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Smart Manufacturing
1. DXC Proprietary and Confidential
June 28, 2017
Smart
Manufacturing
M. Sc. Lukas Ott
Sommersemester 2017
Hochschule Aschaffenburg
2. June 28, 2017 2DXC Proprietary and Confidential
Thrive on change
CSC and HPE Enterprise
Services brought innovation
to clients for 60+ years
Together, we serve nearly
6,000 private and public
sector enterprises across
70 countries
Our clients benefit from our
technology independence,
global talent, expertise and
extensive partner network
We are uniquely positioned to
lead digital transformations,
creating greater value for our
people, clients and partners
DXC Technology is the world’s leading independent, end-to-end IT
services company. We guide clients on their digital transformation
journeys, multiply their capabilities, and help them harness the
power of innovation to thrive on change.
3. June 28, 2017 3DXC Proprietary and Confidential
DXC Technology at a glance
$25BGLOBAL IT
SERVICES LEADER
250+PARTNER NETWORK WITH
BEST-OF-BREED PARTNERS
60+YEARS OF INNOVATION EMPLOYEES
WORLDWIDE
170,000+ 91DATA CENTERS
COUNTRIES
70+ CERTIFIED PROJECT
MANAGERS
3,600+37STRATEGIC
DELIVERY
CENTERS
~6,000CLIENTS
200+ Fortune 500 companies14 STRATEGIC PARTNERS
4. June 28, 2017 4DXC Proprietary and Confidential
Agenda
• Smart manufacturing
• ISA 95 – Unternehmensebenen
• Short Interval Technology (SIT)
• Diskussionsrunde “Die Zukunft der Produktion”
5. June 28, 2017 5DXC Proprietary and Confidential
Smart manufacturing
• Big data processing
• Advanced robotics
• Industrial connectivity devices and services
• Cyber Physical Systems
6. June 28, 2017 6DXC Proprietary and Confidential
Smart Connected Manufacturing
Three strategic options for digitalisation in manufacturing industries
Expand the
top line
Connected
Customer
eXperience
Defend the
core
Connected
Operations
Excellence
Exploit the
opportunities
Connected
Business
Models Digital Industry Services
marketplaces
Product-as-a-Service
new offerings
Startup – Scaleup – Incumbent
innovation networks
Connected Product
business ecosystems
Physical & Digital (Value Networks)
Product
Development
Manufacturing
Operations
Supply Chain
Operations
Service Chain
Operations
Manage
Business
Marketing
and Sales
Applications
Knowledge
Data-Driven
Services
“smart”
Functions
Core
Product ++
Usability & Innovation (Customer Touchpoints)
• Enhanced efficiency
through greater
automation
• Customized products
at the cost of a mass-
produced product
• Higher revenues
from digitally refined
products
• Access to new
markets
• Leverage internet
business platform
scale and speed
• Collaborate with
digital natives
Digital Factory Digital Logistics Digital MRODigital TwinDigital Customer
7. June 28, 2017 7DXC Proprietary and Confidential
Gartner Hypecycle - Explained
8. June 28, 2017 8DXC Proprietary and Confidential
Gartner Hypecycle – Manufacturing - 2016
On the Rise
Blockchain/
Distributed Ledgers
in Supply Chain
Execution
Cyber Physical
Systems
Cognitive
Expert Advisors
Digital Twin
Talent Science
Digital Business
Smart Robots
At the Peak
Machine Learning
Predictive Analytics
IT/OT Convergence
and Alignment
Sliding Into the Trough
Cloud Computing in Manufacturing Operations
Supply Chain Execution Convergence
Internet of Things for Manufacturing Operations
Manufacturing Segmentation
3D Printing in Manufacturing Operations
Supply Planning
Synchronized BOMs
Corporate Social Responsibility
Industrial Operational Intelligence
Asset Performance Management
Climbing the Slope
Center of Excellence
Lean Production Systems
Supplier Quality
External
(Third-Party) Manufacturing
Operational Technology Security
Digital Manufacturing
Mobility in Manufacturing
Operations
Overall Equipment Effectiveness (OEE)
Track-and-Trace and Serialization
Manufacturing Network Design
9. June 28, 2017 9DXC Proprietary and Confidential
Iron Triangle of quality
10. June 28, 2017 10DXC Proprietary and Confidential
Iron triangle of production
11. June 28, 2017 11DXC Proprietary and Confidential
Production as control loop
Input (article,
amount, date,
quality, costs,
etc.)
ruler production
measuring
element
disturbances
(technical/
organizational)
article, amount,
date, quality,
costs, etc.
-
Source 2: Die perfekte Produktion
12. June 28, 2017 12DXC Proprietary and Confidential
ISA 95 – Enterprise layers
Business Planning
& Logistics
Manufacturing
Operations
Management
13. June 28, 2017 13DXC Proprietary and Confidential
ISA 88 – Batch Controlled Production
Design patterns for software,
assets and processes
14. June 28, 2017 14DXC Proprietary and Confidential
Control loop with ERP-system
ERP-system production
manual
confirmation
(day / shift)
-
Source 2: Die perfekte Produktion
Input (article,
amount, date,
quality, costs,
etc.)
disturbances
(technical/
organizational)
article, amount,
date, quality,
costs, etc.
