Attendance List General Managersrsquo Meeting
September 10 2014 Attendees ABIMAQ - Brazilian Machinery Builders Association Brazil
Gustavo Marcelo Szymsiowicz General Manager CSMF AFM - Advanced Manufacturing Technologies Spain
Xabier Ortueta Director General Juan Joseacute Goacutemez International Department
AMDM - Asociacioacuten Mexicana de Distribuidores de Maquinaria AC (Mexican Machinery Distributors Association) Mexico
Ing Salvador Icazbalceta Valle President CP Duber Enrique Aguilar Campos General Manager
AMTIL - Australian Manufacturing Technology Institute Limited Australia
Shane Infanti CEO Paul Fowler President
Austrian Trade Commission (Representing FMMI ndash Association of the Austrian Machinery amp Metalware Industries) United States Office
Peter Sedlmayer Austrian Trade Commissioner Anders Benson Sector Manager Machines amp Metals
CARMAHE - Argentine Chamber of Machine Tools Argentina
Federico D Meligrana Dorin Executive Manager Jorge Goumlttert President Luis Lewin Vice President
CECIMO - The European Association of the Machine Tool Industries Belgium
Filip Geerts Director General CELIMO - European Association for Machine Tools Tooling amp Technologies United Kingdom
Geoff Noon Secretary - General
CMTBA - China Machine Tool amp Tool Buildersrsquo Association China
Chen Huiren President amp CEO Ms Zhang Jing Director
CMTDA - Canadian Machine Tool Distributors Association Canada
Frank Haydar President
-2- Gardner Business Media Inc United States
Rick Kline Sr President Ms Melissa Skavlem COO Travis Egan Publisher Rick Kline Jr Group Publisher Steve Kline Jr Director of Market Intelligence
GIE Media Inc United States
Tom J Grasson Associate Publisher (Aerospace Manufacturing amp Design) JMTBA - Japan Machine Tool Builders Association Japan
Yoji Ishimaru President Kazuhiko Tanaka Director International Marketing Department Futoshi Murata Assistant Manager Administration Department
JMTDA - Japan Machine Tool Distributors Asssociation Japan
Hiroshi Usami President JMTIA - Japan Machine Tool Importers Association Japan
Toshihisa Yamashita Executive Director Yuzo Chiba Chairman
KOMMA - Korea Machine Tool Manufacturersrsquo Association Korea
In-Ho Shin General Director Hee-Jeong Choi Coordinator Sunny Lee Interpreter
MIB - Association of Turkish Machine Manufacturers Turkey
Mrs Sevda Kayhan Yilmaz President M Nail Tuumlrker Secretary General
MTA - The Manufacturing Technologies Association United Kingdom
James Selka CEO Adrian Sell Membership amp Events Director
SST - Association of Engineering Technology Czech Republic
Oldrich Paclik General Manager SWISSMEM - Swiss Mechanical and Electrical Engineering Industries Switzerland
Christoph Blaumlttler Secretary General
-3- SYMOP - French Association for Manufacturing Technologies France
Jean Tournoux General Director TAMI - Taiwan Association of Machinery Industry Taiwan
CC Wang President Ms Lisa Weng Director of Exhibition Division
TMBA - Taiwan Machine Tool amp Accessory Buildersrsquo Association Taiwan
Carl CC Huang Secretary General Ms Stephanie Ho Specialist
UCIMU ndash Sistemi Per Produrre Italian Machine Tools Robots and Automation Manufacturers Association Italy
Dott Alfredo Mariotti General Manager Ing Alberto Nicolai Marketing Manager Ing Enrico Annacondia Technical Department Officer
VDW - German Machine Tool Builders Association Germany
Dr Wilfried Schafer Executive Director Gerhard Hein Director Economic Department
Speakers (in order of appearance) AMT - The Association For Manufacturing Technology United States
Douglas K Woods President
Oxford Economics United States
Gregory Daco Chief US Economist
FORCAM Inc United States
Franz E Gruber Founder amp CEO Dr Mohamed Abuali PhD COO
MTConnect Institute United States
Courtney J Hill Chairman amp President VDW ndash German Machine Tool Buildersrsquo Association Germany
Dr Wilfried Schaumlfer Executive Director
-4- Staff of AMT - The Association For Manufacturing Technology United States
Douglas K Woods President Steve Lesnewich Vice President - Global Services Knox Johnstone Global Services Director Malcolm Mason Global Services Director Mario Winterstein Global Services Director Patrick W McGibbon Vice President - Strategic Analytics Kate Fritz Strategic Analytics Director Jackie McFarland Industry Analyst Juan Guerra Industry Analyst Sebastian Herrador Industry Analyst
AMT - Beijing Representative Office China
Xingbin Li Chief Representative AMT - Shanghai Technology and Service Center China
Harry Xiao General Manager China Business Consultant to AMT Canada
Feng (Sean) Jiang Global Services Manager
AMT - Chennai Technology amp Service Center India
Arun Mahajan General Manager AMT ndash Monterrey Technology amp Service Center Mexico
Carlos Mortera General Manager AMT - CentralEastern Europe Liaison Poland
Hubert Sawicki Consultant - C amp E Europe AMT - Sao Paulo Technology Center Brazil
Achilles Arbex General Manager
GENERAL MANAGERSrsquo MEETING September 10 2014 800am ndash 100pm
McCormick Place West Hall mdash Rooms 470aampb 800 am ndash 830 am Continental Breakfast Room W470a 830 am ndash 845 am Welcome by Mr Douglas K Woods President AMT ndash The Association For Manufacturing Technology 845 am ndash 945 am Economic Outlook Global Economic Outlook Improvements But Risks Remain Mr Gregory Daco Chief US Economist Oxford Economics
Mr Gregory Daco is Chief US Economist at Oxford Economics He is responsible for producing the US macroeconomic forecast using Oxford Economicsrsquo proprietary Global Economic Model Gregory tracks and forecasts high-frequency indicators and oversees the production of US research pieces on consumer markets housing business investment international trade labor markets inflation and fiscal and monetary policy Gregory is frequently cited in leading business publications such as the Financial Times the New York Times and the Wall Street Journal and he regularly appears on radio and television programs Prior to joining Oxford Economics Gregory was Director US Macroeconomics at IHS Global Insight He also worked in the Economic Affairs Department of the Belgian Embassy in Australia and the Permanent Representation of Belgium to the UN in Geneva Gregory is co-founder and president of the Boston Chapter of the National Association for Business Economics He holds a Master of Arts in economics from Boston University and a Master in Business Administration from Universiteacute de Louvain in Belgium
945 am ndash 1000 am Break 1000 am ndash 1100 am Digital Manufacturing
World Class Shop Floor Management Release 5 The Smart Factory Revolution
Mr Franz E Gruber Founder amp CEO Dr Mohamed Abuali PhD COO FORCAM Inc
Mr Franz Gruber is the Founder Chairman and CEO of FORCAM A former IBM Manager and a veteran SAP Executive Franz has over 25 years of practical experience working directly with automotive aerospace and defense and medical devices discrete manufacturing industries Within a decade of founding FORCAM in Germany he strategically expanded company operations globally to the United Kingdom Eastern Europe and the United States FORCAMs technology now monitors and optimizes the performance of over 50000 industrial assets globally in automotive aerospace and defense machinery medical devices and other industrial sectors Dr Mohamed Abuali is responsible for leading and managing the full life cycle of FORCAMrsquos shop floor technology at discrete manufacturing companies in automotive aerospace medical devices and oil amp gas Mohamed brings 15 years of
manufacturing experience specializing in program and project management as well as research and development of shop floor technologies Dr Abuali has a PhD in Industrial Engineering through his studies at the Center for Intelligent Maintenance Systems (IMS) at the University of Cincinnati He is also a Project Management Professional (PMP) a Six Sigma Green Belt (SSGB) and a Certified Quality Engineer (CQE) FORCAM will be exhibiting at IMTS at Booth E-4929 and Dr Abuali extends an invitation to all to visit their booth to see interoperability in action
MTConnect Evolution of a Standard and Next Generation Interoperability Mr Courtney Hill Chairman amp President MTConnect Institute
Mr Courtney Hill retired from the General Electric Company after a 36-year career in manufacturing technology process development and commercialization Presently Courtney operates CJ Hill Consulting Services As the General Manager of Manufacturing Technology a global technology organization for GE Aviation Courtney was responsible for the development of next generation affordable manufacturing and inspection processes that support GE Aviationrsquos products and services worldwide Notable areas of recent technology development and commercialization include high performance structural composites additive manufacturing ceramic matric composites advanced robotic applications and digital manufacturing A graduate of Lehigh University Mr Hill currently serves as Chairman of the Board of the National Center for Manufacturing Sciences and the President and Chairman of the Board for the MTConnect Institute He has also served on the boards of TechSolve and the Edison Welding Institute
QampA Session 1100 am ndash 1115 am International Additive Manufacturing Award Dr Wilfried Schaumlfer Executive Director VDW ndash German Machine Tool Buildersrsquo Association Douglas K Woods President AMT ndash The Association For Manufacturing Technology 1115 am ndash 1145 am Open Forum
Open discussion on common issues pressing on the manufacturing technology industry markets and technological advances Examples of such issues bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment
Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
1145 am ndash 100 pm Reception amp Luncheon Room W470b
September 10 2014 2014 General Managersrsquo Meeting
Meeting Agenda 800 am - 830am Continental Breakfast 830 am - 845am Welcome by Mr Douglas K Woods 845 am - 945am Economic Outlook 945 am - 1000am Break 1000 am - 1100am Digital Manufacturing 1100 am - 1115am International Award for Additive Manufacturing 1115 am - 1145am Open Forum 1145 am - 100pm Reception and Luncheon
September 10 2014 2014 General Managersrsquo Meeting
Welcome
Mr Douglas K Woods President
AMT - The Association For Manufacturing Technology
September 10 2014 2014 General Managersrsquo Meeting
Economic Outlook
Mr Gregory Daco Chief US Economist
Oxford Economics
Global Economic Outlook Improvements But Risks Remain
Gregory Daco
Chief US Economist gregorydacooxfordeconomicscom
September 2014
Global economy on a modest growth path
After a roller-coaster ride in early 2014 the US economy should steady around 3 upcoming quarters
Eurozone improving but risks remain (deflation Ukraine)
Japan on a modest expansion path with inflation trending up but questions around the resilience of the economy (tax hike)
Additional support from the government has fed through to growth in China and the economy is now expected to come close to the governmentrsquos 75 growth target for this year
Outlook for other emergers is less positive Russiarsquos economy continues to suffer from structural weaknesses and the repercussions of the conflict in Ukraine Brazil and India are showing no signs of picking up with structural deficiencies weighing on growth
US pulling ahead after slow start to 2014
6
Eurozone outlook Caution slow recovery in progress
Eurozone recovery still ongoing buthellip
8
Strong disinflationary forces in the Eurozone
9
Recovery will be steady rather than spectacular
10
-8
-6
-4
-2
0
2
4
6
1999 2002 2005 2008 2011 2014 2017 2020
Source Oxford EconomicsHaver Analytics
Europe GDP year
UK
Eurozone
Forecast
Current situation not dramatic but full scale conflict hellip
11
-6
-5
-4
-3
-2
-1
0
1
2
3
4
2006 2008 2010 2012 2014 2016 2018
Eurozone GDP year
Source Oxford EconomicsHaver Analytics
BaselineForecast
Military conflict in Ukraine
China Outlook A bumpy landing
China growth to slow as rebalancing continueshellip
13
hellipas debt piles up to worrying levels
14
Real estate sector increasingly at risk
15
Japan Slowing in spite of Abenomics
Consumption tax weighs heavily on growth
17
2013 2014
-40
-30
-20
-10
00
10
20
30
Q3 Q4 Q1 Q2
Private consumptionFixed investmentNet exportsGovernment consumptionStockbuildingGDP
Japan Quarterly GDP contributions
quarterly contribution
Source Cabinet Office of Japan Haver Analytics
-3
-2
-1
0
1
2
3
4
1990 1995 2000 2005 2010 2015
Japan Fiscal policyChange in structural budget balance of GDP
Source International Monetary Fund Haver Analytics
ForecastExpansion
Contraction
Emergers Modest growth with structural issues
19
Does it still make sense to talk about ldquoBRICSrdquo
Some countries more vulnerable than others
20
1 Turkey 1182 S Africa 763 Brazil 404 Thailand 295 Russia 266 Malaysia 187 India 018 Poland 019 Mexico -2010 Indonesia -2511 Korea -8012 Philippines -9113 China -93
Oxford Economics Risk Scorecard
Emerging markets will still outpace developed world
21
US Outlook The US is the cleanest shirt in the laundry basket
GDP on a roller-coaster but employment is better indicator
19
Business surveys pointing to strong growthhellip
24
Consumers are feeling more cheerfulhellip
25
Wages expected to risehellip
26
Key domestic risk is housing activityhellip
27
hellipbut rising income and pent-up demand will help
24
Energy prices remain relatively stable
29
Fed to taper on but hold off on rate hikes
30
This image cannot currently be displayed
First rate hike in 2015Q2
Manufacturing in focus
Manufacturing activity is boominghellip
Further indication that GDP decline is due to unique factors
28
hellipwith encouraging signs from leading indicators
29
US manufacturing has outperformed its peershellip
30
US has made substantial gains in competitiveness
35
Remarkable improvements
Due to productivity gains amp modest wage growthhellip
36
Remarkable improvements
Business sentiment in Europe remains weak while new orders have slowed
37
China amp Brazil have lost their edgehellip
38
Chinese wages have more than doubled over the past decade
Key industries
Loose credit and rising demand for autoshellip
36
hellipshould support productionhellip
20
25
30
35
40
45
50
405060708090
100110120130140150160
Jul-09 Jul-10 Jul-11 Jul-12 Jul-13 Jul-14
2010=100 US$ bn
Output (LHS)
Orders (RHS)
Source Oxford Economics Haver Analytics
US Output and orders
3 month moving average
37
hellipas will opportunities in the Emergers
38
Revamp of car stock to be key long-term driver
Ageing vehicle fleet replacement as economy recovers ndash average age of vehicle on US roads in 11frac12 years
Rising fuel efficiency standards leading to replacement of clunkers
Rising fuels costs resulting in smaller cars
Automakers likely to increase new models helping drive investment
Aerospace solid order books at the big twohellip
0
250
500
750
1000
1250
1500
1750
1994 1996 1998 2000 2002 2004 2006 2008 2010 2012 2014
Source Company reports
Airbus versus Boeing Orders
Airbus
Boeing
Number of aircraft
Note 2014 annual estimate based on annualized data through July
40
hellipwith APAC to drive long-term growth
Asia will account for almost 32 of global passenger traffic by 2017 compared to 28 in 2012
APAC to account for 40 of plane deliveries over next 20 years
US and Europe sales mainly for replacement of existing fleet
41
Need for efficiency will provide demand supporthellip
A330 revamped for 15 efficiency improvement to compete with Dreamliner 25 new orders on day of announcement
Long-haul efficiency has some ways to go to maintain airline profitability
42
Order backlogs remain high
0
500
1000
1500
2000
2500
3000
3500
1990 1993 1996 1999 2002 2005 2008 2011 2014
Deliveries
Orders
Number of aircraftAirbus amp Boeing Orders amp deliveries
Source Company reports and forecasts
43
Weaker demand for metalshellip
44
hellipand over capacity are weighing on priceshellip
45
hellipand discouraging investment
BHP Capital spending fell 32 in FY14 with another 8 fall expected next year
Rio Tinto Capital spending in FY14 cut faster than initially projected and further cut is budgeted for 2015
This is weighing on equipment makers
Caterpillar reported sales down 9 in the three months to July with sales to mining firms down 33 from the same period a year earlier
Bumper crop has brought down grain prices
47
helliphitting margins and investment
Producers are facing higher costs due to the implementation of Tier 4 engines developed to comply with emissions standards
Weaker margins are leading to farmers cutting back investment spending
John Deere has posted a 5 yy decline in revenues with an 11 decline in its agricultural division
Conclusions amp market implications
Conclusion and business implications
54
bull US economy expected to gradually accelerate through 2014 with support from a dovish Fed
bull Europe expected to recover but more ECB action could be required
bull Chinese economy is gradually rebalancing but banking crisis cannot be discounted
bull Emerging markets quiet for now but structural issue unsolved
bull Geopolitical tensions in the Middle East and Ukraine are being monitored carefully
Thank you
Gregory Daco
Chief US Economist gregorydacooxfordeconomicscom
September 2014
September 10 2014 2014 General Managersrsquo Meeting
Digital Manufacturing
World Class Shop Floor Management Release 5 The Smart Factory Revolution Mr Franz E Gruber Founder amp CEO
Dr Mohamed Abuali COO FORCAM Inc
MTConnect Evolution of a Standard and
Next Generation Interoperability Mr Courtney J Hill Chairman amp President
MTConnect Institute
QampA Session
World Class
Shop Floor Management
The Smart Factory Revolution
Franz E Gruber
Founder amp CEO
Mohamed Abuali
COO
汉语
World Class Shop Floor Management
FORCAM 2014 Page 2
FORCAMlsquos Passion
FORCAM provides proven
manufacturing solutions to
Continuously Improve Productivity
To be the global solutions provider of
the best-in-class Manufacturing
Execution Systems
FORCAM 2014 Page 3
FORCAM ndash 2014 Best Practices Award by Frost amp Sullivan
Frost amp Sullivan
ldquoFORCAM is a plant production software
solution provider that understands and
supports Industry 40 needsrdquo
FORCAM 2014 Page 4
FORCAMrsquos Testimonials and Industry Leadership
FORCAM 2014 Page 5
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
6 B Bartke S Wagner IPI-2
Shop Floor Management Audi - FORCAM FIT 2011-
Bernhard Bartke - Director Components Manufacturing
Stefan Wagner - Director Gear Manufacturing
7 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
bull Collection and recording of Operational Data via a database
(ex Machine States and State Changes)
Machine
Operator
Production Manager
Technical Assistant IT
Plant
Manager
Team Leader
8 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Interfaces
Time
Objectivity of Process Data
9 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Need for Continuous Improvement
bull Objective Information and Communication ndash across ALL levels
bull Transperancy and Visualization - Online
bull Real-time availability of operational data ndash Live Reports
bull Measurable increase in Plant Efficiency (OEE)
10 B Bartke S Wagner IPI-2
Shop Floor Management ndash Realtime bdquoANDONldquo Visualization
bull Web-based Interface Anywhere Anytime Access
bull Real-time Production Status Visualization
In Production
Overflow
Stoppage
Organizational
Stoppage
Idle (Pause)
Tool
Problem
11 B Bartke S Wagner IPI-2
Shop Floor Management Reporting ndash Hierarchical Status Diagrams
bull Reporting for Machines Groups Lines or the whole Plant
Technical
Stoppage In Production
Organizational
Stoppage Pause Overflow
Stoppage
Tool Problem In Setup
12 B Bartke S Wagner IPI-2
Audi Production System (APS)
Leadership Communication
bull Process Control
Standards
bull In Processes
bull Im Products
bull In the Organization
Learning Organization
bull Employee Development
bull Problem-Solving
bull CIP Culture
13 B Bartke S Wagner IPI-2
Shop Floor Management Process Control Panel on the shop floor
OEE Trend
(Day Week Month)
Measures
Quality
Process Control
14 B Bartke S Wagner IPI-2
OEE - Yesterday
Availability Trend
OEE ndash Last Week
OEE ndash Last Month
Naoki Nojiri IPI-25 BDE-Ist Stand 05042011
Shop Floor Management Process Control Panel on the shop floor
15 B Bartke S Wagner IPI-2
Shop Floor Management Management Cockpit
Planned vs Actual
(shift)
Top problems
(challenges)
OEE ndash Last Week
16 B Bartke S Wagner IPI-2
hellipand what have we achieved
17 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development suspension components (OEE Overall Equipment Effectiveness)
Radtraumlger
Start Shop Floor Management with
FORCAM +10
_
18 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development (20+ Increase in OEE in AUDI Stamping Facilities) (OEE Overall Equipment Effectiveness)
Radtraumlger
Start SFM +20
_
Our Beliefs
Respect
Collaboration
Excellence
Integrity
Community
Oct 30th 2013
Lean with Shop Floor Management BorgWarner Turbo Systems Rzeszow
Operator FactoryFrameworktrade Worker Client- Book On
Operator Downtime Reasons
Operator Actual versus Target Performance
TargetPlanned
Throughput
Actual
Performance
Opportunity for
Improvement
Actual
Throughput Machine
Data
ERP
Data
Supervisor Gantt Status
visualzation
Top 5
downtimes
Cip Top 5
Production
orders
Real data
history
Supervisor Cockpit machine
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
-2- Gardner Business Media Inc United States
Rick Kline Sr President Ms Melissa Skavlem COO Travis Egan Publisher Rick Kline Jr Group Publisher Steve Kline Jr Director of Market Intelligence
GIE Media Inc United States
Tom J Grasson Associate Publisher (Aerospace Manufacturing amp Design) JMTBA - Japan Machine Tool Builders Association Japan
Yoji Ishimaru President Kazuhiko Tanaka Director International Marketing Department Futoshi Murata Assistant Manager Administration Department
JMTDA - Japan Machine Tool Distributors Asssociation Japan
Hiroshi Usami President JMTIA - Japan Machine Tool Importers Association Japan
Toshihisa Yamashita Executive Director Yuzo Chiba Chairman
KOMMA - Korea Machine Tool Manufacturersrsquo Association Korea
