expand asset visibility beyond the 4-walls to the yard• Reduce manual yard checks• Reduced late, demurrage and detention fees
Business Need (Operational Efficiency in Mobile Environment) 1. Enhance Inventory Accuracy & Warehouse Efficiency2. Provide Wireless Backbone to Support Laptop Needs
• Durability was Key – Moisture Resistant, High Heat• Cost, Proven Reliability and Strong Partnerships• Partner Experience in Site Surveys and Hardware Staging
ROI Factors• ROI in 9 Months• 10% Labor Savings – Achieved Almost Immediately• Increased Visibility into Real-Time Production By Line• Reduced Truck Load Time
50-70%of potential service revenue is lost because of poor record keeping and management
$1BAverage revenue lost each year by consumer packaged goods companies due to out of stock conditions on the retail shelf.
FIELD OPERATIONS
- AMR Research, via Zebra Technologies “Improving Route Accounting with Mobile Printing Applications”
- “A Comprehensive Guide To Retail Out-of-Stock Reduction In the Fast-Moving Consumer Goods Industry,” by Thomas W. Gruen, Ph.D., University of Colorado at Colorado Springs and Dr. Daniel Corsten, IE Business School Madrid24%
Of manufacturers indicate that ‘increased customer service orientation’ is the most important transformation to their company’s future business success over the next 3-5 years
OUR SOLUTIONS ARE BUILT ON A DEEP UNDERSTANDING OF THE CHALLENGES YOU FACE IN YOUR FIELD OPERATIONS.
FIELD SERVICEDIRECT STORE DELIVERY
PRE SALES & MERCHANDIZING
PROMPT SERVICE PROVIDED, FIRST TIME FIX COMPLETED
Dispatch receives work order and reconfigures existing route plan. Technician schedules are adjusted based on proximity, expertise, and equipment availability so work can be completed promptly, protecting customer satisfaction and reducing cost to serve.
SALES CALL COMPLETED, ORDER PROCESSED
Sales representative previews new product with store manager, secures initial order and end cap placement. Also notes competitive pricing and ensures planogram compliance while on site.
DELIVERY MADE, CUSTOMER INVOICED
The route sales representative delivers the perfect order and replenishes the shelf. Billing is completed quickly and accurately. During stop, store manager mentions intermittent issue with one of the refrigerators, so sales rep opens up ticket with the field service team.
1. OPTIMIZING SALES, DELIVERY, MERCHANDISING
Signature Capture Personal Area Network
“PAN”
Image / Video Utilization
Gained ProductivitySales Increases
Best Practice TrainingCompany Compliance
Innovation in Image Capture & ScanningDecreased Costs…… Proof of Performance…….. Productivity
WLA
N -W
iFiW
WA
N -
Carriers
+ +Improved RevenueDecreased Costs
Gained Productivity
Gained ProductivityDecreased CostsImproved Service
“Turn right onto East Avenue…”
Route Optimization • Bread Crumbing• Geo-Fencing
Asset Tracking• Geo-Coding• Goods localization
Fleet Management• Telematics Seamless integration• GPS and Engine diagnostics• DOT and IFTA Reporting
2. Practical Use of Telematics, GPS, Location Based Services
3. OPTIMIZING PRODUCTIVITY AND REVENUE RECOVERY
Voice RecognitionGained Productivity
Hands Free Capture
PCI Compliant PlatformDelivers New Savings
Debit / Credit PaymentIncreased Sales
Improved Revenue
Hands Free Data CaptureGained Productivity
Voice / DataConvergence
Voice (Person to Person)Decreased Cost
Gained Productivity
OPTIMIZING ACROSS THE ENTERPRISE
Real Time AlertsEnterprise Wide ImprovementsService, Productivity, Efficiency, Inventory,
…more
• Service Alerts• Order Submission• Inventory Allocation• Delivery Notification• Management Alerts• Competitive Activity
• Pricing Updates• Inventory Visibility• Service Directives• Collections Notes• Promotion Approvals• More…….
From and To all Mobile Users
Tools
Rockwell Microsite: http://www.motorolasolutions.com/rockwellautomation
www.plantcalculator.motorolasolutions.com
CALCULATING THE ROI FOR A MOBILITY PROJECT
Safety & Environmental• Soft and Hard Costs
Time Savings• Hard Costs – Downtime• Soft Costs – Labor Productivity
Equipment Savings• Hard Costs – Reconfiguration• Soft Costs – License Utilization
Material Savings• Hard Costs – Scrap / Waste
www.plantcalculator.motorolasolutions.com
Investment Type Technology Investment
Cost per Device $1,500
Wireless Coverage Cost per Plant $200,000
Other Upfront Costs (Software, Training, etc.)
$57,500
Recurring Service Contract Costs per Device
$250
Total 5 Year Investment $364,750
ROI in 3 months with Cost Reduction5% In downtime resolution10% In alarm troubleshooting time5% less scrap per downtime event
BEST PRACTICES FOR REALIZING YOUR CALCULATED ROI
Envision, Document, and Execute a Mobile Strategy
• Engage Cross Functional Team Representing All User Groups
Embrace the Opportunities for Nascent Solution Interfaces
• Control Systems (PLCs) – Mobilize and Route Alarms and Alerts
• Visualization & HMI – Operator Rounds, Maintenance Technicians
• ERP / WMS / MES Systems – Inventory Management, Asset Tracking, Traceability
Enhance ROI by Selecting Industrial Devices and Networks
• Operations-Critical Solutions Built for Your Workflows & Environments
• Size for Today and Tomorrow’s Voice and Data Communications Needs
Explore Joint Solutions from Encompass Partners
BUILDING A CUSTOM TCO MODEL
https://partnercentral.motorolasolutions.com/TCO
Motorola MFG Resources
• Industry Week Webinar: http://bit.ly/plantmobility
• MSI MFG Page: http://www.motorola.com/Business/US-EN/Business+Solutions/Industry+Solutions/Manufacturing
• Rockwell/Motorola Microsite: http://www.motorolasolutions.com/rockwellautomation
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
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Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
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