15. June 28, 2017 15DXC Proprietary and Confidential
Control loop with MES-system
production
MES-system
data acquisition (real-
time)
ERP-
system
-
MES-system
Short-term. control
-
Short-term data
Long-term data and
evaluations, production
acknowledgment
Source 2: Die perfekte Produktion
Input (article,
amount, date,
quality, costs,
etc.)
disturbances
(technical/
organizational)
article, amount,
date, quality,
costs, etc.
16. June 28, 2017 16DXC Proprietary and Confidential
Automation pyramide
ERP / PPS
MES
Automation
Mid-term
Real-time &
technology
Machine- level
APS
System control
Source 3: MES- Fig1.2
18. June 28, 2017 18DXC Proprietary and Confidential
Job-shop manufacturing
Examplary for
one product A
process 2
cutting
process 1
pressing
process 3
screwing
process 6
painting
process 4
process 5
19. June 28, 2017 19DXC Proprietary and Confidential
Flow production
process 2
cutting
process 1
pressing
process 3
screwing
process 4
painting
20. June 28, 2017 20DXC Proprietary and Confidential
Group manufacturing
cuttingpressing
screwing painting
Group 1 Group 2
21. June 28, 2017 21DXC Proprietary and Confidential
Make-to-Order / Engineer-to-Order
Station B
Cutting
Station A
Pressing
Station C
Screwing
Station D
Painting
22. June 28, 2017 22DXC Proprietary and Confidential
Short Interval Technology
• Lean Production (Schlanke Produktionsprozesse)
• Manufacturing Execution System (MES)
• Lean Planning (Schlanke Planungsabläufe)
• Manufacturing Scorecard (Prozessorientierte Kennzahlen)
23. June 28, 2017 23DXC Proprietary and Confidential
The weak points of classical production
• to strong focus on individual processes
• lacking transparency
• lacking quality
• lacking efficiency
• exaggerated inventory
• long cycle times
• bad adherence to delivery dates
24. June 28, 2017 24DXC Proprietary and Confidential
Individual processes – horizontal isolation
25. June 28, 2017 25DXC Proprietary and Confidential
Functional level – vertical isolation
26. June 28, 2017 26DXC Proprietary and Confidential
The building blocks for perfect production
• clarification of status quo
• lean production processes
• lean information sequences
• process oriented operating figures
• Near real-time availability of information (data-centric approach)
• Manufacturing Execution System
• Advanced Analytics
• OEE – Index = availability rate * performance rate * quality rate
27. June 28, 2017 27DXC Proprietary and Confidential
Lean Production
1. over production
2. waiting time
3. transportation
4. inefficient processing
5. inventory
6. needless movement
7. errors
Waste through lacking staff integration and motivation
Waste through bad information interfaces
28. June 28, 2017 28DXC Proprietary and Confidential
Increase of machine and factory productivity
• 5S-methode
• Seiri (sort out)
• Seiton (adjust)
• Seiso (clean)
• Seiktesu (standardize)
• Shitsuke (self-discipline)
• Setup Time Reduction (SMED)
• observe, measure and document
• classify in internal and external tasks
• eliminate unnecessary tasks
• document and train
29. June 28, 2017 29DXC Proprietary and Confidential
Increase of machine and factory productivity
• Total Productive Maintenance (TPM)
• removal of main focus issues
• autonomous maintenance
• planed maintenance
• preventive maintenance
• education and training of the staff
• Optimization of the value stream
• orientation on the customer pulse
• introduction of flow production (One Piece Flow)
• introduction of FIFO or KANBAN-supermarkets
30. June 28, 2017 30DXC Proprietary and Confidential
Support of the continuous improvement processes
31. June 28, 2017 31DXC Proprietary and Confidential
Target-oriented process improvement
• focus on the overall process
• increase of transparency
• improvement of quality
• increase of machine and workstation efficiency
• reduction of inventory
• reduction of cycle times
• improvement of delivery dates
• effective staff integration
32. June 28, 2017 32DXC Proprietary and Confidential
Corporate management for data collection
33. June 28, 2017 33DXC Proprietary and Confidential
Digital Twin
34. June 28, 2017 34DXC Proprietary and Confidential
Production control as a control loop – detailed view
35. June 28, 2017 35DXC Proprietary and Confidential
Integration of the software landscape into the company
caption:
CAD Computer Aided Design
CAE Computer Aided Engineering
CAM Computer Aided
Manufacturing
DIS Distribution
DMS Document Management
System
ERP Enterprise Resource
Planning
FIN Finance
MES Manufacturing Execution
System
NC Numerical Control
PDM Product Data Management
PLM Product Lifecycle
Management
PPS Product Planning and
Scheduling
36. June 28, 2017 36DXC Proprietary and Confidential
The integrated production database
40. June 28, 2017 40DXC Proprietary and Confidential
Conflicting objectives in production planning
Low
set-up costs
Constant
capacity load
utilization
High degree of on-
time delivery
performance
Low work
in progress
Individual goal
41. June 28, 2017 41DXC Proprietary and Confidential
ORGANIZATION:
Focuses on the people within the enterprise:
their culture, their capabilities, their roles, their
team structures, and their organizational units
LOCATION:
Specifies where the enterprise does
business, both in terms of geographic
location types and in terms of specific
physical facilities at specific locations
BUSINESS PROCESS:
Addresses what the enterprise
does, how it does it, in what
sequence it does it, what rules
it follows, and what type of
results it obtains
TECHNOLOGY:
Identifies the hardware, system
software, and communications
components used to support the
entire enterprise
APPLICATION:
Encompasses the capabilities, structure, and user
interface of software provided to the business users
DATA:
Addresses the content, structure,
relationships, and business data
rules surrounding information the
enterprise retains permanently
P
O
L
D
A
T
Domains of Change in a Holistic Perspective
42. June 28, 2017 42DXC Proprietary and Confidential
Diskussionsrunde „Die Zukunft der Produktion“
Einfluss von Maschine Learning
43. June 28, 2017 43DXC Proprietary and Confidential
Outlook and abstract
Smart
manufacturing
Short Interval
Technology
Future of
manufacturing
44. June 28, 2017 44DXC Proprietary and Confidential
Thank you!