In-Ho Shin General Director Hee-Jeong Choi Coordinator Sunny Lee Interpreter
MIB - Association of Turkish Machine Manufacturers Turkey
Mrs Sevda Kayhan Yilmaz President M Nail Tuumlrker Secretary General
MTA - The Manufacturing Technologies Association United Kingdom
James Selka CEO Adrian Sell Membership amp Events Director
SST - Association of Engineering Technology Czech Republic
Oldrich Paclik General Manager SWISSMEM - Swiss Mechanical and Electrical Engineering Industries Switzerland
Christoph Blaumlttler Secretary General
-3- SYMOP - French Association for Manufacturing Technologies France
Jean Tournoux General Director TAMI - Taiwan Association of Machinery Industry Taiwan
CC Wang President Ms Lisa Weng Director of Exhibition Division
TMBA - Taiwan Machine Tool amp Accessory Buildersrsquo Association Taiwan
Carl CC Huang Secretary General Ms Stephanie Ho Specialist
UCIMU ndash Sistemi Per Produrre Italian Machine Tools Robots and Automation Manufacturers Association Italy
Dott Alfredo Mariotti General Manager Ing Alberto Nicolai Marketing Manager Ing Enrico Annacondia Technical Department Officer
VDW - German Machine Tool Builders Association Germany
Dr Wilfried Schafer Executive Director Gerhard Hein Director Economic Department
Speakers (in order of appearance) AMT - The Association For Manufacturing Technology United States
Douglas K Woods President
Oxford Economics United States
Gregory Daco Chief US Economist
FORCAM Inc United States
Franz E Gruber Founder amp CEO Dr Mohamed Abuali PhD COO
MTConnect Institute United States
Courtney J Hill Chairman amp President VDW ndash German Machine Tool Buildersrsquo Association Germany
Dr Wilfried Schaumlfer Executive Director
-4- Staff of AMT - The Association For Manufacturing Technology United States
Douglas K Woods President Steve Lesnewich Vice President - Global Services Knox Johnstone Global Services Director Malcolm Mason Global Services Director Mario Winterstein Global Services Director Patrick W McGibbon Vice President - Strategic Analytics Kate Fritz Strategic Analytics Director Jackie McFarland Industry Analyst Juan Guerra Industry Analyst Sebastian Herrador Industry Analyst
AMT - Beijing Representative Office China
Xingbin Li Chief Representative AMT - Shanghai Technology and Service Center China
Harry Xiao General Manager China Business Consultant to AMT Canada
Feng (Sean) Jiang Global Services Manager
AMT - Chennai Technology amp Service Center India
Arun Mahajan General Manager AMT ndash Monterrey Technology amp Service Center Mexico
Carlos Mortera General Manager AMT - CentralEastern Europe Liaison Poland
Hubert Sawicki Consultant - C amp E Europe AMT - Sao Paulo Technology Center Brazil
Achilles Arbex General Manager
GENERAL MANAGERSrsquo MEETING September 10 2014 800am ndash 100pm
McCormick Place West Hall mdash Rooms 470aampb 800 am ndash 830 am Continental Breakfast Room W470a 830 am ndash 845 am Welcome by Mr Douglas K Woods President AMT ndash The Association For Manufacturing Technology 845 am ndash 945 am Economic Outlook Global Economic Outlook Improvements But Risks Remain Mr Gregory Daco Chief US Economist Oxford Economics
Mr Gregory Daco is Chief US Economist at Oxford Economics He is responsible for producing the US macroeconomic forecast using Oxford Economicsrsquo proprietary Global Economic Model Gregory tracks and forecasts high-frequency indicators and oversees the production of US research pieces on consumer markets housing business investment international trade labor markets inflation and fiscal and monetary policy Gregory is frequently cited in leading business publications such as the Financial Times the New York Times and the Wall Street Journal and he regularly appears on radio and television programs Prior to joining Oxford Economics Gregory was Director US Macroeconomics at IHS Global Insight He also worked in the Economic Affairs Department of the Belgian Embassy in Australia and the Permanent Representation of Belgium to the UN in Geneva Gregory is co-founder and president of the Boston Chapter of the National Association for Business Economics He holds a Master of Arts in economics from Boston University and a Master in Business Administration from Universiteacute de Louvain in Belgium
945 am ndash 1000 am Break 1000 am ndash 1100 am Digital Manufacturing
World Class Shop Floor Management Release 5 The Smart Factory Revolution
Mr Franz E Gruber Founder amp CEO Dr Mohamed Abuali PhD COO FORCAM Inc
Mr Franz Gruber is the Founder Chairman and CEO of FORCAM A former IBM Manager and a veteran SAP Executive Franz has over 25 years of practical experience working directly with automotive aerospace and defense and medical devices discrete manufacturing industries Within a decade of founding FORCAM in Germany he strategically expanded company operations globally to the United Kingdom Eastern Europe and the United States FORCAMs technology now monitors and optimizes the performance of over 50000 industrial assets globally in automotive aerospace and defense machinery medical devices and other industrial sectors Dr Mohamed Abuali is responsible for leading and managing the full life cycle of FORCAMrsquos shop floor technology at discrete manufacturing companies in automotive aerospace medical devices and oil amp gas Mohamed brings 15 years of
manufacturing experience specializing in program and project management as well as research and development of shop floor technologies Dr Abuali has a PhD in Industrial Engineering through his studies at the Center for Intelligent Maintenance Systems (IMS) at the University of Cincinnati He is also a Project Management Professional (PMP) a Six Sigma Green Belt (SSGB) and a Certified Quality Engineer (CQE) FORCAM will be exhibiting at IMTS at Booth E-4929 and Dr Abuali extends an invitation to all to visit their booth to see interoperability in action
MTConnect Evolution of a Standard and Next Generation Interoperability Mr Courtney Hill Chairman amp President MTConnect Institute
Mr Courtney Hill retired from the General Electric Company after a 36-year career in manufacturing technology process development and commercialization Presently Courtney operates CJ Hill Consulting Services As the General Manager of Manufacturing Technology a global technology organization for GE Aviation Courtney was responsible for the development of next generation affordable manufacturing and inspection processes that support GE Aviationrsquos products and services worldwide Notable areas of recent technology development and commercialization include high performance structural composites additive manufacturing ceramic matric composites advanced robotic applications and digital manufacturing A graduate of Lehigh University Mr Hill currently serves as Chairman of the Board of the National Center for Manufacturing Sciences and the President and Chairman of the Board for the MTConnect Institute He has also served on the boards of TechSolve and the Edison Welding Institute
QampA Session 1100 am ndash 1115 am International Additive Manufacturing Award Dr Wilfried Schaumlfer Executive Director VDW ndash German Machine Tool Buildersrsquo Association Douglas K Woods President AMT ndash The Association For Manufacturing Technology 1115 am ndash 1145 am Open Forum
Open discussion on common issues pressing on the manufacturing technology industry markets and technological advances Examples of such issues bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment
Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
1145 am ndash 100 pm Reception amp Luncheon Room W470b
September 10 2014 2014 General Managersrsquo Meeting
Meeting Agenda 800 am - 830am Continental Breakfast 830 am - 845am Welcome by Mr Douglas K Woods 845 am - 945am Economic Outlook 945 am - 1000am Break 1000 am - 1100am Digital Manufacturing 1100 am - 1115am International Award for Additive Manufacturing 1115 am - 1145am Open Forum 1145 am - 100pm Reception and Luncheon
September 10 2014 2014 General Managersrsquo Meeting
Welcome
Mr Douglas K Woods President
AMT - The Association For Manufacturing Technology
September 10 2014 2014 General Managersrsquo Meeting
Economic Outlook
Mr Gregory Daco Chief US Economist
Oxford Economics
Global Economic Outlook Improvements But Risks Remain
Gregory Daco
Chief US Economist gregorydacooxfordeconomicscom
September 2014
Global economy on a modest growth path
After a roller-coaster ride in early 2014 the US economy should steady around 3 upcoming quarters
Eurozone improving but risks remain (deflation Ukraine)
Japan on a modest expansion path with inflation trending up but questions around the resilience of the economy (tax hike)
Additional support from the government has fed through to growth in China and the economy is now expected to come close to the governmentrsquos 75 growth target for this year
Outlook for other emergers is less positive Russiarsquos economy continues to suffer from structural weaknesses and the repercussions of the conflict in Ukraine Brazil and India are showing no signs of picking up with structural deficiencies weighing on growth
US pulling ahead after slow start to 2014
6
Eurozone outlook Caution slow recovery in progress
Eurozone recovery still ongoing buthellip
8
Strong disinflationary forces in the Eurozone
9
Recovery will be steady rather than spectacular
10
-8
-6
-4
-2
0
2
4
6
1999 2002 2005 2008 2011 2014 2017 2020
Source Oxford EconomicsHaver Analytics
Europe GDP year
UK
Eurozone
Forecast
Current situation not dramatic but full scale conflict hellip
11
-6
-5
-4
-3
-2
-1
0
1
2
3
4
2006 2008 2010 2012 2014 2016 2018
Eurozone GDP year
Source Oxford EconomicsHaver Analytics
BaselineForecast
Military conflict in Ukraine
China Outlook A bumpy landing
China growth to slow as rebalancing continueshellip
13
hellipas debt piles up to worrying levels
14
Real estate sector increasingly at risk
15
Japan Slowing in spite of Abenomics
Consumption tax weighs heavily on growth
17
2013 2014
-40
-30
-20
-10
00
10
20
30
Q3 Q4 Q1 Q2
Private consumptionFixed investmentNet exportsGovernment consumptionStockbuildingGDP
Japan Quarterly GDP contributions
quarterly contribution
Source Cabinet Office of Japan Haver Analytics
-3
-2
-1
0
1
2
3
4
1990 1995 2000 2005 2010 2015
Japan Fiscal policyChange in structural budget balance of GDP
Source International Monetary Fund Haver Analytics
ForecastExpansion
Contraction
Emergers Modest growth with structural issues
19
Does it still make sense to talk about ldquoBRICSrdquo
Some countries more vulnerable than others
20
1 Turkey 1182 S Africa 763 Brazil 404 Thailand 295 Russia 266 Malaysia 187 India 018 Poland 019 Mexico -2010 Indonesia -2511 Korea -8012 Philippines -9113 China -93
Oxford Economics Risk Scorecard
Emerging markets will still outpace developed world
21
US Outlook The US is the cleanest shirt in the laundry basket
GDP on a roller-coaster but employment is better indicator
19
Business surveys pointing to strong growthhellip
24
Consumers are feeling more cheerfulhellip
25
Wages expected to risehellip
26
Key domestic risk is housing activityhellip
27
hellipbut rising income and pent-up demand will help
24
Energy prices remain relatively stable
29
Fed to taper on but hold off on rate hikes
30
This image cannot currently be displayed
First rate hike in 2015Q2
Manufacturing in focus
Manufacturing activity is boominghellip
Further indication that GDP decline is due to unique factors
28
hellipwith encouraging signs from leading indicators
29
US manufacturing has outperformed its peershellip
30
US has made substantial gains in competitiveness
35
Remarkable improvements
Due to productivity gains amp modest wage growthhellip
36
Remarkable improvements
Business sentiment in Europe remains weak while new orders have slowed
37
China amp Brazil have lost their edgehellip
38
Chinese wages have more than doubled over the past decade
Key industries
Loose credit and rising demand for autoshellip
36
hellipshould support productionhellip
20
25
30
35
40
45
50
405060708090
100110120130140150160
Jul-09 Jul-10 Jul-11 Jul-12 Jul-13 Jul-14
2010=100 US$ bn
Output (LHS)
Orders (RHS)
Source Oxford Economics Haver Analytics
US Output and orders
3 month moving average
37
hellipas will opportunities in the Emergers
38
Revamp of car stock to be key long-term driver
Ageing vehicle fleet replacement as economy recovers ndash average age of vehicle on US roads in 11frac12 years
Rising fuel efficiency standards leading to replacement of clunkers
Rising fuels costs resulting in smaller cars
Automakers likely to increase new models helping drive investment
Aerospace solid order books at the big twohellip
0
250
500
750
1000
1250
1500
1750
1994 1996 1998 2000 2002 2004 2006 2008 2010 2012 2014
Source Company reports
Airbus versus Boeing Orders
Airbus
Boeing
Number of aircraft
Note 2014 annual estimate based on annualized data through July
40
hellipwith APAC to drive long-term growth
Asia will account for almost 32 of global passenger traffic by 2017 compared to 28 in 2012
APAC to account for 40 of plane deliveries over next 20 years
US and Europe sales mainly for replacement of existing fleet
41
Need for efficiency will provide demand supporthellip
A330 revamped for 15 efficiency improvement to compete with Dreamliner 25 new orders on day of announcement
Long-haul efficiency has some ways to go to maintain airline profitability
42
Order backlogs remain high
0
500
1000
1500
2000
2500
3000
3500
1990 1993 1996 1999 2002 2005 2008 2011 2014
Deliveries
Orders
Number of aircraftAirbus amp Boeing Orders amp deliveries
Source Company reports and forecasts
43
Weaker demand for metalshellip
44
hellipand over capacity are weighing on priceshellip
45
hellipand discouraging investment
BHP Capital spending fell 32 in FY14 with another 8 fall expected next year
Rio Tinto Capital spending in FY14 cut faster than initially projected and further cut is budgeted for 2015
This is weighing on equipment makers
Caterpillar reported sales down 9 in the three months to July with sales to mining firms down 33 from the same period a year earlier
Bumper crop has brought down grain prices
47
helliphitting margins and investment
Producers are facing higher costs due to the implementation of Tier 4 engines developed to comply with emissions standards
Weaker margins are leading to farmers cutting back investment spending
John Deere has posted a 5 yy decline in revenues with an 11 decline in its agricultural division
Conclusions amp market implications
Conclusion and business implications
54
bull US economy expected to gradually accelerate through 2014 with support from a dovish Fed
bull Europe expected to recover but more ECB action could be required
bull Chinese economy is gradually rebalancing but banking crisis cannot be discounted
bull Emerging markets quiet for now but structural issue unsolved
bull Geopolitical tensions in the Middle East and Ukraine are being monitored carefully
Thank you
Gregory Daco
Chief US Economist gregorydacooxfordeconomicscom
September 2014
September 10 2014 2014 General Managersrsquo Meeting
Digital Manufacturing
World Class Shop Floor Management Release 5 The Smart Factory Revolution Mr Franz E Gruber Founder amp CEO
Dr Mohamed Abuali COO FORCAM Inc
MTConnect Evolution of a Standard and
Next Generation Interoperability Mr Courtney J Hill Chairman amp President
MTConnect Institute
QampA Session
World Class
Shop Floor Management
The Smart Factory Revolution
Franz E Gruber
Founder amp CEO
Mohamed Abuali
COO
汉语
World Class Shop Floor Management
FORCAM 2014 Page 2
FORCAMlsquos Passion
FORCAM provides proven
manufacturing solutions to
Continuously Improve Productivity
To be the global solutions provider of
the best-in-class Manufacturing
Execution Systems
FORCAM 2014 Page 3
FORCAM ndash 2014 Best Practices Award by Frost amp Sullivan
Frost amp Sullivan
ldquoFORCAM is a plant production software
solution provider that understands and
supports Industry 40 needsrdquo
FORCAM 2014 Page 4
FORCAMrsquos Testimonials and Industry Leadership
FORCAM 2014 Page 5
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
6 B Bartke S Wagner IPI-2
Shop Floor Management Audi - FORCAM FIT 2011-
Bernhard Bartke - Director Components Manufacturing
Stefan Wagner - Director Gear Manufacturing
7 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
bull Collection and recording of Operational Data via a database
(ex Machine States and State Changes)
Machine
Operator
Production Manager
Technical Assistant IT
Plant
Manager
Team Leader
8 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Interfaces
Time
Objectivity of Process Data
9 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Need for Continuous Improvement
bull Objective Information and Communication ndash across ALL levels
bull Transperancy and Visualization - Online
bull Real-time availability of operational data ndash Live Reports
bull Measurable increase in Plant Efficiency (OEE)
10 B Bartke S Wagner IPI-2
Shop Floor Management ndash Realtime bdquoANDONldquo Visualization
bull Web-based Interface Anywhere Anytime Access
bull Real-time Production Status Visualization
In Production
Overflow
Stoppage
Organizational
Stoppage
Idle (Pause)
Tool
Problem
11 B Bartke S Wagner IPI-2
Shop Floor Management Reporting ndash Hierarchical Status Diagrams
bull Reporting for Machines Groups Lines or the whole Plant
Technical
Stoppage In Production
Organizational
Stoppage Pause Overflow
Stoppage
Tool Problem In Setup
12 B Bartke S Wagner IPI-2
Audi Production System (APS)
Leadership Communication
bull Process Control
Standards
bull In Processes
bull Im Products
bull In the Organization
Learning Organization
bull Employee Development
bull Problem-Solving
bull CIP Culture
13 B Bartke S Wagner IPI-2
Shop Floor Management Process Control Panel on the shop floor
OEE Trend
(Day Week Month)
Measures
Quality
Process Control
14 B Bartke S Wagner IPI-2
OEE - Yesterday
Availability Trend
OEE ndash Last Week
OEE ndash Last Month
Naoki Nojiri IPI-25 BDE-Ist Stand 05042011
Shop Floor Management Process Control Panel on the shop floor
15 B Bartke S Wagner IPI-2
Shop Floor Management Management Cockpit
Planned vs Actual
(shift)
Top problems
(challenges)
OEE ndash Last Week
16 B Bartke S Wagner IPI-2
hellipand what have we achieved
17 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development suspension components (OEE Overall Equipment Effectiveness)
Radtraumlger
Start Shop Floor Management with
FORCAM +10
_
18 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development (20+ Increase in OEE in AUDI Stamping Facilities) (OEE Overall Equipment Effectiveness)
Radtraumlger
Start SFM +20
_
Our Beliefs
Respect
Collaboration
Excellence
Integrity
Community
Oct 30th 2013
Lean with Shop Floor Management BorgWarner Turbo Systems Rzeszow
Operator FactoryFrameworktrade Worker Client- Book On
Operator Downtime Reasons
Operator Actual versus Target Performance
TargetPlanned
Throughput
Actual
Performance
Opportunity for
Improvement
Actual
Throughput Machine
Data
ERP
Data
Supervisor Gantt Status
visualzation
Top 5
downtimes
Cip Top 5
Production
orders
Real data
history
Supervisor Cockpit machine
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
-3- SYMOP - French Association for Manufacturing Technologies France
Jean Tournoux General Director TAMI - Taiwan Association of Machinery Industry Taiwan
CC Wang President Ms Lisa Weng Director of Exhibition Division
TMBA - Taiwan Machine Tool amp Accessory Buildersrsquo Association Taiwan
Carl CC Huang Secretary General Ms Stephanie Ho Specialist
UCIMU ndash Sistemi Per Produrre Italian Machine Tools Robots and Automation Manufacturers Association Italy
Dott Alfredo Mariotti General Manager Ing Alberto Nicolai Marketing Manager Ing Enrico Annacondia Technical Department Officer
VDW - German Machine Tool Builders Association Germany
Dr Wilfried Schafer Executive Director Gerhard Hein Director Economic Department
Speakers (in order of appearance) AMT - The Association For Manufacturing Technology United States
Douglas K Woods President
Oxford Economics United States
Gregory Daco Chief US Economist
FORCAM Inc United States
Franz E Gruber Founder amp CEO Dr Mohamed Abuali PhD COO
MTConnect Institute United States
Courtney J Hill Chairman amp President VDW ndash German Machine Tool Buildersrsquo Association Germany
Dr Wilfried Schaumlfer Executive Director
-4- Staff of AMT - The Association For Manufacturing Technology United States
Douglas K Woods President Steve Lesnewich Vice President - Global Services Knox Johnstone Global Services Director Malcolm Mason Global Services Director Mario Winterstein Global Services Director Patrick W McGibbon Vice President - Strategic Analytics Kate Fritz Strategic Analytics Director Jackie McFarland Industry Analyst Juan Guerra Industry Analyst Sebastian Herrador Industry Analyst
AMT - Beijing Representative Office China
Xingbin Li Chief Representative AMT - Shanghai Technology and Service Center China
Harry Xiao General Manager China Business Consultant to AMT Canada
Feng (Sean) Jiang Global Services Manager
AMT - Chennai Technology amp Service Center India
Arun Mahajan General Manager AMT ndash Monterrey Technology amp Service Center Mexico
Carlos Mortera General Manager AMT - CentralEastern Europe Liaison Poland
Hubert Sawicki Consultant - C amp E Europe AMT - Sao Paulo Technology Center Brazil
Achilles Arbex General Manager
GENERAL MANAGERSrsquo MEETING September 10 2014 800am ndash 100pm
McCormick Place West Hall mdash Rooms 470aampb 800 am ndash 830 am Continental Breakfast Room W470a 830 am ndash 845 am Welcome by Mr Douglas K Woods President AMT ndash The Association For Manufacturing Technology 845 am ndash 945 am Economic Outlook Global Economic Outlook Improvements But Risks Remain Mr Gregory Daco Chief US Economist Oxford Economics
Mr Gregory Daco is Chief US Economist at Oxford Economics He is responsible for producing the US macroeconomic forecast using Oxford Economicsrsquo proprietary Global Economic Model Gregory tracks and forecasts high-frequency indicators and oversees the production of US research pieces on consumer markets housing business investment international trade labor markets inflation and fiscal and monetary policy Gregory is frequently cited in leading business publications such as the Financial Times the New York Times and the Wall Street Journal and he regularly appears on radio and television programs Prior to joining Oxford Economics Gregory was Director US Macroeconomics at IHS Global Insight He also worked in the Economic Affairs Department of the Belgian Embassy in Australia and the Permanent Representation of Belgium to the UN in Geneva Gregory is co-founder and president of the Boston Chapter of the National Association for Business Economics He holds a Master of Arts in economics from Boston University and a Master in Business Administration from Universiteacute de Louvain in Belgium
945 am ndash 1000 am Break 1000 am ndash 1100 am Digital Manufacturing
World Class Shop Floor Management Release 5 The Smart Factory Revolution
Mr Franz E Gruber Founder amp CEO Dr Mohamed Abuali PhD COO FORCAM Inc
Mr Franz Gruber is the Founder Chairman and CEO of FORCAM A former IBM Manager and a veteran SAP Executive Franz has over 25 years of practical experience working directly with automotive aerospace and defense and medical devices discrete manufacturing industries Within a decade of founding FORCAM in Germany he strategically expanded company operations globally to the United Kingdom Eastern Europe and the United States FORCAMs technology now monitors and optimizes the performance of over 50000 industrial assets globally in automotive aerospace and defense machinery medical devices and other industrial sectors Dr Mohamed Abuali is responsible for leading and managing the full life cycle of FORCAMrsquos shop floor technology at discrete manufacturing companies in automotive aerospace medical devices and oil amp gas Mohamed brings 15 years of
manufacturing experience specializing in program and project management as well as research and development of shop floor technologies Dr Abuali has a PhD in Industrial Engineering through his studies at the Center for Intelligent Maintenance Systems (IMS) at the University of Cincinnati He is also a Project Management Professional (PMP) a Six Sigma Green Belt (SSGB) and a Certified Quality Engineer (CQE) FORCAM will be exhibiting at IMTS at Booth E-4929 and Dr Abuali extends an invitation to all to visit their booth to see interoperability in action
MTConnect Evolution of a Standard and Next Generation Interoperability Mr Courtney Hill Chairman amp President MTConnect Institute
Mr Courtney Hill retired from the General Electric Company after a 36-year career in manufacturing technology process development and commercialization Presently Courtney operates CJ Hill Consulting Services As the General Manager of Manufacturing Technology a global technology organization for GE Aviation Courtney was responsible for the development of next generation affordable manufacturing and inspection processes that support GE Aviationrsquos products and services worldwide Notable areas of recent technology development and commercialization include high performance structural composites additive manufacturing ceramic matric composites advanced robotic applications and digital manufacturing A graduate of Lehigh University Mr Hill currently serves as Chairman of the Board of the National Center for Manufacturing Sciences and the President and Chairman of the Board for the MTConnect Institute He has also served on the boards of TechSolve and the Edison Welding Institute
QampA Session 1100 am ndash 1115 am International Additive Manufacturing Award Dr Wilfried Schaumlfer Executive Director VDW ndash German Machine Tool Buildersrsquo Association Douglas K Woods President AMT ndash The Association For Manufacturing Technology 1115 am ndash 1145 am Open Forum
Open discussion on common issues pressing on the manufacturing technology industry markets and technological advances Examples of such issues bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment
Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
1145 am ndash 100 pm Reception amp Luncheon Room W470b
September 10 2014 2014 General Managersrsquo Meeting
Meeting Agenda 800 am - 830am Continental Breakfast 830 am - 845am Welcome by Mr Douglas K Woods 845 am - 945am Economic Outlook 945 am - 1000am Break 1000 am - 1100am Digital Manufacturing 1100 am - 1115am International Award for Additive Manufacturing 1115 am - 1145am Open Forum 1145 am - 100pm Reception and Luncheon
September 10 2014 2014 General Managersrsquo Meeting
Welcome
Mr Douglas K Woods President
AMT - The Association For Manufacturing Technology
September 10 2014 2014 General Managersrsquo Meeting
Economic Outlook
Mr Gregory Daco Chief US Economist
Oxford Economics
Global Economic Outlook Improvements But Risks Remain
Gregory Daco
Chief US Economist gregorydacooxfordeconomicscom
September 2014
Global economy on a modest growth path
After a roller-coaster ride in early 2014 the US economy should steady around 3 upcoming quarters
Eurozone improving but risks remain (deflation Ukraine)
Japan on a modest expansion path with inflation trending up but questions around the resilience of the economy (tax hike)
Additional support from the government has fed through to growth in China and the economy is now expected to come close to the governmentrsquos 75 growth target for this year
Outlook for other emergers is less positive Russiarsquos economy continues to suffer from structural weaknesses and the repercussions of the conflict in Ukraine Brazil and India are showing no signs of picking up with structural deficiencies weighing on growth
US pulling ahead after slow start to 2014
6
Eurozone outlook Caution slow recovery in progress
Eurozone recovery still ongoing buthellip
8
Strong disinflationary forces in the Eurozone
9
Recovery will be steady rather than spectacular
10
-8
-6
-4
-2
0
2
4
6
1999 2002 2005 2008 2011 2014 2017 2020
Source Oxford EconomicsHaver Analytics
Europe GDP year
UK
Eurozone
Forecast
Current situation not dramatic but full scale conflict hellip
11
-6
-5
-4
-3
-2
-1
0
1
2
3
4
2006 2008 2010 2012 2014 2016 2018
Eurozone GDP year
Source Oxford EconomicsHaver Analytics
BaselineForecast
Military conflict in Ukraine
China Outlook A bumpy landing
China growth to slow as rebalancing continueshellip
13
hellipas debt piles up to worrying levels
14
Real estate sector increasingly at risk
15
Japan Slowing in spite of Abenomics
Consumption tax weighs heavily on growth
17
2013 2014
-40
-30
-20
-10
00
10
20
30
Q3 Q4 Q1 Q2
Private consumptionFixed investmentNet exportsGovernment consumptionStockbuildingGDP
Japan Quarterly GDP contributions
quarterly contribution
Source Cabinet Office of Japan Haver Analytics
-3
-2
-1
0
1
2
3
4
1990 1995 2000 2005 2010 2015
Japan Fiscal policyChange in structural budget balance of GDP
Source International Monetary Fund Haver Analytics
ForecastExpansion
Contraction
Emergers Modest growth with structural issues
19
Does it still make sense to talk about ldquoBRICSrdquo
Some countries more vulnerable than others
20
1 Turkey 1182 S Africa 763 Brazil 404 Thailand 295 Russia 266 Malaysia 187 India 018 Poland 019 Mexico -2010 Indonesia -2511 Korea -8012 Philippines -9113 China -93
Oxford Economics Risk Scorecard
Emerging markets will still outpace developed world
21
US Outlook The US is the cleanest shirt in the laundry basket
GDP on a roller-coaster but employment is better indicator
19
Business surveys pointing to strong growthhellip
24
Consumers are feeling more cheerfulhellip
25
Wages expected to risehellip
26
Key domestic risk is housing activityhellip
27
hellipbut rising income and pent-up demand will help
24
Energy prices remain relatively stable
29
Fed to taper on but hold off on rate hikes
30
This image cannot currently be displayed
First rate hike in 2015Q2
Manufacturing in focus
Manufacturing activity is boominghellip
Further indication that GDP decline is due to unique factors
28
hellipwith encouraging signs from leading indicators
29
US manufacturing has outperformed its peershellip
30
US has made substantial gains in competitiveness
35
Remarkable improvements
Due to productivity gains amp modest wage growthhellip
36
Remarkable improvements
Business sentiment in Europe remains weak while new orders have slowed
37
China amp Brazil have lost their edgehellip
38
Chinese wages have more than doubled over the past decade
Key industries
Loose credit and rising demand for autoshellip
36
hellipshould support productionhellip
20
25
30
35
40
45
50
405060708090
100110120130140150160
Jul-09 Jul-10 Jul-11 Jul-12 Jul-13 Jul-14
2010=100 US$ bn
Output (LHS)
Orders (RHS)
Source Oxford Economics Haver Analytics
US Output and orders
3 month moving average
37
hellipas will opportunities in the Emergers
38
Revamp of car stock to be key long-term driver
Ageing vehicle fleet replacement as economy recovers ndash average age of vehicle on US roads in 11frac12 years
Rising fuel efficiency standards leading to replacement of clunkers
Rising fuels costs resulting in smaller cars
Automakers likely to increase new models helping drive investment
Aerospace solid order books at the big twohellip
0
250
500
750
1000
1250
1500
1750
1994 1996 1998 2000 2002 2004 2006 2008 2010 2012 2014
Source Company reports
Airbus versus Boeing Orders
Airbus
Boeing
Number of aircraft
Note 2014 annual estimate based on annualized data through July
40
hellipwith APAC to drive long-term growth
Asia will account for almost 32 of global passenger traffic by 2017 compared to 28 in 2012
APAC to account for 40 of plane deliveries over next 20 years
US and Europe sales mainly for replacement of existing fleet
41
Need for efficiency will provide demand supporthellip
A330 revamped for 15 efficiency improvement to compete with Dreamliner 25 new orders on day of announcement
Long-haul efficiency has some ways to go to maintain airline profitability
42
Order backlogs remain high
0
500
1000
1500
2000
2500
3000
3500
1990 1993 1996 1999 2002 2005 2008 2011 2014
Deliveries
Orders
Number of aircraftAirbus amp Boeing Orders amp deliveries
Source Company reports and forecasts
43
Weaker demand for metalshellip
44
hellipand over capacity are weighing on priceshellip
45
hellipand discouraging investment
BHP Capital spending fell 32 in FY14 with another 8 fall expected next year
Rio Tinto Capital spending in FY14 cut faster than initially projected and further cut is budgeted for 2015
This is weighing on equipment makers
Caterpillar reported sales down 9 in the three months to July with sales to mining firms down 33 from the same period a year earlier
Bumper crop has brought down grain prices
47
helliphitting margins and investment
Producers are facing higher costs due to the implementation of Tier 4 engines developed to comply with emissions standards
Weaker margins are leading to farmers cutting back investment spending
John Deere has posted a 5 yy decline in revenues with an 11 decline in its agricultural division
Conclusions amp market implications
Conclusion and business implications
54
bull US economy expected to gradually accelerate through 2014 with support from a dovish Fed
bull Europe expected to recover but more ECB action could be required
bull Chinese economy is gradually rebalancing but banking crisis cannot be discounted
bull Emerging markets quiet for now but structural issue unsolved
bull Geopolitical tensions in the Middle East and Ukraine are being monitored carefully
Thank you
Gregory Daco
Chief US Economist gregorydacooxfordeconomicscom
September 2014
September 10 2014 2014 General Managersrsquo Meeting
Digital Manufacturing
World Class Shop Floor Management Release 5 The Smart Factory Revolution Mr Franz E Gruber Founder amp CEO
Dr Mohamed Abuali COO FORCAM Inc
MTConnect Evolution of a Standard and
Next Generation Interoperability Mr Courtney J Hill Chairman amp President
MTConnect Institute
QampA Session
World Class
Shop Floor Management
The Smart Factory Revolution
Franz E Gruber
Founder amp CEO
Mohamed Abuali
COO
汉语
World Class Shop Floor Management
FORCAM 2014 Page 2
FORCAMlsquos Passion
FORCAM provides proven
manufacturing solutions to
Continuously Improve Productivity
To be the global solutions provider of
the best-in-class Manufacturing
Execution Systems
FORCAM 2014 Page 3
FORCAM ndash 2014 Best Practices Award by Frost amp Sullivan
Frost amp Sullivan
ldquoFORCAM is a plant production software
solution provider that understands and
supports Industry 40 needsrdquo
FORCAM 2014 Page 4
FORCAMrsquos Testimonials and Industry Leadership
FORCAM 2014 Page 5
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
6 B Bartke S Wagner IPI-2
Shop Floor Management Audi - FORCAM FIT 2011-
Bernhard Bartke - Director Components Manufacturing
Stefan Wagner - Director Gear Manufacturing
7 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
bull Collection and recording of Operational Data via a database
(ex Machine States and State Changes)
Machine
Operator
Production Manager
Technical Assistant IT
Plant
Manager
Team Leader
8 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Interfaces
Time
Objectivity of Process Data
9 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Need for Continuous Improvement
bull Objective Information and Communication ndash across ALL levels
bull Transperancy and Visualization - Online
bull Real-time availability of operational data ndash Live Reports
bull Measurable increase in Plant Efficiency (OEE)
10 B Bartke S Wagner IPI-2
Shop Floor Management ndash Realtime bdquoANDONldquo Visualization
bull Web-based Interface Anywhere Anytime Access
bull Real-time Production Status Visualization
In Production
Overflow
Stoppage
Organizational
Stoppage
Idle (Pause)
Tool
Problem
11 B Bartke S Wagner IPI-2
Shop Floor Management Reporting ndash Hierarchical Status Diagrams
bull Reporting for Machines Groups Lines or the whole Plant
Technical
Stoppage In Production
Organizational
Stoppage Pause Overflow
Stoppage
Tool Problem In Setup
12 B Bartke S Wagner IPI-2
Audi Production System (APS)
Leadership Communication
bull Process Control
Standards
bull In Processes
bull Im Products
bull In the Organization
Learning Organization
bull Employee Development
bull Problem-Solving
bull CIP Culture
13 B Bartke S Wagner IPI-2
Shop Floor Management Process Control Panel on the shop floor
OEE Trend
(Day Week Month)
Measures
Quality
Process Control
14 B Bartke S Wagner IPI-2
OEE - Yesterday
Availability Trend
OEE ndash Last Week
OEE ndash Last Month
Naoki Nojiri IPI-25 BDE-Ist Stand 05042011
Shop Floor Management Process Control Panel on the shop floor
15 B Bartke S Wagner IPI-2
Shop Floor Management Management Cockpit
Planned vs Actual
(shift)
Top problems
(challenges)
OEE ndash Last Week
16 B Bartke S Wagner IPI-2
hellipand what have we achieved
17 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development suspension components (OEE Overall Equipment Effectiveness)
Radtraumlger
Start Shop Floor Management with
FORCAM +10
_
18 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development (20+ Increase in OEE in AUDI Stamping Facilities) (OEE Overall Equipment Effectiveness)
Radtraumlger
Start SFM +20
_
Our Beliefs
Respect
Collaboration
Excellence
Integrity
Community
Oct 30th 2013
Lean with Shop Floor Management BorgWarner Turbo Systems Rzeszow
Operator FactoryFrameworktrade Worker Client- Book On
Operator Downtime Reasons
Operator Actual versus Target Performance
TargetPlanned
Throughput
Actual
Performance
Opportunity for
Improvement
Actual
Throughput Machine
Data
ERP
Data
Supervisor Gantt Status
visualzation
Top 5
downtimes
Cip Top 5
Production
orders
Real data
history
Supervisor Cockpit machine
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
-4- Staff of AMT - The Association For Manufacturing Technology United States
Douglas K Woods President Steve Lesnewich Vice President - Global Services Knox Johnstone Global Services Director Malcolm Mason Global Services Director Mario Winterstein Global Services Director Patrick W McGibbon Vice President - Strategic Analytics Kate Fritz Strategic Analytics Director Jackie McFarland Industry Analyst Juan Guerra Industry Analyst Sebastian Herrador Industry Analyst
AMT - Beijing Representative Office China
Xingbin Li Chief Representative AMT - Shanghai Technology and Service Center China
Harry Xiao General Manager China Business Consultant to AMT Canada
Feng (Sean) Jiang Global Services Manager
AMT - Chennai Technology amp Service Center India
Arun Mahajan General Manager AMT ndash Monterrey Technology amp Service Center Mexico
Carlos Mortera General Manager AMT - CentralEastern Europe Liaison Poland
Hubert Sawicki Consultant - C amp E Europe AMT - Sao Paulo Technology Center Brazil
Achilles Arbex General Manager
GENERAL MANAGERSrsquo MEETING September 10 2014 800am ndash 100pm
McCormick Place West Hall mdash Rooms 470aampb 800 am ndash 830 am Continental Breakfast Room W470a 830 am ndash 845 am Welcome by Mr Douglas K Woods President AMT ndash The Association For Manufacturing Technology 845 am ndash 945 am Economic Outlook Global Economic Outlook Improvements But Risks Remain Mr Gregory Daco Chief US Economist Oxford Economics
Mr Gregory Daco is Chief US Economist at Oxford Economics He is responsible for producing the US macroeconomic forecast using Oxford Economicsrsquo proprietary Global Economic Model Gregory tracks and forecasts high-frequency indicators and oversees the production of US research pieces on consumer markets housing business investment international trade labor markets inflation and fiscal and monetary policy Gregory is frequently cited in leading business publications such as the Financial Times the New York Times and the Wall Street Journal and he regularly appears on radio and television programs Prior to joining Oxford Economics Gregory was Director US Macroeconomics at IHS Global Insight He also worked in the Economic Affairs Department of the Belgian Embassy in Australia and the Permanent Representation of Belgium to the UN in Geneva Gregory is co-founder and president of the Boston Chapter of the National Association for Business Economics He holds a Master of Arts in economics from Boston University and a Master in Business Administration from Universiteacute de Louvain in Belgium
945 am ndash 1000 am Break 1000 am ndash 1100 am Digital Manufacturing
World Class Shop Floor Management Release 5 The Smart Factory Revolution
Mr Franz E Gruber Founder amp CEO Dr Mohamed Abuali PhD COO FORCAM Inc
Mr Franz Gruber is the Founder Chairman and CEO of FORCAM A former IBM Manager and a veteran SAP Executive Franz has over 25 years of practical experience working directly with automotive aerospace and defense and medical devices discrete manufacturing industries Within a decade of founding FORCAM in Germany he strategically expanded company operations globally to the United Kingdom Eastern Europe and the United States FORCAMs technology now monitors and optimizes the performance of over 50000 industrial assets globally in automotive aerospace and defense machinery medical devices and other industrial sectors Dr Mohamed Abuali is responsible for leading and managing the full life cycle of FORCAMrsquos shop floor technology at discrete manufacturing companies in automotive aerospace medical devices and oil amp gas Mohamed brings 15 years of
manufacturing experience specializing in program and project management as well as research and development of shop floor technologies Dr Abuali has a PhD in Industrial Engineering through his studies at the Center for Intelligent Maintenance Systems (IMS) at the University of Cincinnati He is also a Project Management Professional (PMP) a Six Sigma Green Belt (SSGB) and a Certified Quality Engineer (CQE) FORCAM will be exhibiting at IMTS at Booth E-4929 and Dr Abuali extends an invitation to all to visit their booth to see interoperability in action
MTConnect Evolution of a Standard and Next Generation Interoperability Mr Courtney Hill Chairman amp President MTConnect Institute
Mr Courtney Hill retired from the General Electric Company after a 36-year career in manufacturing technology process development and commercialization Presently Courtney operates CJ Hill Consulting Services As the General Manager of Manufacturing Technology a global technology organization for GE Aviation Courtney was responsible for the development of next generation affordable manufacturing and inspection processes that support GE Aviationrsquos products and services worldwide Notable areas of recent technology development and commercialization include high performance structural composites additive manufacturing ceramic matric composites advanced robotic applications and digital manufacturing A graduate of Lehigh University Mr Hill currently serves as Chairman of the Board of the National Center for Manufacturing Sciences and the President and Chairman of the Board for the MTConnect Institute He has also served on the boards of TechSolve and the Edison Welding Institute
QampA Session 1100 am ndash 1115 am International Additive Manufacturing Award Dr Wilfried Schaumlfer Executive Director VDW ndash German Machine Tool Buildersrsquo Association Douglas K Woods President AMT ndash The Association For Manufacturing Technology 1115 am ndash 1145 am Open Forum
Open discussion on common issues pressing on the manufacturing technology industry markets and technological advances Examples of such issues bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment
Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
1145 am ndash 100 pm Reception amp Luncheon Room W470b
September 10 2014 2014 General Managersrsquo Meeting
Meeting Agenda 800 am - 830am Continental Breakfast 830 am - 845am Welcome by Mr Douglas K Woods 845 am - 945am Economic Outlook 945 am - 1000am Break 1000 am - 1100am Digital Manufacturing 1100 am - 1115am International Award for Additive Manufacturing 1115 am - 1145am Open Forum 1145 am - 100pm Reception and Luncheon
September 10 2014 2014 General Managersrsquo Meeting
Welcome