Questions?
Feedback!
45. June 28, 2017 45DXC Proprietary and Confidential
Sources
• https://www.heise.de/newsticker/meldung/Adidas-Sohlen-aus-dem-3D-
Drucker-fuer-den-Massenmarkt-3679027.html
• Die perfekte Produktion, Springer Vieweg, ISBN 978-3-662-45440-4
• Manufacturing Execution Systems – MES, Springer, ISBN 978-3-540-49743-1
• https://en.wikipedia.org/wiki/Value_stream_mapping
• https://en.wikipedia.org/wiki/Project_management_triangle
• https://en.wikipedia.org/wiki/PDCA
Volume, Velocity, Variety, Variability, Veracity, Visualization, and Value.
Velocity
Velocity is the speed in which data is accessible. I remember the days of nightly batches, now if it’s not real-time it’s usually not fast enough.
Variety
Variety describes one of the biggest challenges of big data. It can be unstructured and it can include so many different types of data from XML to video to SMS. Organizing the data in a meaningful way is no simple task, especially when the data itself changes rapidly.
Variability
Variability is different from variety. A coffee shop may offer 6 different blends of coffee, but if you get the same blend every day and it tastes different every day, that is variability. The same is true of data, if the meaning is constantly changing it can have a huge impact on your data homogenization.
Veracity
Veracity is all about making sure the data is accurate, which requires processes to keep the bad data from accumulating in your systems. The simplest example is contacts that enter your marketing automation system with false names and inaccurate contact information. How many times have you seen Mickey Mouse in your database? It’s the classic “garbage in, garbage out” challenge.
Visualization
Visualization is critical in today’s world. Using charts and graphs to visualize large amounts of complex data is much more effective in conveying meaning than spreadsheets and reports chock-full of numbers and formulas.
Value
Value is the end game. After addressing volume, velocity, variety, variability, veracity, and visualization – which takes a lot of time, effort and resources – you want to be sure your organization is getting value from the data.
Basis der ISA 95 ist die ISA 88
ISA 88 – Batch Controlled Production for software, assets and processes
Norm für chargenorientierte Fahrweise
Regelung mit ERP-System (Anwendungsmodule – SD (Sales und Distribution) , MM (Materials Mangment), Produktionsplanung (PP), QM, PS (Project System) , PM (Plant Maintenance))
Regelung mit ERP-System (Anwendungsmodule – SD (Sales und Distribution) , MM (Materials Mangment), Produktionsplanung (PP), QM, PS (Project System) , PM (Plant Maintenance))
Advanced Planning and Scheduling (APS)
Automatisierungspyramide
ISA-88
ISA-95
IEC-62264
Je nachdem ob Discrete Job-shop
Wertstromdigramm – Value stream map
Wertstromdigramm – Value stream map
Lean Production ( Überproduktion, Wartezeit, Transport, Ineffiziente Bearbeitung, Lagerung, Überflüssige Bewegungen, Fehler)
+ Verschwendung druch mangelnde Mitarbeitereinbindung und –motivation , Verschwendung durch schlechte Informationsschnittstellen
SMED (Single-Minute Exchange of Dies) – Single digit minute (less than 10 minutes)
OTED (One-Touch Exchange of Die)
“Maximize flexibility while maintanining productivity. „ - Jerry Hyouck Woo, Kim (DXC.technology) - 2017
Unterstützung des kontinuierlichen Verbesserungsprozesses (KVP)
PDCA-Circle
Each area of activity in corporate management has a particular data collection method assigned to it which is also independetn of the others
Avoid vertical isolation!
SPC - Statistical process control
NC – Numerical control
RFC - Request for Comments
OPC (object linking and embedding for process control)
Venetzung – mit Cloud und Mobility
Funktion – As a servivce
Semantisch – Daten mit Bedeutung für maschinen verständlich machen ( Zukunft A.I. / Sprachassisten)