Mr Douglas K Woods President
AMT - The Association For Manufacturing Technology
September 10 2014 2014 General Managersrsquo Meeting
Economic Outlook
Mr Gregory Daco Chief US Economist
Oxford Economics
Global Economic Outlook Improvements But Risks Remain
Gregory Daco
Chief US Economist gregorydacooxfordeconomicscom
September 2014
Global economy on a modest growth path
After a roller-coaster ride in early 2014 the US economy should steady around 3 upcoming quarters
Eurozone improving but risks remain (deflation Ukraine)
Japan on a modest expansion path with inflation trending up but questions around the resilience of the economy (tax hike)
Additional support from the government has fed through to growth in China and the economy is now expected to come close to the governmentrsquos 75 growth target for this year
Outlook for other emergers is less positive Russiarsquos economy continues to suffer from structural weaknesses and the repercussions of the conflict in Ukraine Brazil and India are showing no signs of picking up with structural deficiencies weighing on growth
US pulling ahead after slow start to 2014
6
Eurozone outlook Caution slow recovery in progress
Eurozone recovery still ongoing buthellip
8
Strong disinflationary forces in the Eurozone
9
Recovery will be steady rather than spectacular
10
-8
-6
-4
-2
0
2
4
6
1999 2002 2005 2008 2011 2014 2017 2020
Source Oxford EconomicsHaver Analytics
Europe GDP year
UK
Eurozone
Forecast
Current situation not dramatic but full scale conflict hellip
11
-6
-5
-4
-3
-2
-1
0
1
2
3
4
2006 2008 2010 2012 2014 2016 2018
Eurozone GDP year
Source Oxford EconomicsHaver Analytics
BaselineForecast
Military conflict in Ukraine
China Outlook A bumpy landing
China growth to slow as rebalancing continueshellip
13
hellipas debt piles up to worrying levels
14
Real estate sector increasingly at risk
15
Japan Slowing in spite of Abenomics
Consumption tax weighs heavily on growth
17
2013 2014
-40
-30
-20
-10
00
10
20
30
Q3 Q4 Q1 Q2
Private consumptionFixed investmentNet exportsGovernment consumptionStockbuildingGDP
Japan Quarterly GDP contributions
quarterly contribution
Source Cabinet Office of Japan Haver Analytics
-3
-2
-1
0
1
2
3
4
1990 1995 2000 2005 2010 2015
Japan Fiscal policyChange in structural budget balance of GDP
Source International Monetary Fund Haver Analytics
ForecastExpansion
Contraction
Emergers Modest growth with structural issues
19
Does it still make sense to talk about ldquoBRICSrdquo
Some countries more vulnerable than others
20
1 Turkey 1182 S Africa 763 Brazil 404 Thailand 295 Russia 266 Malaysia 187 India 018 Poland 019 Mexico -2010 Indonesia -2511 Korea -8012 Philippines -9113 China -93
Oxford Economics Risk Scorecard
Emerging markets will still outpace developed world
21
US Outlook The US is the cleanest shirt in the laundry basket
GDP on a roller-coaster but employment is better indicator
19
Business surveys pointing to strong growthhellip
24
Consumers are feeling more cheerfulhellip
25
Wages expected to risehellip
26
Key domestic risk is housing activityhellip
27
hellipbut rising income and pent-up demand will help
24
Energy prices remain relatively stable
29
Fed to taper on but hold off on rate hikes
30
This image cannot currently be displayed
First rate hike in 2015Q2
Manufacturing in focus
Manufacturing activity is boominghellip
Further indication that GDP decline is due to unique factors
28
hellipwith encouraging signs from leading indicators
29
US manufacturing has outperformed its peershellip
30
US has made substantial gains in competitiveness
35
Remarkable improvements
Due to productivity gains amp modest wage growthhellip
36
Remarkable improvements
Business sentiment in Europe remains weak while new orders have slowed
37
China amp Brazil have lost their edgehellip
38
Chinese wages have more than doubled over the past decade
Key industries
Loose credit and rising demand for autoshellip
36
hellipshould support productionhellip
20
25
30
35
40
45
50
405060708090
100110120130140150160
Jul-09 Jul-10 Jul-11 Jul-12 Jul-13 Jul-14
2010=100 US$ bn
Output (LHS)
Orders (RHS)
Source Oxford Economics Haver Analytics
US Output and orders
3 month moving average
37
hellipas will opportunities in the Emergers
38
Revamp of car stock to be key long-term driver
Ageing vehicle fleet replacement as economy recovers ndash average age of vehicle on US roads in 11frac12 years
Rising fuel efficiency standards leading to replacement of clunkers
Rising fuels costs resulting in smaller cars
Automakers likely to increase new models helping drive investment
Aerospace solid order books at the big twohellip
0
250
500
750
1000
1250
1500
1750
1994 1996 1998 2000 2002 2004 2006 2008 2010 2012 2014
Source Company reports
Airbus versus Boeing Orders
Airbus
Boeing
Number of aircraft
Note 2014 annual estimate based on annualized data through July
40
hellipwith APAC to drive long-term growth
Asia will account for almost 32 of global passenger traffic by 2017 compared to 28 in 2012
APAC to account for 40 of plane deliveries over next 20 years
US and Europe sales mainly for replacement of existing fleet
41
Need for efficiency will provide demand supporthellip
A330 revamped for 15 efficiency improvement to compete with Dreamliner 25 new orders on day of announcement
Long-haul efficiency has some ways to go to maintain airline profitability
42
Order backlogs remain high
0
500
1000
1500
2000
2500
3000
3500
1990 1993 1996 1999 2002 2005 2008 2011 2014
Deliveries
Orders
Number of aircraftAirbus amp Boeing Orders amp deliveries
Source Company reports and forecasts
43
Weaker demand for metalshellip
44
hellipand over capacity are weighing on priceshellip
45
hellipand discouraging investment
BHP Capital spending fell 32 in FY14 with another 8 fall expected next year
Rio Tinto Capital spending in FY14 cut faster than initially projected and further cut is budgeted for 2015
This is weighing on equipment makers
Caterpillar reported sales down 9 in the three months to July with sales to mining firms down 33 from the same period a year earlier
Bumper crop has brought down grain prices
47
helliphitting margins and investment
Producers are facing higher costs due to the implementation of Tier 4 engines developed to comply with emissions standards
Weaker margins are leading to farmers cutting back investment spending
John Deere has posted a 5 yy decline in revenues with an 11 decline in its agricultural division
Conclusions amp market implications
Conclusion and business implications
54
bull US economy expected to gradually accelerate through 2014 with support from a dovish Fed
bull Europe expected to recover but more ECB action could be required
bull Chinese economy is gradually rebalancing but banking crisis cannot be discounted
bull Emerging markets quiet for now but structural issue unsolved
bull Geopolitical tensions in the Middle East and Ukraine are being monitored carefully
Thank you
Gregory Daco
Chief US Economist gregorydacooxfordeconomicscom
September 2014
September 10 2014 2014 General Managersrsquo Meeting
Digital Manufacturing
World Class Shop Floor Management Release 5 The Smart Factory Revolution Mr Franz E Gruber Founder amp CEO
Dr Mohamed Abuali COO FORCAM Inc
MTConnect Evolution of a Standard and
Next Generation Interoperability Mr Courtney J Hill Chairman amp President
MTConnect Institute
QampA Session
World Class
Shop Floor Management
The Smart Factory Revolution
Franz E Gruber
Founder amp CEO
Mohamed Abuali
COO
汉语
World Class Shop Floor Management
FORCAM 2014 Page 2
FORCAMlsquos Passion
FORCAM provides proven
manufacturing solutions to
Continuously Improve Productivity
To be the global solutions provider of
the best-in-class Manufacturing
Execution Systems
FORCAM 2014 Page 3
FORCAM ndash 2014 Best Practices Award by Frost amp Sullivan
Frost amp Sullivan
ldquoFORCAM is a plant production software
solution provider that understands and
supports Industry 40 needsrdquo
FORCAM 2014 Page 4
FORCAMrsquos Testimonials and Industry Leadership
FORCAM 2014 Page 5
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
6 B Bartke S Wagner IPI-2
Shop Floor Management Audi - FORCAM FIT 2011-
Bernhard Bartke - Director Components Manufacturing
Stefan Wagner - Director Gear Manufacturing
7 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
bull Collection and recording of Operational Data via a database
(ex Machine States and State Changes)
Machine
Operator
Production Manager
Technical Assistant IT
Plant
Manager
Team Leader
8 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Interfaces
Time
Objectivity of Process Data
9 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Need for Continuous Improvement
bull Objective Information and Communication ndash across ALL levels
bull Transperancy and Visualization - Online
bull Real-time availability of operational data ndash Live Reports
bull Measurable increase in Plant Efficiency (OEE)
10 B Bartke S Wagner IPI-2
Shop Floor Management ndash Realtime bdquoANDONldquo Visualization
bull Web-based Interface Anywhere Anytime Access
bull Real-time Production Status Visualization
In Production
Overflow
Stoppage
Organizational
Stoppage
Idle (Pause)
Tool
Problem
11 B Bartke S Wagner IPI-2
Shop Floor Management Reporting ndash Hierarchical Status Diagrams
bull Reporting for Machines Groups Lines or the whole Plant
Technical
Stoppage In Production
Organizational
Stoppage Pause Overflow
Stoppage
Tool Problem In Setup
12 B Bartke S Wagner IPI-2
Audi Production System (APS)
Leadership Communication
bull Process Control
Standards
bull In Processes
bull Im Products
bull In the Organization
Learning Organization
bull Employee Development
bull Problem-Solving
bull CIP Culture
13 B Bartke S Wagner IPI-2
Shop Floor Management Process Control Panel on the shop floor
OEE Trend
(Day Week Month)
Measures
Quality
Process Control
14 B Bartke S Wagner IPI-2
OEE - Yesterday
Availability Trend
OEE ndash Last Week
OEE ndash Last Month
Naoki Nojiri IPI-25 BDE-Ist Stand 05042011
Shop Floor Management Process Control Panel on the shop floor
15 B Bartke S Wagner IPI-2
Shop Floor Management Management Cockpit
Planned vs Actual
(shift)
Top problems
(challenges)
OEE ndash Last Week
16 B Bartke S Wagner IPI-2
hellipand what have we achieved
17 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development suspension components (OEE Overall Equipment Effectiveness)
Radtraumlger
Start Shop Floor Management with
FORCAM +10
_
18 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development (20+ Increase in OEE in AUDI Stamping Facilities) (OEE Overall Equipment Effectiveness)
Radtraumlger
Start SFM +20
_
Our Beliefs
Respect
Collaboration
Excellence
Integrity
Community
Oct 30th 2013
Lean with Shop Floor Management BorgWarner Turbo Systems Rzeszow
Operator FactoryFrameworktrade Worker Client- Book On
Operator Downtime Reasons
Operator Actual versus Target Performance
TargetPlanned
Throughput
Actual
Performance
Opportunity for
Improvement
Actual
Throughput Machine
Data
ERP
Data
Supervisor Gantt Status
visualzation
Top 5
downtimes
Cip Top 5
Production
orders
Real data
history
Supervisor Cockpit machine
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
GENERAL MANAGERSrsquo MEETING September 10 2014 800am ndash 100pm
McCormick Place West Hall mdash Rooms 470aampb 800 am ndash 830 am Continental Breakfast Room W470a 830 am ndash 845 am Welcome by Mr Douglas K Woods President AMT ndash The Association For Manufacturing Technology 845 am ndash 945 am Economic Outlook Global Economic Outlook Improvements But Risks Remain Mr Gregory Daco Chief US Economist Oxford Economics
Mr Gregory Daco is Chief US Economist at Oxford Economics He is responsible for producing the US macroeconomic forecast using Oxford Economicsrsquo proprietary Global Economic Model Gregory tracks and forecasts high-frequency indicators and oversees the production of US research pieces on consumer markets housing business investment international trade labor markets inflation and fiscal and monetary policy Gregory is frequently cited in leading business publications such as the Financial Times the New York Times and the Wall Street Journal and he regularly appears on radio and television programs Prior to joining Oxford Economics Gregory was Director US Macroeconomics at IHS Global Insight He also worked in the Economic Affairs Department of the Belgian Embassy in Australia and the Permanent Representation of Belgium to the UN in Geneva Gregory is co-founder and president of the Boston Chapter of the National Association for Business Economics He holds a Master of Arts in economics from Boston University and a Master in Business Administration from Universiteacute de Louvain in Belgium
945 am ndash 1000 am Break 1000 am ndash 1100 am Digital Manufacturing
World Class Shop Floor Management Release 5 The Smart Factory Revolution
Mr Franz E Gruber Founder amp CEO Dr Mohamed Abuali PhD COO FORCAM Inc
Mr Franz Gruber is the Founder Chairman and CEO of FORCAM A former IBM Manager and a veteran SAP Executive Franz has over 25 years of practical experience working directly with automotive aerospace and defense and medical devices discrete manufacturing industries Within a decade of founding FORCAM in Germany he strategically expanded company operations globally to the United Kingdom Eastern Europe and the United States FORCAMs technology now monitors and optimizes the performance of over 50000 industrial assets globally in automotive aerospace and defense machinery medical devices and other industrial sectors Dr Mohamed Abuali is responsible for leading and managing the full life cycle of FORCAMrsquos shop floor technology at discrete manufacturing companies in automotive aerospace medical devices and oil amp gas Mohamed brings 15 years of
manufacturing experience specializing in program and project management as well as research and development of shop floor technologies Dr Abuali has a PhD in Industrial Engineering through his studies at the Center for Intelligent Maintenance Systems (IMS) at the University of Cincinnati He is also a Project Management Professional (PMP) a Six Sigma Green Belt (SSGB) and a Certified Quality Engineer (CQE) FORCAM will be exhibiting at IMTS at Booth E-4929 and Dr Abuali extends an invitation to all to visit their booth to see interoperability in action
MTConnect Evolution of a Standard and Next Generation Interoperability Mr Courtney Hill Chairman amp President MTConnect Institute
Mr Courtney Hill retired from the General Electric Company after a 36-year career in manufacturing technology process development and commercialization Presently Courtney operates CJ Hill Consulting Services As the General Manager of Manufacturing Technology a global technology organization for GE Aviation Courtney was responsible for the development of next generation affordable manufacturing and inspection processes that support GE Aviationrsquos products and services worldwide Notable areas of recent technology development and commercialization include high performance structural composites additive manufacturing ceramic matric composites advanced robotic applications and digital manufacturing A graduate of Lehigh University Mr Hill currently serves as Chairman of the Board of the National Center for Manufacturing Sciences and the President and Chairman of the Board for the MTConnect Institute He has also served on the boards of TechSolve and the Edison Welding Institute
QampA Session 1100 am ndash 1115 am International Additive Manufacturing Award Dr Wilfried Schaumlfer Executive Director VDW ndash German Machine Tool Buildersrsquo Association Douglas K Woods President AMT ndash The Association For Manufacturing Technology 1115 am ndash 1145 am Open Forum
Open discussion on common issues pressing on the manufacturing technology industry markets and technological advances Examples of such issues bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment
Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
1145 am ndash 100 pm Reception amp Luncheon Room W470b
September 10 2014 2014 General Managersrsquo Meeting
Meeting Agenda 800 am - 830am Continental Breakfast 830 am - 845am Welcome by Mr Douglas K Woods 845 am - 945am Economic Outlook 945 am - 1000am Break 1000 am - 1100am Digital Manufacturing 1100 am - 1115am International Award for Additive Manufacturing 1115 am - 1145am Open Forum 1145 am - 100pm Reception and Luncheon
September 10 2014 2014 General Managersrsquo Meeting
Welcome
Mr Douglas K Woods President
AMT - The Association For Manufacturing Technology
September 10 2014 2014 General Managersrsquo Meeting
Economic Outlook
Mr Gregory Daco Chief US Economist
Oxford Economics
Global Economic Outlook Improvements But Risks Remain
Gregory Daco
Chief US Economist gregorydacooxfordeconomicscom
September 2014
Global economy on a modest growth path
After a roller-coaster ride in early 2014 the US economy should steady around 3 upcoming quarters
Eurozone improving but risks remain (deflation Ukraine)
Japan on a modest expansion path with inflation trending up but questions around the resilience of the economy (tax hike)
Additional support from the government has fed through to growth in China and the economy is now expected to come close to the governmentrsquos 75 growth target for this year
Outlook for other emergers is less positive Russiarsquos economy continues to suffer from structural weaknesses and the repercussions of the conflict in Ukraine Brazil and India are showing no signs of picking up with structural deficiencies weighing on growth
US pulling ahead after slow start to 2014
6
Eurozone outlook Caution slow recovery in progress
Eurozone recovery still ongoing buthellip
8
Strong disinflationary forces in the Eurozone
9
Recovery will be steady rather than spectacular
10
-8
-6
-4
-2
0
2
4
6
1999 2002 2005 2008 2011 2014 2017 2020
Source Oxford EconomicsHaver Analytics
Europe GDP year
UK
Eurozone
Forecast
Current situation not dramatic but full scale conflict hellip
11
-6
-5
-4
-3
-2
-1
0
1
2
3
4
2006 2008 2010 2012 2014 2016 2018
Eurozone GDP year
Source Oxford EconomicsHaver Analytics
BaselineForecast
Military conflict in Ukraine
China Outlook A bumpy landing
China growth to slow as rebalancing continueshellip
13
hellipas debt piles up to worrying levels
14
Real estate sector increasingly at risk
15
Japan Slowing in spite of Abenomics
Consumption tax weighs heavily on growth
17
2013 2014
-40
-30
-20
-10
00
10
20
30
Q3 Q4 Q1 Q2
Private consumptionFixed investmentNet exportsGovernment consumptionStockbuildingGDP
Japan Quarterly GDP contributions
quarterly contribution
Source Cabinet Office of Japan Haver Analytics
-3
-2
-1
0
1
2
3
4
1990 1995 2000 2005 2010 2015
Japan Fiscal policyChange in structural budget balance of GDP
Source International Monetary Fund Haver Analytics
ForecastExpansion
Contraction
Emergers Modest growth with structural issues
19
Does it still make sense to talk about ldquoBRICSrdquo
Some countries more vulnerable than others
20
1 Turkey 1182 S Africa 763 Brazil 404 Thailand 295 Russia 266 Malaysia 187 India 018 Poland 019 Mexico -2010 Indonesia -2511 Korea -8012 Philippines -9113 China -93
Oxford Economics Risk Scorecard
Emerging markets will still outpace developed world
21
US Outlook The US is the cleanest shirt in the laundry basket
GDP on a roller-coaster but employment is better indicator
19
Business surveys pointing to strong growthhellip
24
Consumers are feeling more cheerfulhellip
25
Wages expected to risehellip
26
Key domestic risk is housing activityhellip
27
hellipbut rising income and pent-up demand will help
24
Energy prices remain relatively stable
29
Fed to taper on but hold off on rate hikes
30
This image cannot currently be displayed
First rate hike in 2015Q2
Manufacturing in focus
Manufacturing activity is boominghellip
Further indication that GDP decline is due to unique factors
28
hellipwith encouraging signs from leading indicators
29
US manufacturing has outperformed its peershellip
30
US has made substantial gains in competitiveness
35
Remarkable improvements
Due to productivity gains amp modest wage growthhellip
36
Remarkable improvements
Business sentiment in Europe remains weak while new orders have slowed
37
China amp Brazil have lost their edgehellip
38
Chinese wages have more than doubled over the past decade
Key industries
Loose credit and rising demand for autoshellip
36
hellipshould support productionhellip
20
25
30
35
40
45
50
405060708090
100110120130140150160
Jul-09 Jul-10 Jul-11 Jul-12 Jul-13 Jul-14
2010=100 US$ bn
Output (LHS)
Orders (RHS)
Source Oxford Economics Haver Analytics
US Output and orders
3 month moving average
37
hellipas will opportunities in the Emergers
38
Revamp of car stock to be key long-term driver
Ageing vehicle fleet replacement as economy recovers ndash average age of vehicle on US roads in 11frac12 years
Rising fuel efficiency standards leading to replacement of clunkers
Rising fuels costs resulting in smaller cars
Automakers likely to increase new models helping drive investment
Aerospace solid order books at the big twohellip
0
250
500
750
1000
1250
1500
1750
1994 1996 1998 2000 2002 2004 2006 2008 2010 2012 2014
Source Company reports
Airbus versus Boeing Orders
Airbus
Boeing
Number of aircraft
Note 2014 annual estimate based on annualized data through July
40
hellipwith APAC to drive long-term growth
Asia will account for almost 32 of global passenger traffic by 2017 compared to 28 in 2012
APAC to account for 40 of plane deliveries over next 20 years
US and Europe sales mainly for replacement of existing fleet
41
Need for efficiency will provide demand supporthellip
A330 revamped for 15 efficiency improvement to compete with Dreamliner 25 new orders on day of announcement
Long-haul efficiency has some ways to go to maintain airline profitability
42
Order backlogs remain high
0
500
1000
1500
2000
2500
3000
3500
1990 1993 1996 1999 2002 2005 2008 2011 2014
Deliveries
Orders
Number of aircraftAirbus amp Boeing Orders amp deliveries
Source Company reports and forecasts
43
Weaker demand for metalshellip
44
hellipand over capacity are weighing on priceshellip
45
hellipand discouraging investment
BHP Capital spending fell 32 in FY14 with another 8 fall expected next year
Rio Tinto Capital spending in FY14 cut faster than initially projected and further cut is budgeted for 2015
This is weighing on equipment makers
Caterpillar reported sales down 9 in the three months to July with sales to mining firms down 33 from the same period a year earlier
Bumper crop has brought down grain prices
47
helliphitting margins and investment
Producers are facing higher costs due to the implementation of Tier 4 engines developed to comply with emissions standards
Weaker margins are leading to farmers cutting back investment spending
John Deere has posted a 5 yy decline in revenues with an 11 decline in its agricultural division
Conclusions amp market implications
Conclusion and business implications
54
bull US economy expected to gradually accelerate through 2014 with support from a dovish Fed
bull Europe expected to recover but more ECB action could be required
bull Chinese economy is gradually rebalancing but banking crisis cannot be discounted
bull Emerging markets quiet for now but structural issue unsolved
bull Geopolitical tensions in the Middle East and Ukraine are being monitored carefully
Thank you
Gregory Daco
Chief US Economist gregorydacooxfordeconomicscom
September 2014
September 10 2014 2014 General Managersrsquo Meeting
Digital Manufacturing
World Class Shop Floor Management Release 5 The Smart Factory Revolution Mr Franz E Gruber Founder amp CEO
Dr Mohamed Abuali COO FORCAM Inc
MTConnect Evolution of a Standard and
Next Generation Interoperability Mr Courtney J Hill Chairman amp President
MTConnect Institute
QampA Session
World Class
Shop Floor Management
The Smart Factory Revolution
Franz E Gruber
Founder amp CEO
Mohamed Abuali
COO
汉语
World Class Shop Floor Management
FORCAM 2014 Page 2
FORCAMlsquos Passion
FORCAM provides proven
manufacturing solutions to
Continuously Improve Productivity
To be the global solutions provider of
the best-in-class Manufacturing
Execution Systems
FORCAM 2014 Page 3
FORCAM ndash 2014 Best Practices Award by Frost amp Sullivan
Frost amp Sullivan
ldquoFORCAM is a plant production software
solution provider that understands and
supports Industry 40 needsrdquo
FORCAM 2014 Page 4
FORCAMrsquos Testimonials and Industry Leadership
FORCAM 2014 Page 5
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
6 B Bartke S Wagner IPI-2
Shop Floor Management Audi - FORCAM FIT 2011-
Bernhard Bartke - Director Components Manufacturing
Stefan Wagner - Director Gear Manufacturing
7 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
bull Collection and recording of Operational Data via a database
(ex Machine States and State Changes)
Machine
Operator
Production Manager
Technical Assistant IT
Plant
Manager
Team Leader
8 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Interfaces
Time
Objectivity of Process Data
9 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Need for Continuous Improvement
bull Objective Information and Communication ndash across ALL levels
bull Transperancy and Visualization - Online
bull Real-time availability of operational data ndash Live Reports
bull Measurable increase in Plant Efficiency (OEE)
10 B Bartke S Wagner IPI-2
Shop Floor Management ndash Realtime bdquoANDONldquo Visualization
bull Web-based Interface Anywhere Anytime Access
bull Real-time Production Status Visualization
In Production
Overflow
Stoppage
Organizational
Stoppage
Idle (Pause)
Tool
Problem
11 B Bartke S Wagner IPI-2
Shop Floor Management Reporting ndash Hierarchical Status Diagrams
bull Reporting for Machines Groups Lines or the whole Plant
Technical
Stoppage In Production
Organizational
Stoppage Pause Overflow
Stoppage
Tool Problem In Setup
12 B Bartke S Wagner IPI-2
Audi Production System (APS)
Leadership Communication
bull Process Control
Standards
bull In Processes
bull Im Products
bull In the Organization
Learning Organization
bull Employee Development
bull Problem-Solving
bull CIP Culture
13 B Bartke S Wagner IPI-2
Shop Floor Management Process Control Panel on the shop floor
OEE Trend
(Day Week Month)
Measures
Quality
Process Control
14 B Bartke S Wagner IPI-2
OEE - Yesterday
Availability Trend
OEE ndash Last Week
OEE ndash Last Month
Naoki Nojiri IPI-25 BDE-Ist Stand 05042011
Shop Floor Management Process Control Panel on the shop floor
15 B Bartke S Wagner IPI-2
Shop Floor Management Management Cockpit
Planned vs Actual
(shift)
Top problems
(challenges)
OEE ndash Last Week
16 B Bartke S Wagner IPI-2
hellipand what have we achieved
17 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development suspension components (OEE Overall Equipment Effectiveness)
Radtraumlger
Start Shop Floor Management with
FORCAM +10
_
18 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development (20+ Increase in OEE in AUDI Stamping Facilities) (OEE Overall Equipment Effectiveness)
Radtraumlger
Start SFM +20
_
Our Beliefs
Respect
Collaboration
Excellence
Integrity
Community
Oct 30th 2013
Lean with Shop Floor Management BorgWarner Turbo Systems Rzeszow
Operator FactoryFrameworktrade Worker Client- Book On
Operator Downtime Reasons
Operator Actual versus Target Performance
TargetPlanned
Throughput
Actual
Performance
Opportunity for
Improvement
Actual
Throughput Machine
Data
ERP
Data
Supervisor Gantt Status
visualzation
Top 5
downtimes
Cip Top 5
Production
orders
Real data
history
Supervisor Cockpit machine
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
manufacturing experience specializing in program and project management as well as research and development of shop floor technologies Dr Abuali has a PhD in Industrial Engineering through his studies at the Center for Intelligent Maintenance Systems (IMS) at the University of Cincinnati He is also a Project Management Professional (PMP) a Six Sigma Green Belt (SSGB) and a Certified Quality Engineer (CQE) FORCAM will be exhibiting at IMTS at Booth E-4929 and Dr Abuali extends an invitation to all to visit their booth to see interoperability in action
MTConnect Evolution of a Standard and Next Generation Interoperability Mr Courtney Hill Chairman amp President MTConnect Institute
Mr Courtney Hill retired from the General Electric Company after a 36-year career in manufacturing technology process development and commercialization Presently Courtney operates CJ Hill Consulting Services As the General Manager of Manufacturing Technology a global technology organization for GE Aviation Courtney was responsible for the development of next generation affordable manufacturing and inspection processes that support GE Aviationrsquos products and services worldwide Notable areas of recent technology development and commercialization include high performance structural composites additive manufacturing ceramic matric composites advanced robotic applications and digital manufacturing A graduate of Lehigh University Mr Hill currently serves as Chairman of the Board of the National Center for Manufacturing Sciences and the President and Chairman of the Board for the MTConnect Institute He has also served on the boards of TechSolve and the Edison Welding Institute
QampA Session 1100 am ndash 1115 am International Additive Manufacturing Award Dr Wilfried Schaumlfer Executive Director VDW ndash German Machine Tool Buildersrsquo Association Douglas K Woods President AMT ndash The Association For Manufacturing Technology 1115 am ndash 1145 am Open Forum
Open discussion on common issues pressing on the manufacturing technology industry markets and technological advances Examples of such issues bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment
Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
1145 am ndash 100 pm Reception amp Luncheon Room W470b
September 10 2014 2014 General Managersrsquo Meeting
Meeting Agenda 800 am - 830am Continental Breakfast 830 am - 845am Welcome by Mr Douglas K Woods 845 am - 945am Economic Outlook 945 am - 1000am Break 1000 am - 1100am Digital Manufacturing 1100 am - 1115am International Award for Additive Manufacturing 1115 am - 1145am Open Forum 1145 am - 100pm Reception and Luncheon
September 10 2014 2014 General Managersrsquo Meeting
Welcome
Mr Douglas K Woods President
AMT - The Association For Manufacturing Technology
September 10 2014 2014 General Managersrsquo Meeting
Economic Outlook
Mr Gregory Daco Chief US Economist
Oxford Economics
Global Economic Outlook Improvements But Risks Remain
Gregory Daco
Chief US Economist gregorydacooxfordeconomicscom
September 2014
Global economy on a modest growth path
After a roller-coaster ride in early 2014 the US economy should steady around 3 upcoming quarters
Eurozone improving but risks remain (deflation Ukraine)
Japan on a modest expansion path with inflation trending up but questions around the resilience of the economy (tax hike)
Additional support from the government has fed through to growth in China and the economy is now expected to come close to the governmentrsquos 75 growth target for this year
Outlook for other emergers is less positive Russiarsquos economy continues to suffer from structural weaknesses and the repercussions of the conflict in Ukraine Brazil and India are showing no signs of picking up with structural deficiencies weighing on growth
US pulling ahead after slow start to 2014
6
Eurozone outlook Caution slow recovery in progress
Eurozone recovery still ongoing buthellip
8
Strong disinflationary forces in the Eurozone
9
Recovery will be steady rather than spectacular
10
-8
-6
-4
-2
0
2
4
6
1999 2002 2005 2008 2011 2014 2017 2020
Source Oxford EconomicsHaver Analytics
Europe GDP year
UK
Eurozone
Forecast
Current situation not dramatic but full scale conflict hellip
11
-6
-5
-4
-3
-2
-1
0
1
2
3
4
2006 2008 2010 2012 2014 2016 2018
Eurozone GDP year
Source Oxford EconomicsHaver Analytics
BaselineForecast
Military conflict in Ukraine
China Outlook A bumpy landing
China growth to slow as rebalancing continueshellip
13
hellipas debt piles up to worrying levels
14
Real estate sector increasingly at risk
15
Japan Slowing in spite of Abenomics
Consumption tax weighs heavily on growth
17
2013 2014
-40
-30
-20
-10
00
10
20
30
Q3 Q4 Q1 Q2
Private consumptionFixed investmentNet exportsGovernment consumptionStockbuildingGDP
Japan Quarterly GDP contributions
quarterly contribution
Source Cabinet Office of Japan Haver Analytics
-3
-2
-1
0
1
2
3
4
1990 1995 2000 2005 2010 2015
Japan Fiscal policyChange in structural budget balance of GDP
Source International Monetary Fund Haver Analytics
ForecastExpansion
Contraction
Emergers Modest growth with structural issues
19
Does it still make sense to talk about ldquoBRICSrdquo
Some countries more vulnerable than others
20
1 Turkey 1182 S Africa 763 Brazil 404 Thailand 295 Russia 266 Malaysia 187 India 018 Poland 019 Mexico -2010 Indonesia -2511 Korea -8012 Philippines -9113 China -93
Oxford Economics Risk Scorecard
Emerging markets will still outpace developed world
21
US Outlook The US is the cleanest shirt in the laundry basket
GDP on a roller-coaster but employment is better indicator
19
Business surveys pointing to strong growthhellip
24
Consumers are feeling more cheerfulhellip
25
Wages expected to risehellip
26
Key domestic risk is housing activityhellip
27
hellipbut rising income and pent-up demand will help
24
Energy prices remain relatively stable
29
Fed to taper on but hold off on rate hikes
30
This image cannot currently be displayed
First rate hike in 2015Q2
Manufacturing in focus
Manufacturing activity is boominghellip
Further indication that GDP decline is due to unique factors
28
hellipwith encouraging signs from leading indicators
29
US manufacturing has outperformed its peershellip
30
US has made substantial gains in competitiveness
35
Remarkable improvements
Due to productivity gains amp modest wage growthhellip
36
Remarkable improvements
Business sentiment in Europe remains weak while new orders have slowed
37
China amp Brazil have lost their edgehellip
38
Chinese wages have more than doubled over the past decade
Key industries
Loose credit and rising demand for autoshellip
36
hellipshould support productionhellip
20
25
30
35
40
45
50
405060708090
100110120130140150160
Jul-09 Jul-10 Jul-11 Jul-12 Jul-13 Jul-14
2010=100 US$ bn
Output (LHS)
Orders (RHS)
Source Oxford Economics Haver Analytics
US Output and orders
3 month moving average
37
hellipas will opportunities in the Emergers
38
Revamp of car stock to be key long-term driver
Ageing vehicle fleet replacement as economy recovers ndash average age of vehicle on US roads in 11frac12 years
Rising fuel efficiency standards leading to replacement of clunkers
Rising fuels costs resulting in smaller cars
Automakers likely to increase new models helping drive investment
Aerospace solid order books at the big twohellip
0
250
500
750
1000
1250
1500
1750
1994 1996 1998 2000 2002 2004 2006 2008 2010 2012 2014
Source Company reports
Airbus versus Boeing Orders
Airbus
Boeing
Number of aircraft
Note 2014 annual estimate based on annualized data through July
40
hellipwith APAC to drive long-term growth
Asia will account for almost 32 of global passenger traffic by 2017 compared to 28 in 2012
APAC to account for 40 of plane deliveries over next 20 years
US and Europe sales mainly for replacement of existing fleet
41
Need for efficiency will provide demand supporthellip
A330 revamped for 15 efficiency improvement to compete with Dreamliner 25 new orders on day of announcement
Long-haul efficiency has some ways to go to maintain airline profitability
42
Order backlogs remain high
0
500
1000
1500
2000
2500
3000
3500
1990 1993 1996 1999 2002 2005 2008 2011 2014
Deliveries
Orders
Number of aircraftAirbus amp Boeing Orders amp deliveries
Source Company reports and forecasts
43
Weaker demand for metalshellip
44
hellipand over capacity are weighing on priceshellip
45
hellipand discouraging investment
BHP Capital spending fell 32 in FY14 with another 8 fall expected next year
Rio Tinto Capital spending in FY14 cut faster than initially projected and further cut is budgeted for 2015
This is weighing on equipment makers
Caterpillar reported sales down 9 in the three months to July with sales to mining firms down 33 from the same period a year earlier
Bumper crop has brought down grain prices
47
helliphitting margins and investment
Producers are facing higher costs due to the implementation of Tier 4 engines developed to comply with emissions standards
Weaker margins are leading to farmers cutting back investment spending
John Deere has posted a 5 yy decline in revenues with an 11 decline in its agricultural division
Conclusions amp market implications
Conclusion and business implications
54
bull US economy expected to gradually accelerate through 2014 with support from a dovish Fed
bull Europe expected to recover but more ECB action could be required
bull Chinese economy is gradually rebalancing but banking crisis cannot be discounted
bull Emerging markets quiet for now but structural issue unsolved
bull Geopolitical tensions in the Middle East and Ukraine are being monitored carefully
Thank you
Gregory Daco
Chief US Economist gregorydacooxfordeconomicscom
September 2014
September 10 2014 2014 General Managersrsquo Meeting
Digital Manufacturing
World Class Shop Floor Management Release 5 The Smart Factory Revolution Mr Franz E Gruber Founder amp CEO
Dr Mohamed Abuali COO FORCAM Inc
MTConnect Evolution of a Standard and
Next Generation Interoperability Mr Courtney J Hill Chairman amp President
MTConnect Institute
QampA Session
World Class
Shop Floor Management
The Smart Factory Revolution
Franz E Gruber
Founder amp CEO
Mohamed Abuali
COO
汉语
World Class Shop Floor Management
FORCAM 2014 Page 2
FORCAMlsquos Passion
FORCAM provides proven
manufacturing solutions to
Continuously Improve Productivity
To be the global solutions provider of
the best-in-class Manufacturing
Execution Systems
FORCAM 2014 Page 3
FORCAM ndash 2014 Best Practices Award by Frost amp Sullivan
Frost amp Sullivan
ldquoFORCAM is a plant production software
solution provider that understands and
supports Industry 40 needsrdquo
FORCAM 2014 Page 4
FORCAMrsquos Testimonials and Industry Leadership
FORCAM 2014 Page 5
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
6 B Bartke S Wagner IPI-2
Shop Floor Management Audi - FORCAM FIT 2011-
Bernhard Bartke - Director Components Manufacturing
Stefan Wagner - Director Gear Manufacturing
7 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
bull Collection and recording of Operational Data via a database
(ex Machine States and State Changes)
Machine
Operator
Production Manager
Technical Assistant IT
Plant
Manager
Team Leader
8 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Interfaces
Time
Objectivity of Process Data
9 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Need for Continuous Improvement
bull Objective Information and Communication ndash across ALL levels
bull Transperancy and Visualization - Online
bull Real-time availability of operational data ndash Live Reports
bull Measurable increase in Plant Efficiency (OEE)
10 B Bartke S Wagner IPI-2
Shop Floor Management ndash Realtime bdquoANDONldquo Visualization
bull Web-based Interface Anywhere Anytime Access
bull Real-time Production Status Visualization
In Production
Overflow
Stoppage
Organizational
Stoppage
Idle (Pause)
Tool
Problem
11 B Bartke S Wagner IPI-2
Shop Floor Management Reporting ndash Hierarchical Status Diagrams
bull Reporting for Machines Groups Lines or the whole Plant
Technical
Stoppage In Production
Organizational
Stoppage Pause Overflow
Stoppage
Tool Problem In Setup
12 B Bartke S Wagner IPI-2
Audi Production System (APS)
Leadership Communication
bull Process Control
Standards
bull In Processes
bull Im Products
bull In the Organization
Learning Organization
bull Employee Development
bull Problem-Solving
bull CIP Culture
13 B Bartke S Wagner IPI-2
Shop Floor Management Process Control Panel on the shop floor
OEE Trend
(Day Week Month)
Measures
Quality
Process Control
14 B Bartke S Wagner IPI-2
OEE - Yesterday
Availability Trend
OEE ndash Last Week
OEE ndash Last Month
Naoki Nojiri IPI-25 BDE-Ist Stand 05042011
Shop Floor Management Process Control Panel on the shop floor
15 B Bartke S Wagner IPI-2
Shop Floor Management Management Cockpit
Planned vs Actual
(shift)
Top problems
(challenges)
OEE ndash Last Week
16 B Bartke S Wagner IPI-2
hellipand what have we achieved
17 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development suspension components (OEE Overall Equipment Effectiveness)
Radtraumlger
Start Shop Floor Management with
FORCAM +10
_
18 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development (20+ Increase in OEE in AUDI Stamping Facilities) (OEE Overall Equipment Effectiveness)
Radtraumlger
Start SFM +20
_
Our Beliefs
Respect
Collaboration
Excellence
Integrity
Community
Oct 30th 2013
Lean with Shop Floor Management BorgWarner Turbo Systems Rzeszow
Operator FactoryFrameworktrade Worker Client- Book On
Operator Downtime Reasons
Operator Actual versus Target Performance
TargetPlanned
Throughput
Actual
Performance
Opportunity for
Improvement
Actual
Throughput Machine
Data
ERP
Data
Supervisor Gantt Status
visualzation
Top 5
downtimes
Cip Top 5
Production
orders
Real data
history
Supervisor Cockpit machine
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
September 10 2014 2014 General Managersrsquo Meeting
Meeting Agenda 800 am - 830am Continental Breakfast 830 am - 845am Welcome by Mr Douglas K Woods 845 am - 945am Economic Outlook 945 am - 1000am Break 1000 am - 1100am Digital Manufacturing 1100 am - 1115am International Award for Additive Manufacturing 1115 am - 1145am Open Forum 1145 am - 100pm Reception and Luncheon
September 10 2014 2014 General Managersrsquo Meeting
Welcome
Mr Douglas K Woods President
AMT - The Association For Manufacturing Technology
September 10 2014 2014 General Managersrsquo Meeting
Economic Outlook
Mr Gregory Daco Chief US Economist
Oxford Economics
Global Economic Outlook Improvements But Risks Remain
Gregory Daco
Chief US Economist gregorydacooxfordeconomicscom
September 2014
Global economy on a modest growth path
After a roller-coaster ride in early 2014 the US economy should steady around 3 upcoming quarters
Eurozone improving but risks remain (deflation Ukraine)
Japan on a modest expansion path with inflation trending up but questions around the resilience of the economy (tax hike)
Additional support from the government has fed through to growth in China and the economy is now expected to come close to the governmentrsquos 75 growth target for this year
Outlook for other emergers is less positive Russiarsquos economy continues to suffer from structural weaknesses and the repercussions of the conflict in Ukraine Brazil and India are showing no signs of picking up with structural deficiencies weighing on growth
US pulling ahead after slow start to 2014
6
Eurozone outlook Caution slow recovery in progress
Eurozone recovery still ongoing buthellip
8
Strong disinflationary forces in the Eurozone
9
Recovery will be steady rather than spectacular
10
-8
-6
-4
-2
0
2
4
6
1999 2002 2005 2008 2011 2014 2017 2020
Source Oxford EconomicsHaver Analytics
Europe GDP year
UK
Eurozone
Forecast
Current situation not dramatic but full scale conflict hellip
11
-6
-5
-4
-3
-2
-1
0
1
2
3
4
2006 2008 2010 2012 2014 2016 2018
Eurozone GDP year
Source Oxford EconomicsHaver Analytics
BaselineForecast
Military conflict in Ukraine
China Outlook A bumpy landing
China growth to slow as rebalancing continueshellip
13
hellipas debt piles up to worrying levels
14
Real estate sector increasingly at risk
15
Japan Slowing in spite of Abenomics
Consumption tax weighs heavily on growth
17
2013 2014
-40
-30
-20
-10
00
10
20
30
Q3 Q4 Q1 Q2
Private consumptionFixed investmentNet exportsGovernment consumptionStockbuildingGDP
Japan Quarterly GDP contributions
quarterly contribution
Source Cabinet Office of Japan Haver Analytics
-3
-2
-1
0
1
2
3
4
1990 1995 2000 2005 2010 2015
Japan Fiscal policyChange in structural budget balance of GDP
Source International Monetary Fund Haver Analytics
ForecastExpansion
Contraction
Emergers Modest growth with structural issues
19
Does it still make sense to talk about ldquoBRICSrdquo
Some countries more vulnerable than others
20
1 Turkey 1182 S Africa 763 Brazil 404 Thailand 295 Russia 266 Malaysia 187 India 018 Poland 019 Mexico -2010 Indonesia -2511 Korea -8012 Philippines -9113 China -93
Oxford Economics Risk Scorecard
Emerging markets will still outpace developed world
21
US Outlook The US is the cleanest shirt in the laundry basket
GDP on a roller-coaster but employment is better indicator
19
Business surveys pointing to strong growthhellip
24
Consumers are feeling more cheerfulhellip
25
Wages expected to risehellip
26
Key domestic risk is housing activityhellip
27
hellipbut rising income and pent-up demand will help
24
Energy prices remain relatively stable
29
Fed to taper on but hold off on rate hikes
30
This image cannot currently be displayed
First rate hike in 2015Q2
Manufacturing in focus
Manufacturing activity is boominghellip
Further indication that GDP decline is due to unique factors
28
hellipwith encouraging signs from leading indicators
29
US manufacturing has outperformed its peershellip
30
US has made substantial gains in competitiveness
35
Remarkable improvements
Due to productivity gains amp modest wage growthhellip
36
Remarkable improvements
Business sentiment in Europe remains weak while new orders have slowed
37
China amp Brazil have lost their edgehellip
38
Chinese wages have more than doubled over the past decade
Key industries
Loose credit and rising demand for autoshellip
36
hellipshould support productionhellip
20
25
30
35
40
45
50
405060708090
100110120130140150160
Jul-09 Jul-10 Jul-11 Jul-12 Jul-13 Jul-14
2010=100 US$ bn
Output (LHS)
Orders (RHS)
Source Oxford Economics Haver Analytics
US Output and orders
3 month moving average
37
hellipas will opportunities in the Emergers
38
Revamp of car stock to be key long-term driver
Ageing vehicle fleet replacement as economy recovers ndash average age of vehicle on US roads in 11frac12 years
Rising fuel efficiency standards leading to replacement of clunkers
Rising fuels costs resulting in smaller cars
Automakers likely to increase new models helping drive investment
Aerospace solid order books at the big twohellip
0
250
500
750
1000
1250
1500
1750
1994 1996 1998 2000 2002 2004 2006 2008 2010 2012 2014
Source Company reports
Airbus versus Boeing Orders
Airbus
Boeing
Number of aircraft
Note 2014 annual estimate based on annualized data through July
40
hellipwith APAC to drive long-term growth
Asia will account for almost 32 of global passenger traffic by 2017 compared to 28 in 2012
APAC to account for 40 of plane deliveries over next 20 years
US and Europe sales mainly for replacement of existing fleet
41
Need for efficiency will provide demand supporthellip
A330 revamped for 15 efficiency improvement to compete with Dreamliner 25 new orders on day of announcement
Long-haul efficiency has some ways to go to maintain airline profitability
42
Order backlogs remain high
0
500
1000
1500
2000
2500
3000
3500
1990 1993 1996 1999 2002 2005 2008 2011 2014
Deliveries
Orders
Number of aircraftAirbus amp Boeing Orders amp deliveries
Source Company reports and forecasts
43
Weaker demand for metalshellip
44
hellipand over capacity are weighing on priceshellip
45
hellipand discouraging investment
BHP Capital spending fell 32 in FY14 with another 8 fall expected next year
Rio Tinto Capital spending in FY14 cut faster than initially projected and further cut is budgeted for 2015
This is weighing on equipment makers
Caterpillar reported sales down 9 in the three months to July with sales to mining firms down 33 from the same period a year earlier
Bumper crop has brought down grain prices
47
helliphitting margins and investment
Producers are facing higher costs due to the implementation of Tier 4 engines developed to comply with emissions standards
Weaker margins are leading to farmers cutting back investment spending
John Deere has posted a 5 yy decline in revenues with an 11 decline in its agricultural division
Conclusions amp market implications
Conclusion and business implications
54
bull US economy expected to gradually accelerate through 2014 with support from a dovish Fed
bull Europe expected to recover but more ECB action could be required
bull Chinese economy is gradually rebalancing but banking crisis cannot be discounted
bull Emerging markets quiet for now but structural issue unsolved
bull Geopolitical tensions in the Middle East and Ukraine are being monitored carefully
Thank you
Gregory Daco
Chief US Economist gregorydacooxfordeconomicscom
September 2014
September 10 2014 2014 General Managersrsquo Meeting
Digital Manufacturing
World Class Shop Floor Management Release 5 The Smart Factory Revolution Mr Franz E Gruber Founder amp CEO
Dr Mohamed Abuali COO FORCAM Inc
MTConnect Evolution of a Standard and
Next Generation Interoperability Mr Courtney J Hill Chairman amp President
MTConnect Institute
QampA Session
World Class
Shop Floor Management
The Smart Factory Revolution
Franz E Gruber
Founder amp CEO
Mohamed Abuali
COO
汉语
World Class Shop Floor Management
FORCAM 2014 Page 2
FORCAMlsquos Passion
FORCAM provides proven
manufacturing solutions to
Continuously Improve Productivity
To be the global solutions provider of
the best-in-class Manufacturing
Execution Systems
FORCAM 2014 Page 3
FORCAM ndash 2014 Best Practices Award by Frost amp Sullivan
Frost amp Sullivan
ldquoFORCAM is a plant production software
solution provider that understands and
supports Industry 40 needsrdquo
FORCAM 2014 Page 4
FORCAMrsquos Testimonials and Industry Leadership
FORCAM 2014 Page 5
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
6 B Bartke S Wagner IPI-2
Shop Floor Management Audi - FORCAM FIT 2011-
Bernhard Bartke - Director Components Manufacturing
Stefan Wagner - Director Gear Manufacturing
7 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
bull Collection and recording of Operational Data via a database
(ex Machine States and State Changes)
Machine
Operator
Production Manager
Technical Assistant IT
Plant
Manager
Team Leader
8 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Interfaces
Time
Objectivity of Process Data
9 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Need for Continuous Improvement
bull Objective Information and Communication ndash across ALL levels
bull Transperancy and Visualization - Online
bull Real-time availability of operational data ndash Live Reports
bull Measurable increase in Plant Efficiency (OEE)
10 B Bartke S Wagner IPI-2
Shop Floor Management ndash Realtime bdquoANDONldquo Visualization
bull Web-based Interface Anywhere Anytime Access
bull Real-time Production Status Visualization
In Production
Overflow
Stoppage
Organizational
Stoppage
Idle (Pause)
Tool
Problem
11 B Bartke S Wagner IPI-2
Shop Floor Management Reporting ndash Hierarchical Status Diagrams
bull Reporting for Machines Groups Lines or the whole Plant
Technical
Stoppage In Production
Organizational
Stoppage Pause Overflow
Stoppage
Tool Problem In Setup
12 B Bartke S Wagner IPI-2
Audi Production System (APS)
Leadership Communication
bull Process Control
Standards
bull In Processes
bull Im Products
bull In the Organization
Learning Organization
bull Employee Development
bull Problem-Solving
bull CIP Culture
13 B Bartke S Wagner IPI-2
Shop Floor Management Process Control Panel on the shop floor
OEE Trend
(Day Week Month)
Measures
Quality
Process Control
14 B Bartke S Wagner IPI-2
OEE - Yesterday
Availability Trend
OEE ndash Last Week
OEE ndash Last Month
Naoki Nojiri IPI-25 BDE-Ist Stand 05042011
Shop Floor Management Process Control Panel on the shop floor
15 B Bartke S Wagner IPI-2
Shop Floor Management Management Cockpit
Planned vs Actual
(shift)
Top problems
(challenges)
OEE ndash Last Week
16 B Bartke S Wagner IPI-2
hellipand what have we achieved
17 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development suspension components (OEE Overall Equipment Effectiveness)
Radtraumlger
Start Shop Floor Management with
FORCAM +10
_
18 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development (20+ Increase in OEE in AUDI Stamping Facilities) (OEE Overall Equipment Effectiveness)
Radtraumlger
Start SFM +20
_
Our Beliefs
Respect
Collaboration
Excellence
Integrity
Community
Oct 30th 2013
Lean with Shop Floor Management BorgWarner Turbo Systems Rzeszow
Operator FactoryFrameworktrade Worker Client- Book On
Operator Downtime Reasons
Operator Actual versus Target Performance
TargetPlanned
Throughput
Actual
Performance
Opportunity for
Improvement
Actual
Throughput Machine
Data
ERP
Data
Supervisor Gantt Status
visualzation
Top 5
downtimes
Cip Top 5
Production
orders
Real data
history
Supervisor Cockpit machine
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
September 10 2014 2014 General Managersrsquo Meeting
Welcome
Mr Douglas K Woods President
AMT - The Association For Manufacturing Technology
September 10 2014 2014 General Managersrsquo Meeting
Economic Outlook
Mr Gregory Daco Chief US Economist
Oxford Economics
Global Economic Outlook Improvements But Risks Remain
Gregory Daco
Chief US Economist gregorydacooxfordeconomicscom
September 2014
Global economy on a modest growth path
After a roller-coaster ride in early 2014 the US economy should steady around 3 upcoming quarters
Eurozone improving but risks remain (deflation Ukraine)
Japan on a modest expansion path with inflation trending up but questions around the resilience of the economy (tax hike)
Additional support from the government has fed through to growth in China and the economy is now expected to come close to the governmentrsquos 75 growth target for this year
Outlook for other emergers is less positive Russiarsquos economy continues to suffer from structural weaknesses and the repercussions of the conflict in Ukraine Brazil and India are showing no signs of picking up with structural deficiencies weighing on growth
US pulling ahead after slow start to 2014
6
Eurozone outlook Caution slow recovery in progress
Eurozone recovery still ongoing buthellip
8
Strong disinflationary forces in the Eurozone
9
Recovery will be steady rather than spectacular
10
-8
-6
-4
-2
0
2
4
6
1999 2002 2005 2008 2011 2014 2017 2020
Source Oxford EconomicsHaver Analytics
Europe GDP year
UK
Eurozone
Forecast
Current situation not dramatic but full scale conflict hellip
11
-6
-5
-4
-3
-2
-1
0
1
2
3
4
2006 2008 2010 2012 2014 2016 2018
Eurozone GDP year
Source Oxford EconomicsHaver Analytics
BaselineForecast
Military conflict in Ukraine
China Outlook A bumpy landing
China growth to slow as rebalancing continueshellip
13
hellipas debt piles up to worrying levels
14
Real estate sector increasingly at risk
15
Japan Slowing in spite of Abenomics
Consumption tax weighs heavily on growth
17
2013 2014
-40
-30
-20
-10
00
10
20
30
Q3 Q4 Q1 Q2
Private consumptionFixed investmentNet exportsGovernment consumptionStockbuildingGDP
Japan Quarterly GDP contributions
quarterly contribution
Source Cabinet Office of Japan Haver Analytics
-3
-2
-1
0
1
2
3
4
1990 1995 2000 2005 2010 2015
Japan Fiscal policyChange in structural budget balance of GDP
Source International Monetary Fund Haver Analytics
ForecastExpansion
Contraction
Emergers Modest growth with structural issues
19
Does it still make sense to talk about ldquoBRICSrdquo
Some countries more vulnerable than others
20
1 Turkey 1182 S Africa 763 Brazil 404 Thailand 295 Russia 266 Malaysia 187 India 018 Poland 019 Mexico -2010 Indonesia -2511 Korea -8012 Philippines -9113 China -93
Oxford Economics Risk Scorecard
Emerging markets will still outpace developed world
21
US Outlook The US is the cleanest shirt in the laundry basket
GDP on a roller-coaster but employment is better indicator
19
Business surveys pointing to strong growthhellip
24
Consumers are feeling more cheerfulhellip
25
Wages expected to risehellip
26
Key domestic risk is housing activityhellip
27
hellipbut rising income and pent-up demand will help
24
Energy prices remain relatively stable
29
Fed to taper on but hold off on rate hikes
30
This image cannot currently be displayed
First rate hike in 2015Q2
Manufacturing in focus
Manufacturing activity is boominghellip
Further indication that GDP decline is due to unique factors
28
hellipwith encouraging signs from leading indicators
29
US manufacturing has outperformed its peershellip
30
US has made substantial gains in competitiveness
35
Remarkable improvements
Due to productivity gains amp modest wage growthhellip
36
Remarkable improvements
Business sentiment in Europe remains weak while new orders have slowed
37
China amp Brazil have lost their edgehellip
38
Chinese wages have more than doubled over the past decade
Key industries
Loose credit and rising demand for autoshellip
36
hellipshould support productionhellip
20
25
30
35
40
45
50
405060708090
100110120130140150160
Jul-09 Jul-10 Jul-11 Jul-12 Jul-13 Jul-14
2010=100 US$ bn
Output (LHS)
Orders (RHS)
Source Oxford Economics Haver Analytics
US Output and orders
3 month moving average
37
hellipas will opportunities in the Emergers
38
Revamp of car stock to be key long-term driver
Ageing vehicle fleet replacement as economy recovers ndash average age of vehicle on US roads in 11frac12 years
Rising fuel efficiency standards leading to replacement of clunkers
Rising fuels costs resulting in smaller cars
Automakers likely to increase new models helping drive investment
Aerospace solid order books at the big twohellip
0
250
500
750
1000
1250
1500
1750
1994 1996 1998 2000 2002 2004 2006 2008 2010 2012 2014
Source Company reports
Airbus versus Boeing Orders
Airbus
Boeing
Number of aircraft
Note 2014 annual estimate based on annualized data through July
40
hellipwith APAC to drive long-term growth
Asia will account for almost 32 of global passenger traffic by 2017 compared to 28 in 2012
APAC to account for 40 of plane deliveries over next 20 years
US and Europe sales mainly for replacement of existing fleet
41
Need for efficiency will provide demand supporthellip
A330 revamped for 15 efficiency improvement to compete with Dreamliner 25 new orders on day of announcement
Long-haul efficiency has some ways to go to maintain airline profitability
42
Order backlogs remain high
0
500
1000
1500
2000
2500
3000
3500
1990 1993 1996 1999 2002 2005 2008 2011 2014
Deliveries
Orders
Number of aircraftAirbus amp Boeing Orders amp deliveries
Source Company reports and forecasts
43
Weaker demand for metalshellip
44
hellipand over capacity are weighing on priceshellip
45
hellipand discouraging investment
BHP Capital spending fell 32 in FY14 with another 8 fall expected next year
Rio Tinto Capital spending in FY14 cut faster than initially projected and further cut is budgeted for 2015
This is weighing on equipment makers
Caterpillar reported sales down 9 in the three months to July with sales to mining firms down 33 from the same period a year earlier
Bumper crop has brought down grain prices
47
helliphitting margins and investment
Producers are facing higher costs due to the implementation of Tier 4 engines developed to comply with emissions standards
Weaker margins are leading to farmers cutting back investment spending
John Deere has posted a 5 yy decline in revenues with an 11 decline in its agricultural division
Conclusions amp market implications
Conclusion and business implications
54
bull US economy expected to gradually accelerate through 2014 with support from a dovish Fed
bull Europe expected to recover but more ECB action could be required
bull Chinese economy is gradually rebalancing but banking crisis cannot be discounted
bull Emerging markets quiet for now but structural issue unsolved
bull Geopolitical tensions in the Middle East and Ukraine are being monitored carefully
Thank you
Gregory Daco
Chief US Economist gregorydacooxfordeconomicscom
September 2014
September 10 2014 2014 General Managersrsquo Meeting
Digital Manufacturing
World Class Shop Floor Management Release 5 The Smart Factory Revolution Mr Franz E Gruber Founder amp CEO
Dr Mohamed Abuali COO FORCAM Inc
MTConnect Evolution of a Standard and
Next Generation Interoperability Mr Courtney J Hill Chairman amp President
MTConnect Institute
QampA Session
World Class
Shop Floor Management
The Smart Factory Revolution
Franz E Gruber
Founder amp CEO
Mohamed Abuali
COO
汉语
World Class Shop Floor Management
FORCAM 2014 Page 2
FORCAMlsquos Passion
FORCAM provides proven
manufacturing solutions to
Continuously Improve Productivity
To be the global solutions provider of
the best-in-class Manufacturing
Execution Systems
FORCAM 2014 Page 3
FORCAM ndash 2014 Best Practices Award by Frost amp Sullivan
Frost amp Sullivan
ldquoFORCAM is a plant production software
solution provider that understands and
supports Industry 40 needsrdquo
FORCAM 2014 Page 4
FORCAMrsquos Testimonials and Industry Leadership
FORCAM 2014 Page 5
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
6 B Bartke S Wagner IPI-2
Shop Floor Management Audi - FORCAM FIT 2011-
Bernhard Bartke - Director Components Manufacturing
Stefan Wagner - Director Gear Manufacturing
7 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
bull Collection and recording of Operational Data via a database
(ex Machine States and State Changes)
Machine
Operator
Production Manager
Technical Assistant IT
Plant
Manager
Team Leader
8 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Interfaces
Time
Objectivity of Process Data
9 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Need for Continuous Improvement
bull Objective Information and Communication ndash across ALL levels
bull Transperancy and Visualization - Online
bull Real-time availability of operational data ndash Live Reports
bull Measurable increase in Plant Efficiency (OEE)
10 B Bartke S Wagner IPI-2
Shop Floor Management ndash Realtime bdquoANDONldquo Visualization
bull Web-based Interface Anywhere Anytime Access
bull Real-time Production Status Visualization
In Production
Overflow
Stoppage
Organizational
Stoppage
Idle (Pause)
Tool
Problem
11 B Bartke S Wagner IPI-2
Shop Floor Management Reporting ndash Hierarchical Status Diagrams
bull Reporting for Machines Groups Lines or the whole Plant
Technical
Stoppage In Production
Organizational
Stoppage Pause Overflow
Stoppage
Tool Problem In Setup
12 B Bartke S Wagner IPI-2
Audi Production System (APS)
Leadership Communication
bull Process Control
Standards
bull In Processes
bull Im Products
bull In the Organization
Learning Organization
bull Employee Development
bull Problem-Solving
bull CIP Culture
13 B Bartke S Wagner IPI-2
Shop Floor Management Process Control Panel on the shop floor
OEE Trend
(Day Week Month)
Measures
Quality
Process Control
14 B Bartke S Wagner IPI-2
OEE - Yesterday
Availability Trend
OEE ndash Last Week
OEE ndash Last Month
Naoki Nojiri IPI-25 BDE-Ist Stand 05042011
Shop Floor Management Process Control Panel on the shop floor
15 B Bartke S Wagner IPI-2
Shop Floor Management Management Cockpit
Planned vs Actual
(shift)
Top problems
(challenges)
OEE ndash Last Week
16 B Bartke S Wagner IPI-2
hellipand what have we achieved
17 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development suspension components (OEE Overall Equipment Effectiveness)
Radtraumlger
Start Shop Floor Management with
FORCAM +10
_
18 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development (20+ Increase in OEE in AUDI Stamping Facilities) (OEE Overall Equipment Effectiveness)
Radtraumlger
Start SFM +20
_
Our Beliefs
Respect
Collaboration
Excellence
Integrity
Community
Oct 30th 2013
Lean with Shop Floor Management BorgWarner Turbo Systems Rzeszow
Operator FactoryFrameworktrade Worker Client- Book On
Operator Downtime Reasons
Operator Actual versus Target Performance
TargetPlanned
Throughput
Actual
Performance
Opportunity for
Improvement
Actual
Throughput Machine
Data
ERP
Data
Supervisor Gantt Status
visualzation
Top 5
downtimes
Cip Top 5
Production
orders
Real data
history
Supervisor Cockpit machine
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
September 10 2014 2014 General Managersrsquo Meeting
Economic Outlook
Mr Gregory Daco Chief US Economist
Oxford Economics
Global Economic Outlook Improvements But Risks Remain
Gregory Daco
Chief US Economist gregorydacooxfordeconomicscom
September 2014
Global economy on a modest growth path
After a roller-coaster ride in early 2014 the US economy should steady around 3 upcoming quarters
Eurozone improving but risks remain (deflation Ukraine)
Japan on a modest expansion path with inflation trending up but questions around the resilience of the economy (tax hike)
Additional support from the government has fed through to growth in China and the economy is now expected to come close to the governmentrsquos 75 growth target for this year
Outlook for other emergers is less positive Russiarsquos economy continues to suffer from structural weaknesses and the repercussions of the conflict in Ukraine Brazil and India are showing no signs of picking up with structural deficiencies weighing on growth
US pulling ahead after slow start to 2014
6
Eurozone outlook Caution slow recovery in progress
Eurozone recovery still ongoing buthellip
8
Strong disinflationary forces in the Eurozone
9
Recovery will be steady rather than spectacular
10
-8
-6
-4
-2
0
2
4
6
1999 2002 2005 2008 2011 2014 2017 2020
Source Oxford EconomicsHaver Analytics
Europe GDP year
UK
Eurozone
Forecast
Current situation not dramatic but full scale conflict hellip
11
-6
-5
-4
-3
-2
-1
0
1
2
3
4
2006 2008 2010 2012 2014 2016 2018
Eurozone GDP year
Source Oxford EconomicsHaver Analytics
BaselineForecast
Military conflict in Ukraine
China Outlook A bumpy landing
China growth to slow as rebalancing continueshellip
13
hellipas debt piles up to worrying levels
14
Real estate sector increasingly at risk
15
Japan Slowing in spite of Abenomics
Consumption tax weighs heavily on growth
17
2013 2014
-40
-30
-20
-10
00
10
20
30
Q3 Q4 Q1 Q2
Private consumptionFixed investmentNet exportsGovernment consumptionStockbuildingGDP
Japan Quarterly GDP contributions
quarterly contribution
Source Cabinet Office of Japan Haver Analytics
-3
-2
-1
0
1
2
3
4
1990 1995 2000 2005 2010 2015
Japan Fiscal policyChange in structural budget balance of GDP
Source International Monetary Fund Haver Analytics
ForecastExpansion
Contraction
Emergers Modest growth with structural issues
19
Does it still make sense to talk about ldquoBRICSrdquo
Some countries more vulnerable than others
20
1 Turkey 1182 S Africa 763 Brazil 404 Thailand 295 Russia 266 Malaysia 187 India 018 Poland 019 Mexico -2010 Indonesia -2511 Korea -8012 Philippines -9113 China -93
Oxford Economics Risk Scorecard
Emerging markets will still outpace developed world
21
US Outlook The US is the cleanest shirt in the laundry basket
GDP on a roller-coaster but employment is better indicator
19
Business surveys pointing to strong growthhellip
24
Consumers are feeling more cheerfulhellip
25
Wages expected to risehellip
26
Key domestic risk is housing activityhellip
27
hellipbut rising income and pent-up demand will help
24
Energy prices remain relatively stable
29
Fed to taper on but hold off on rate hikes
30
This image cannot currently be displayed
First rate hike in 2015Q2
Manufacturing in focus
Manufacturing activity is boominghellip
Further indication that GDP decline is due to unique factors
28
hellipwith encouraging signs from leading indicators
29
US manufacturing has outperformed its peershellip
30
US has made substantial gains in competitiveness
35
Remarkable improvements
Due to productivity gains amp modest wage growthhellip
36
Remarkable improvements
Business sentiment in Europe remains weak while new orders have slowed
37
China amp Brazil have lost their edgehellip
38
Chinese wages have more than doubled over the past decade
Key industries
Loose credit and rising demand for autoshellip
36
hellipshould support productionhellip
20
25
30
35
40
45
50
405060708090
100110120130140150160
Jul-09 Jul-10 Jul-11 Jul-12 Jul-13 Jul-14
2010=100 US$ bn
Output (LHS)
Orders (RHS)
Source Oxford Economics Haver Analytics
US Output and orders
3 month moving average
37
hellipas will opportunities in the Emergers
38
Revamp of car stock to be key long-term driver
Ageing vehicle fleet replacement as economy recovers ndash average age of vehicle on US roads in 11frac12 years
Rising fuel efficiency standards leading to replacement of clunkers
Rising fuels costs resulting in smaller cars
Automakers likely to increase new models helping drive investment
Aerospace solid order books at the big twohellip
0
250
500
750
1000
1250
1500
1750
1994 1996 1998 2000 2002 2004 2006 2008 2010 2012 2014
Source Company reports
Airbus versus Boeing Orders
Airbus
Boeing
Number of aircraft
Note 2014 annual estimate based on annualized data through July
40
hellipwith APAC to drive long-term growth
Asia will account for almost 32 of global passenger traffic by 2017 compared to 28 in 2012
APAC to account for 40 of plane deliveries over next 20 years
US and Europe sales mainly for replacement of existing fleet
41
Need for efficiency will provide demand supporthellip
A330 revamped for 15 efficiency improvement to compete with Dreamliner 25 new orders on day of announcement
Long-haul efficiency has some ways to go to maintain airline profitability
42
Order backlogs remain high
0
500
1000
1500
2000
2500
3000
3500
1990 1993 1996 1999 2002 2005 2008 2011 2014
Deliveries
Orders
Number of aircraftAirbus amp Boeing Orders amp deliveries
Source Company reports and forecasts
43
Weaker demand for metalshellip
44
hellipand over capacity are weighing on priceshellip
45
hellipand discouraging investment
BHP Capital spending fell 32 in FY14 with another 8 fall expected next year
Rio Tinto Capital spending in FY14 cut faster than initially projected and further cut is budgeted for 2015
This is weighing on equipment makers
Caterpillar reported sales down 9 in the three months to July with sales to mining firms down 33 from the same period a year earlier
Bumper crop has brought down grain prices
47
helliphitting margins and investment
Producers are facing higher costs due to the implementation of Tier 4 engines developed to comply with emissions standards
Weaker margins are leading to farmers cutting back investment spending
John Deere has posted a 5 yy decline in revenues with an 11 decline in its agricultural division
Conclusions amp market implications
Conclusion and business implications
54
bull US economy expected to gradually accelerate through 2014 with support from a dovish Fed
bull Europe expected to recover but more ECB action could be required
bull Chinese economy is gradually rebalancing but banking crisis cannot be discounted
bull Emerging markets quiet for now but structural issue unsolved
bull Geopolitical tensions in the Middle East and Ukraine are being monitored carefully
Thank you
Gregory Daco
Chief US Economist gregorydacooxfordeconomicscom
September 2014
September 10 2014 2014 General Managersrsquo Meeting
Digital Manufacturing
World Class Shop Floor Management Release 5 The Smart Factory Revolution Mr Franz E Gruber Founder amp CEO
Dr Mohamed Abuali COO FORCAM Inc
MTConnect Evolution of a Standard and
Next Generation Interoperability Mr Courtney J Hill Chairman amp President
MTConnect Institute
QampA Session
World Class
Shop Floor Management
The Smart Factory Revolution
Franz E Gruber
Founder amp CEO
Mohamed Abuali
COO
汉语
World Class Shop Floor Management
FORCAM 2014 Page 2
FORCAMlsquos Passion
FORCAM provides proven
manufacturing solutions to
Continuously Improve Productivity
To be the global solutions provider of
the best-in-class Manufacturing
Execution Systems
FORCAM 2014 Page 3
FORCAM ndash 2014 Best Practices Award by Frost amp Sullivan
Frost amp Sullivan
ldquoFORCAM is a plant production software
solution provider that understands and
supports Industry 40 needsrdquo
FORCAM 2014 Page 4
FORCAMrsquos Testimonials and Industry Leadership
FORCAM 2014 Page 5
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
6 B Bartke S Wagner IPI-2
Shop Floor Management Audi - FORCAM FIT 2011-
Bernhard Bartke - Director Components Manufacturing
Stefan Wagner - Director Gear Manufacturing
7 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
bull Collection and recording of Operational Data via a database
(ex Machine States and State Changes)
Machine
Operator
Production Manager
Technical Assistant IT
Plant
Manager
Team Leader
8 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Interfaces
Time
Objectivity of Process Data
9 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Need for Continuous Improvement
bull Objective Information and Communication ndash across ALL levels
bull Transperancy and Visualization - Online
bull Real-time availability of operational data ndash Live Reports
bull Measurable increase in Plant Efficiency (OEE)
10 B Bartke S Wagner IPI-2
Shop Floor Management ndash Realtime bdquoANDONldquo Visualization
bull Web-based Interface Anywhere Anytime Access
bull Real-time Production Status Visualization
In Production
Overflow
Stoppage
Organizational
Stoppage
Idle (Pause)
Tool
Problem
11 B Bartke S Wagner IPI-2
Shop Floor Management Reporting ndash Hierarchical Status Diagrams
bull Reporting for Machines Groups Lines or the whole Plant
Technical
Stoppage In Production
Organizational
Stoppage Pause Overflow
Stoppage
Tool Problem In Setup
12 B Bartke S Wagner IPI-2
Audi Production System (APS)
Leadership Communication
bull Process Control
Standards
bull In Processes
bull Im Products
bull In the Organization
Learning Organization
bull Employee Development
bull Problem-Solving
bull CIP Culture
13 B Bartke S Wagner IPI-2
Shop Floor Management Process Control Panel on the shop floor
OEE Trend
(Day Week Month)
Measures
Quality
Process Control
14 B Bartke S Wagner IPI-2
OEE - Yesterday
Availability Trend
OEE ndash Last Week
OEE ndash Last Month
Naoki Nojiri IPI-25 BDE-Ist Stand 05042011
Shop Floor Management Process Control Panel on the shop floor
15 B Bartke S Wagner IPI-2
Shop Floor Management Management Cockpit
Planned vs Actual
(shift)
Top problems
(challenges)
OEE ndash Last Week
16 B Bartke S Wagner IPI-2
hellipand what have we achieved
17 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development suspension components (OEE Overall Equipment Effectiveness)
Radtraumlger
Start Shop Floor Management with
FORCAM +10
_
18 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development (20+ Increase in OEE in AUDI Stamping Facilities) (OEE Overall Equipment Effectiveness)
Radtraumlger
Start SFM +20
_
Our Beliefs
Respect
Collaboration
Excellence
Integrity
Community
Oct 30th 2013
Lean with Shop Floor Management BorgWarner Turbo Systems Rzeszow
Operator FactoryFrameworktrade Worker Client- Book On
Operator Downtime Reasons
Operator Actual versus Target Performance
TargetPlanned
Throughput
Actual
Performance
Opportunity for
Improvement
Actual
Throughput Machine
Data
ERP
Data
Supervisor Gantt Status
visualzation
Top 5
downtimes
Cip Top 5
Production
orders
Real data
history
Supervisor Cockpit machine
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
Global Economic Outlook Improvements But Risks Remain
Gregory Daco
Chief US Economist gregorydacooxfordeconomicscom
September 2014
Global economy on a modest growth path
After a roller-coaster ride in early 2014 the US economy should steady around 3 upcoming quarters
Eurozone improving but risks remain (deflation Ukraine)
Japan on a modest expansion path with inflation trending up but questions around the resilience of the economy (tax hike)
Additional support from the government has fed through to growth in China and the economy is now expected to come close to the governmentrsquos 75 growth target for this year
Outlook for other emergers is less positive Russiarsquos economy continues to suffer from structural weaknesses and the repercussions of the conflict in Ukraine Brazil and India are showing no signs of picking up with structural deficiencies weighing on growth
US pulling ahead after slow start to 2014
6
Eurozone outlook Caution slow recovery in progress
Eurozone recovery still ongoing buthellip
8
Strong disinflationary forces in the Eurozone
9
Recovery will be steady rather than spectacular
10
-8
-6
-4
-2
0
2
4
6
1999 2002 2005 2008 2011 2014 2017 2020
Source Oxford EconomicsHaver Analytics
Europe GDP year
UK
Eurozone
Forecast
Current situation not dramatic but full scale conflict hellip
11
-6
-5
-4
-3
-2
-1
0
1
2
3
4
2006 2008 2010 2012 2014 2016 2018
Eurozone GDP year
Source Oxford EconomicsHaver Analytics
BaselineForecast
Military conflict in Ukraine
China Outlook A bumpy landing
China growth to slow as rebalancing continueshellip
13
hellipas debt piles up to worrying levels
14
Real estate sector increasingly at risk
15
Japan Slowing in spite of Abenomics
Consumption tax weighs heavily on growth
17
2013 2014
-40
-30
-20
-10
00
10
20
30
Q3 Q4 Q1 Q2
Private consumptionFixed investmentNet exportsGovernment consumptionStockbuildingGDP
Japan Quarterly GDP contributions
quarterly contribution
Source Cabinet Office of Japan Haver Analytics
-3
-2
-1
0
1
2
3
4
1990 1995 2000 2005 2010 2015
Japan Fiscal policyChange in structural budget balance of GDP
Source International Monetary Fund Haver Analytics
ForecastExpansion
Contraction
Emergers Modest growth with structural issues
19
Does it still make sense to talk about ldquoBRICSrdquo
Some countries more vulnerable than others
20
1 Turkey 1182 S Africa 763 Brazil 404 Thailand 295 Russia 266 Malaysia 187 India 018 Poland 019 Mexico -2010 Indonesia -2511 Korea -8012 Philippines -9113 China -93
Oxford Economics Risk Scorecard
Emerging markets will still outpace developed world
21
US Outlook The US is the cleanest shirt in the laundry basket
GDP on a roller-coaster but employment is better indicator
19
Business surveys pointing to strong growthhellip
24
Consumers are feeling more cheerfulhellip
25
Wages expected to risehellip
26
Key domestic risk is housing activityhellip
27
hellipbut rising income and pent-up demand will help
24
Energy prices remain relatively stable
29
Fed to taper on but hold off on rate hikes
30
This image cannot currently be displayed
First rate hike in 2015Q2
Manufacturing in focus
Manufacturing activity is boominghellip
Further indication that GDP decline is due to unique factors
28
hellipwith encouraging signs from leading indicators
29
US manufacturing has outperformed its peershellip
30
US has made substantial gains in competitiveness
35
Remarkable improvements
Due to productivity gains amp modest wage growthhellip
36
Remarkable improvements
Business sentiment in Europe remains weak while new orders have slowed
37
China amp Brazil have lost their edgehellip
38
Chinese wages have more than doubled over the past decade
Key industries
Loose credit and rising demand for autoshellip
36
hellipshould support productionhellip
20
25
30
35
40
45
50
405060708090
100110120130140150160
Jul-09 Jul-10 Jul-11 Jul-12 Jul-13 Jul-14
2010=100 US$ bn
Output (LHS)
Orders (RHS)
Source Oxford Economics Haver Analytics
US Output and orders
3 month moving average
37
hellipas will opportunities in the Emergers
38
Revamp of car stock to be key long-term driver
Ageing vehicle fleet replacement as economy recovers ndash average age of vehicle on US roads in 11frac12 years
Rising fuel efficiency standards leading to replacement of clunkers
Rising fuels costs resulting in smaller cars
Automakers likely to increase new models helping drive investment
Aerospace solid order books at the big twohellip
0
250
500
750
1000
1250
1500
1750
1994 1996 1998 2000 2002 2004 2006 2008 2010 2012 2014
Source Company reports
Airbus versus Boeing Orders
Airbus
Boeing
Number of aircraft
Note 2014 annual estimate based on annualized data through July
40
hellipwith APAC to drive long-term growth
Asia will account for almost 32 of global passenger traffic by 2017 compared to 28 in 2012
APAC to account for 40 of plane deliveries over next 20 years
US and Europe sales mainly for replacement of existing fleet
41
Need for efficiency will provide demand supporthellip
A330 revamped for 15 efficiency improvement to compete with Dreamliner 25 new orders on day of announcement
Long-haul efficiency has some ways to go to maintain airline profitability
42
Order backlogs remain high
0
500
1000
1500
2000
2500
3000
3500
1990 1993 1996 1999 2002 2005 2008 2011 2014
Deliveries
Orders
Number of aircraftAirbus amp Boeing Orders amp deliveries
Source Company reports and forecasts
43
Weaker demand for metalshellip
44
hellipand over capacity are weighing on priceshellip
45
hellipand discouraging investment
BHP Capital spending fell 32 in FY14 with another 8 fall expected next year
Rio Tinto Capital spending in FY14 cut faster than initially projected and further cut is budgeted for 2015
This is weighing on equipment makers
Caterpillar reported sales down 9 in the three months to July with sales to mining firms down 33 from the same period a year earlier
Bumper crop has brought down grain prices
47
helliphitting margins and investment
Producers are facing higher costs due to the implementation of Tier 4 engines developed to comply with emissions standards
Weaker margins are leading to farmers cutting back investment spending
John Deere has posted a 5 yy decline in revenues with an 11 decline in its agricultural division
Conclusions amp market implications
Conclusion and business implications
54
bull US economy expected to gradually accelerate through 2014 with support from a dovish Fed
bull Europe expected to recover but more ECB action could be required
bull Chinese economy is gradually rebalancing but banking crisis cannot be discounted
bull Emerging markets quiet for now but structural issue unsolved
bull Geopolitical tensions in the Middle East and Ukraine are being monitored carefully
Thank you
Gregory Daco
Chief US Economist gregorydacooxfordeconomicscom
September 2014
September 10 2014 2014 General Managersrsquo Meeting
Digital Manufacturing
World Class Shop Floor Management Release 5 The Smart Factory Revolution Mr Franz E Gruber Founder amp CEO
Dr Mohamed Abuali COO FORCAM Inc
MTConnect Evolution of a Standard and
Next Generation Interoperability Mr Courtney J Hill Chairman amp President
MTConnect Institute
QampA Session
World Class
Shop Floor Management
The Smart Factory Revolution
Franz E Gruber
Founder amp CEO
Mohamed Abuali
COO
汉语
World Class Shop Floor Management
FORCAM 2014 Page 2
FORCAMlsquos Passion
FORCAM provides proven
manufacturing solutions to
Continuously Improve Productivity
To be the global solutions provider of
the best-in-class Manufacturing
Execution Systems
FORCAM 2014 Page 3
FORCAM ndash 2014 Best Practices Award by Frost amp Sullivan
Frost amp Sullivan
ldquoFORCAM is a plant production software
solution provider that understands and
supports Industry 40 needsrdquo
FORCAM 2014 Page 4
FORCAMrsquos Testimonials and Industry Leadership
FORCAM 2014 Page 5
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
6 B Bartke S Wagner IPI-2
Shop Floor Management Audi - FORCAM FIT 2011-
Bernhard Bartke - Director Components Manufacturing
Stefan Wagner - Director Gear Manufacturing
7 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
bull Collection and recording of Operational Data via a database
(ex Machine States and State Changes)
Machine
Operator
Production Manager
Technical Assistant IT
Plant
Manager
Team Leader
8 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Interfaces
Time
Objectivity of Process Data
9 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Need for Continuous Improvement
bull Objective Information and Communication ndash across ALL levels
bull Transperancy and Visualization - Online
bull Real-time availability of operational data ndash Live Reports
bull Measurable increase in Plant Efficiency (OEE)
10 B Bartke S Wagner IPI-2
Shop Floor Management ndash Realtime bdquoANDONldquo Visualization
bull Web-based Interface Anywhere Anytime Access
bull Real-time Production Status Visualization
In Production
Overflow
Stoppage
Organizational
Stoppage
Idle (Pause)
Tool
Problem
11 B Bartke S Wagner IPI-2
Shop Floor Management Reporting ndash Hierarchical Status Diagrams
bull Reporting for Machines Groups Lines or the whole Plant
Technical
Stoppage In Production
Organizational
Stoppage Pause Overflow
Stoppage
Tool Problem In Setup
12 B Bartke S Wagner IPI-2
Audi Production System (APS)
Leadership Communication
bull Process Control
Standards
bull In Processes
bull Im Products
bull In the Organization
Learning Organization
bull Employee Development
bull Problem-Solving
bull CIP Culture
13 B Bartke S Wagner IPI-2
Shop Floor Management Process Control Panel on the shop floor
OEE Trend
(Day Week Month)
Measures
Quality
Process Control
14 B Bartke S Wagner IPI-2
OEE - Yesterday
Availability Trend
OEE ndash Last Week
OEE ndash Last Month
Naoki Nojiri IPI-25 BDE-Ist Stand 05042011
Shop Floor Management Process Control Panel on the shop floor
15 B Bartke S Wagner IPI-2
Shop Floor Management Management Cockpit
Planned vs Actual
(shift)
Top problems
(challenges)
OEE ndash Last Week
16 B Bartke S Wagner IPI-2
hellipand what have we achieved
17 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development suspension components (OEE Overall Equipment Effectiveness)
Radtraumlger
Start Shop Floor Management with
FORCAM +10
_
18 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development (20+ Increase in OEE in AUDI Stamping Facilities) (OEE Overall Equipment Effectiveness)
Radtraumlger
Start SFM +20
_
Our Beliefs
Respect
Collaboration
Excellence
Integrity
Community
Oct 30th 2013
Lean with Shop Floor Management BorgWarner Turbo Systems Rzeszow
Operator FactoryFrameworktrade Worker Client- Book On
Operator Downtime Reasons
Operator Actual versus Target Performance
TargetPlanned
Throughput
Actual
Performance
Opportunity for
Improvement
Actual
Throughput Machine
Data
ERP
Data
Supervisor Gantt Status
visualzation
Top 5
downtimes
Cip Top 5
Production
orders
Real data
history
Supervisor Cockpit machine
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
Global economy on a modest growth path
After a roller-coaster ride in early 2014 the US economy should steady around 3 upcoming quarters
Eurozone improving but risks remain (deflation Ukraine)
Japan on a modest expansion path with inflation trending up but questions around the resilience of the economy (tax hike)
Additional support from the government has fed through to growth in China and the economy is now expected to come close to the governmentrsquos 75 growth target for this year
Outlook for other emergers is less positive Russiarsquos economy continues to suffer from structural weaknesses and the repercussions of the conflict in Ukraine Brazil and India are showing no signs of picking up with structural deficiencies weighing on growth
US pulling ahead after slow start to 2014
6
Eurozone outlook Caution slow recovery in progress
Eurozone recovery still ongoing buthellip
8
Strong disinflationary forces in the Eurozone
9
Recovery will be steady rather than spectacular
10
-8
-6
-4
-2
0
2
4
6
1999 2002 2005 2008 2011 2014 2017 2020
Source Oxford EconomicsHaver Analytics
Europe GDP year
UK
Eurozone
Forecast
Current situation not dramatic but full scale conflict hellip
11
-6
-5
-4
-3
-2
-1
0
1
2
3
4
2006 2008 2010 2012 2014 2016 2018
Eurozone GDP year
Source Oxford EconomicsHaver Analytics
BaselineForecast
Military conflict in Ukraine
China Outlook A bumpy landing
China growth to slow as rebalancing continueshellip
13
hellipas debt piles up to worrying levels
14
Real estate sector increasingly at risk
15
Japan Slowing in spite of Abenomics
Consumption tax weighs heavily on growth
17
2013 2014
-40
-30
-20
-10
00
10
20
30
Q3 Q4 Q1 Q2
Private consumptionFixed investmentNet exportsGovernment consumptionStockbuildingGDP
Japan Quarterly GDP contributions
quarterly contribution
Source Cabinet Office of Japan Haver Analytics
-3
-2
-1
0
1
2
3
4
1990 1995 2000 2005 2010 2015
Japan Fiscal policyChange in structural budget balance of GDP
Source International Monetary Fund Haver Analytics
ForecastExpansion
Contraction
Emergers Modest growth with structural issues
19
Does it still make sense to talk about ldquoBRICSrdquo
Some countries more vulnerable than others
20
1 Turkey 1182 S Africa 763 Brazil 404 Thailand 295 Russia 266 Malaysia 187 India 018 Poland 019 Mexico -2010 Indonesia -2511 Korea -8012 Philippines -9113 China -93
Oxford Economics Risk Scorecard
Emerging markets will still outpace developed world
21
US Outlook The US is the cleanest shirt in the laundry basket
GDP on a roller-coaster but employment is better indicator
19
Business surveys pointing to strong growthhellip
24
Consumers are feeling more cheerfulhellip
25
Wages expected to risehellip
26
Key domestic risk is housing activityhellip
27
hellipbut rising income and pent-up demand will help
24
Energy prices remain relatively stable
29
Fed to taper on but hold off on rate hikes
30
This image cannot currently be displayed
First rate hike in 2015Q2
Manufacturing in focus
Manufacturing activity is boominghellip
Further indication that GDP decline is due to unique factors
28
hellipwith encouraging signs from leading indicators
29
US manufacturing has outperformed its peershellip
30
US has made substantial gains in competitiveness
35
Remarkable improvements
Due to productivity gains amp modest wage growthhellip
36
Remarkable improvements
Business sentiment in Europe remains weak while new orders have slowed
37
China amp Brazil have lost their edgehellip
38
Chinese wages have more than doubled over the past decade
Key industries
Loose credit and rising demand for autoshellip
36
hellipshould support productionhellip
20
25
30
35
40
45
50
405060708090
100110120130140150160
Jul-09 Jul-10 Jul-11 Jul-12 Jul-13 Jul-14
2010=100 US$ bn
Output (LHS)
Orders (RHS)
Source Oxford Economics Haver Analytics
US Output and orders
3 month moving average
37
hellipas will opportunities in the Emergers
38
Revamp of car stock to be key long-term driver
Ageing vehicle fleet replacement as economy recovers ndash average age of vehicle on US roads in 11frac12 years
Rising fuel efficiency standards leading to replacement of clunkers
Rising fuels costs resulting in smaller cars
Automakers likely to increase new models helping drive investment
Aerospace solid order books at the big twohellip
0
250
500
750
1000
1250
1500
1750
1994 1996 1998 2000 2002 2004 2006 2008 2010 2012 2014
Source Company reports
Airbus versus Boeing Orders
Airbus
Boeing
Number of aircraft
Note 2014 annual estimate based on annualized data through July
40
hellipwith APAC to drive long-term growth
Asia will account for almost 32 of global passenger traffic by 2017 compared to 28 in 2012
APAC to account for 40 of plane deliveries over next 20 years
US and Europe sales mainly for replacement of existing fleet
41
Need for efficiency will provide demand supporthellip
A330 revamped for 15 efficiency improvement to compete with Dreamliner 25 new orders on day of announcement
Long-haul efficiency has some ways to go to maintain airline profitability
42
Order backlogs remain high
0
500
1000
1500
2000
2500
3000
3500
1990 1993 1996 1999 2002 2005 2008 2011 2014
Deliveries
Orders
Number of aircraftAirbus amp Boeing Orders amp deliveries
Source Company reports and forecasts
43
Weaker demand for metalshellip
44
hellipand over capacity are weighing on priceshellip
45
hellipand discouraging investment
BHP Capital spending fell 32 in FY14 with another 8 fall expected next year
Rio Tinto Capital spending in FY14 cut faster than initially projected and further cut is budgeted for 2015
This is weighing on equipment makers
Caterpillar reported sales down 9 in the three months to July with sales to mining firms down 33 from the same period a year earlier
Bumper crop has brought down grain prices
47
helliphitting margins and investment
Producers are facing higher costs due to the implementation of Tier 4 engines developed to comply with emissions standards
Weaker margins are leading to farmers cutting back investment spending
John Deere has posted a 5 yy decline in revenues with an 11 decline in its agricultural division
Conclusions amp market implications
Conclusion and business implications
54
bull US economy expected to gradually accelerate through 2014 with support from a dovish Fed
bull Europe expected to recover but more ECB action could be required
bull Chinese economy is gradually rebalancing but banking crisis cannot be discounted
bull Emerging markets quiet for now but structural issue unsolved
bull Geopolitical tensions in the Middle East and Ukraine are being monitored carefully
Thank you
Gregory Daco
Chief US Economist gregorydacooxfordeconomicscom
September 2014
September 10 2014 2014 General Managersrsquo Meeting
Digital Manufacturing
World Class Shop Floor Management Release 5 The Smart Factory Revolution Mr Franz E Gruber Founder amp CEO
Dr Mohamed Abuali COO FORCAM Inc
MTConnect Evolution of a Standard and
Next Generation Interoperability Mr Courtney J Hill Chairman amp President
MTConnect Institute
QampA Session
World Class
Shop Floor Management
The Smart Factory Revolution
Franz E Gruber
Founder amp CEO
Mohamed Abuali
COO
汉语
World Class Shop Floor Management
FORCAM 2014 Page 2
FORCAMlsquos Passion
FORCAM provides proven
manufacturing solutions to
Continuously Improve Productivity
To be the global solutions provider of
the best-in-class Manufacturing
Execution Systems
FORCAM 2014 Page 3
FORCAM ndash 2014 Best Practices Award by Frost amp Sullivan
Frost amp Sullivan
ldquoFORCAM is a plant production software
solution provider that understands and
supports Industry 40 needsrdquo
FORCAM 2014 Page 4
FORCAMrsquos Testimonials and Industry Leadership
FORCAM 2014 Page 5
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
6 B Bartke S Wagner IPI-2
Shop Floor Management Audi - FORCAM FIT 2011-
Bernhard Bartke - Director Components Manufacturing
Stefan Wagner - Director Gear Manufacturing
7 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
bull Collection and recording of Operational Data via a database
(ex Machine States and State Changes)
Machine
Operator
Production Manager
Technical Assistant IT
Plant
Manager
Team Leader
8 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Interfaces
Time
Objectivity of Process Data
9 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Need for Continuous Improvement
bull Objective Information and Communication ndash across ALL levels
bull Transperancy and Visualization - Online
bull Real-time availability of operational data ndash Live Reports
bull Measurable increase in Plant Efficiency (OEE)
10 B Bartke S Wagner IPI-2
Shop Floor Management ndash Realtime bdquoANDONldquo Visualization
bull Web-based Interface Anywhere Anytime Access
bull Real-time Production Status Visualization
In Production
Overflow
Stoppage
Organizational
Stoppage
Idle (Pause)
Tool
Problem
11 B Bartke S Wagner IPI-2
Shop Floor Management Reporting ndash Hierarchical Status Diagrams
bull Reporting for Machines Groups Lines or the whole Plant
Technical
Stoppage In Production
Organizational
Stoppage Pause Overflow
Stoppage
Tool Problem In Setup
12 B Bartke S Wagner IPI-2
Audi Production System (APS)
Leadership Communication
bull Process Control
Standards
bull In Processes
bull Im Products
bull In the Organization
Learning Organization
bull Employee Development
bull Problem-Solving
bull CIP Culture
13 B Bartke S Wagner IPI-2
Shop Floor Management Process Control Panel on the shop floor
OEE Trend
(Day Week Month)
Measures
Quality
Process Control
14 B Bartke S Wagner IPI-2
OEE - Yesterday
Availability Trend
OEE ndash Last Week
OEE ndash Last Month
Naoki Nojiri IPI-25 BDE-Ist Stand 05042011
Shop Floor Management Process Control Panel on the shop floor
15 B Bartke S Wagner IPI-2
Shop Floor Management Management Cockpit
Planned vs Actual
(shift)
Top problems
(challenges)
OEE ndash Last Week
16 B Bartke S Wagner IPI-2
hellipand what have we achieved
17 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development suspension components (OEE Overall Equipment Effectiveness)
Radtraumlger
Start Shop Floor Management with
FORCAM +10
_
18 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development (20+ Increase in OEE in AUDI Stamping Facilities) (OEE Overall Equipment Effectiveness)
Radtraumlger
Start SFM +20
_
Our Beliefs
Respect
Collaboration
Excellence
Integrity
Community
Oct 30th 2013
Lean with Shop Floor Management BorgWarner Turbo Systems Rzeszow
Operator FactoryFrameworktrade Worker Client- Book On
Operator Downtime Reasons
Operator Actual versus Target Performance
TargetPlanned
Throughput
Actual
Performance
Opportunity for
Improvement
Actual
Throughput Machine
Data
ERP
Data
Supervisor Gantt Status
visualzation
Top 5
downtimes
Cip Top 5
Production
orders
Real data
history
Supervisor Cockpit machine
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
US pulling ahead after slow start to 2014
6
Eurozone outlook Caution slow recovery in progress
Eurozone recovery still ongoing buthellip
8
Strong disinflationary forces in the Eurozone
9
Recovery will be steady rather than spectacular
10
-8
-6
-4
-2
0
2
4
6
1999 2002 2005 2008 2011 2014 2017 2020
Source Oxford EconomicsHaver Analytics
Europe GDP year
UK
Eurozone
Forecast
Current situation not dramatic but full scale conflict hellip
11
-6
-5
-4
-3
-2
-1
0
1
2
3
4
2006 2008 2010 2012 2014 2016 2018
Eurozone GDP year
Source Oxford EconomicsHaver Analytics
BaselineForecast
Military conflict in Ukraine
China Outlook A bumpy landing
China growth to slow as rebalancing continueshellip
13
hellipas debt piles up to worrying levels
14
Real estate sector increasingly at risk
15
Japan Slowing in spite of Abenomics
Consumption tax weighs heavily on growth
17
2013 2014
-40
-30
-20
-10
00
10
20
30
Q3 Q4 Q1 Q2
Private consumptionFixed investmentNet exportsGovernment consumptionStockbuildingGDP
Japan Quarterly GDP contributions
quarterly contribution
Source Cabinet Office of Japan Haver Analytics
-3
-2
-1
0
1
2
3
4
1990 1995 2000 2005 2010 2015
Japan Fiscal policyChange in structural budget balance of GDP
Source International Monetary Fund Haver Analytics
ForecastExpansion
Contraction
Emergers Modest growth with structural issues
19
Does it still make sense to talk about ldquoBRICSrdquo
Some countries more vulnerable than others
20
1 Turkey 1182 S Africa 763 Brazil 404 Thailand 295 Russia 266 Malaysia 187 India 018 Poland 019 Mexico -2010 Indonesia -2511 Korea -8012 Philippines -9113 China -93
Oxford Economics Risk Scorecard
Emerging markets will still outpace developed world
21
US Outlook The US is the cleanest shirt in the laundry basket
GDP on a roller-coaster but employment is better indicator
19
Business surveys pointing to strong growthhellip
24
Consumers are feeling more cheerfulhellip
25
Wages expected to risehellip
26
Key domestic risk is housing activityhellip
27
hellipbut rising income and pent-up demand will help
24
Energy prices remain relatively stable
29
Fed to taper on but hold off on rate hikes
30
This image cannot currently be displayed
First rate hike in 2015Q2
Manufacturing in focus
Manufacturing activity is boominghellip
Further indication that GDP decline is due to unique factors
28
hellipwith encouraging signs from leading indicators
29
US manufacturing has outperformed its peershellip
30
US has made substantial gains in competitiveness
35
Remarkable improvements
Due to productivity gains amp modest wage growthhellip
36
Remarkable improvements
Business sentiment in Europe remains weak while new orders have slowed
37
China amp Brazil have lost their edgehellip
38
Chinese wages have more than doubled over the past decade
Key industries
Loose credit and rising demand for autoshellip
36
hellipshould support productionhellip
20
25
30
35
40
45
50
405060708090
100110120130140150160
Jul-09 Jul-10 Jul-11 Jul-12 Jul-13 Jul-14
2010=100 US$ bn
Output (LHS)
Orders (RHS)
Source Oxford Economics Haver Analytics
US Output and orders
3 month moving average
37
hellipas will opportunities in the Emergers
38
Revamp of car stock to be key long-term driver
Ageing vehicle fleet replacement as economy recovers ndash average age of vehicle on US roads in 11frac12 years
Rising fuel efficiency standards leading to replacement of clunkers
Rising fuels costs resulting in smaller cars
Automakers likely to increase new models helping drive investment
Aerospace solid order books at the big twohellip
0
250
500
750
1000
1250
1500
1750
1994 1996 1998 2000 2002 2004 2006 2008 2010 2012 2014
Source Company reports
Airbus versus Boeing Orders
Airbus
Boeing
Number of aircraft
Note 2014 annual estimate based on annualized data through July
40
hellipwith APAC to drive long-term growth
Asia will account for almost 32 of global passenger traffic by 2017 compared to 28 in 2012
APAC to account for 40 of plane deliveries over next 20 years
US and Europe sales mainly for replacement of existing fleet
41
Need for efficiency will provide demand supporthellip
A330 revamped for 15 efficiency improvement to compete with Dreamliner 25 new orders on day of announcement
Long-haul efficiency has some ways to go to maintain airline profitability
42
Order backlogs remain high
0
500
1000
1500
2000
2500
3000
3500
1990 1993 1996 1999 2002 2005 2008 2011 2014
Deliveries
Orders
Number of aircraftAirbus amp Boeing Orders amp deliveries
Source Company reports and forecasts
43
Weaker demand for metalshellip
44
hellipand over capacity are weighing on priceshellip
45
hellipand discouraging investment
BHP Capital spending fell 32 in FY14 with another 8 fall expected next year
Rio Tinto Capital spending in FY14 cut faster than initially projected and further cut is budgeted for 2015
This is weighing on equipment makers
Caterpillar reported sales down 9 in the three months to July with sales to mining firms down 33 from the same period a year earlier
Bumper crop has brought down grain prices
47
helliphitting margins and investment
Producers are facing higher costs due to the implementation of Tier 4 engines developed to comply with emissions standards
Weaker margins are leading to farmers cutting back investment spending
John Deere has posted a 5 yy decline in revenues with an 11 decline in its agricultural division
Conclusions amp market implications
Conclusion and business implications
54
bull US economy expected to gradually accelerate through 2014 with support from a dovish Fed
bull Europe expected to recover but more ECB action could be required
bull Chinese economy is gradually rebalancing but banking crisis cannot be discounted
bull Emerging markets quiet for now but structural issue unsolved
bull Geopolitical tensions in the Middle East and Ukraine are being monitored carefully
Thank you
Gregory Daco
Chief US Economist gregorydacooxfordeconomicscom
September 2014
September 10 2014 2014 General Managersrsquo Meeting
Digital Manufacturing
World Class Shop Floor Management Release 5 The Smart Factory Revolution Mr Franz E Gruber Founder amp CEO
Dr Mohamed Abuali COO FORCAM Inc
MTConnect Evolution of a Standard and
Next Generation Interoperability Mr Courtney J Hill Chairman amp President
MTConnect Institute
QampA Session
World Class
Shop Floor Management
The Smart Factory Revolution
Franz E Gruber
Founder amp CEO
Mohamed Abuali
COO
汉语
World Class Shop Floor Management
FORCAM 2014 Page 2
FORCAMlsquos Passion
FORCAM provides proven
manufacturing solutions to
Continuously Improve Productivity
To be the global solutions provider of
the best-in-class Manufacturing
Execution Systems
FORCAM 2014 Page 3
FORCAM ndash 2014 Best Practices Award by Frost amp Sullivan
Frost amp Sullivan
ldquoFORCAM is a plant production software
solution provider that understands and
supports Industry 40 needsrdquo
FORCAM 2014 Page 4
FORCAMrsquos Testimonials and Industry Leadership
FORCAM 2014 Page 5
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
6 B Bartke S Wagner IPI-2
Shop Floor Management Audi - FORCAM FIT 2011-
Bernhard Bartke - Director Components Manufacturing
Stefan Wagner - Director Gear Manufacturing
7 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
bull Collection and recording of Operational Data via a database
(ex Machine States and State Changes)
Machine
Operator
Production Manager
Technical Assistant IT
Plant
Manager
Team Leader
8 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Interfaces
Time
Objectivity of Process Data
9 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Need for Continuous Improvement
bull Objective Information and Communication ndash across ALL levels
bull Transperancy and Visualization - Online
bull Real-time availability of operational data ndash Live Reports
bull Measurable increase in Plant Efficiency (OEE)
10 B Bartke S Wagner IPI-2
Shop Floor Management ndash Realtime bdquoANDONldquo Visualization
bull Web-based Interface Anywhere Anytime Access
bull Real-time Production Status Visualization
In Production
Overflow
Stoppage
Organizational
Stoppage
Idle (Pause)
Tool
Problem
11 B Bartke S Wagner IPI-2
Shop Floor Management Reporting ndash Hierarchical Status Diagrams
bull Reporting for Machines Groups Lines or the whole Plant
Technical
Stoppage In Production
Organizational
Stoppage Pause Overflow
Stoppage
Tool Problem In Setup
12 B Bartke S Wagner IPI-2
Audi Production System (APS)
Leadership Communication
bull Process Control
Standards
bull In Processes
bull Im Products
bull In the Organization
Learning Organization
bull Employee Development
bull Problem-Solving
bull CIP Culture
13 B Bartke S Wagner IPI-2
Shop Floor Management Process Control Panel on the shop floor
OEE Trend
(Day Week Month)
Measures
Quality
Process Control
14 B Bartke S Wagner IPI-2
OEE - Yesterday
Availability Trend
OEE ndash Last Week
OEE ndash Last Month
Naoki Nojiri IPI-25 BDE-Ist Stand 05042011
Shop Floor Management Process Control Panel on the shop floor
15 B Bartke S Wagner IPI-2
Shop Floor Management Management Cockpit
Planned vs Actual
(shift)
Top problems
(challenges)
OEE ndash Last Week
16 B Bartke S Wagner IPI-2
hellipand what have we achieved
17 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development suspension components (OEE Overall Equipment Effectiveness)
Radtraumlger
Start Shop Floor Management with
FORCAM +10
_
18 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development (20+ Increase in OEE in AUDI Stamping Facilities) (OEE Overall Equipment Effectiveness)
Radtraumlger
Start SFM +20
_
Our Beliefs
Respect
Collaboration
Excellence
Integrity
Community
Oct 30th 2013
Lean with Shop Floor Management BorgWarner Turbo Systems Rzeszow
Operator FactoryFrameworktrade Worker Client- Book On
Operator Downtime Reasons
Operator Actual versus Target Performance
TargetPlanned
Throughput
Actual
Performance
Opportunity for
Improvement
Actual
Throughput Machine
Data
ERP
Data
Supervisor Gantt Status
visualzation
Top 5
downtimes
Cip Top 5
Production
orders
Real data
history
Supervisor Cockpit machine
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
Eurozone outlook Caution slow recovery in progress
Eurozone recovery still ongoing buthellip
8
Strong disinflationary forces in the Eurozone
9
Recovery will be steady rather than spectacular
10
-8
-6
-4
-2
0
2
4
6
1999 2002 2005 2008 2011 2014 2017 2020
Source Oxford EconomicsHaver Analytics
Europe GDP year
UK
Eurozone
Forecast
Current situation not dramatic but full scale conflict hellip
11
-6
-5
-4
-3
-2
-1
0
1
2
3
4
2006 2008 2010 2012 2014 2016 2018
Eurozone GDP year
Source Oxford EconomicsHaver Analytics
BaselineForecast
Military conflict in Ukraine
China Outlook A bumpy landing
China growth to slow as rebalancing continueshellip
13
hellipas debt piles up to worrying levels
14
Real estate sector increasingly at risk
15
Japan Slowing in spite of Abenomics
Consumption tax weighs heavily on growth
17
2013 2014
-40
-30
-20
-10
00
10
20
30
Q3 Q4 Q1 Q2
Private consumptionFixed investmentNet exportsGovernment consumptionStockbuildingGDP
Japan Quarterly GDP contributions
quarterly contribution
Source Cabinet Office of Japan Haver Analytics
-3
-2
-1
0
1
2
3
4
1990 1995 2000 2005 2010 2015
Japan Fiscal policyChange in structural budget balance of GDP
Source International Monetary Fund Haver Analytics
ForecastExpansion
Contraction
Emergers Modest growth with structural issues
19
Does it still make sense to talk about ldquoBRICSrdquo
Some countries more vulnerable than others
20
1 Turkey 1182 S Africa 763 Brazil 404 Thailand 295 Russia 266 Malaysia 187 India 018 Poland 019 Mexico -2010 Indonesia -2511 Korea -8012 Philippines -9113 China -93
Oxford Economics Risk Scorecard
Emerging markets will still outpace developed world
21
US Outlook The US is the cleanest shirt in the laundry basket
GDP on a roller-coaster but employment is better indicator
19
Business surveys pointing to strong growthhellip
24
Consumers are feeling more cheerfulhellip
25
Wages expected to risehellip
26
Key domestic risk is housing activityhellip
27
hellipbut rising income and pent-up demand will help
24
Energy prices remain relatively stable
29
Fed to taper on but hold off on rate hikes
30
This image cannot currently be displayed
First rate hike in 2015Q2
Manufacturing in focus
Manufacturing activity is boominghellip
Further indication that GDP decline is due to unique factors
28
hellipwith encouraging signs from leading indicators
29
US manufacturing has outperformed its peershellip
30
US has made substantial gains in competitiveness
35
Remarkable improvements
Due to productivity gains amp modest wage growthhellip
36
Remarkable improvements
Business sentiment in Europe remains weak while new orders have slowed
37
China amp Brazil have lost their edgehellip
38
Chinese wages have more than doubled over the past decade
Key industries
Loose credit and rising demand for autoshellip
36
hellipshould support productionhellip
20
25
30
35
40
45
50
405060708090
100110120130140150160
Jul-09 Jul-10 Jul-11 Jul-12 Jul-13 Jul-14
2010=100 US$ bn
Output (LHS)
Orders (RHS)
Source Oxford Economics Haver Analytics
US Output and orders
3 month moving average
37
hellipas will opportunities in the Emergers
38
Revamp of car stock to be key long-term driver
Ageing vehicle fleet replacement as economy recovers ndash average age of vehicle on US roads in 11frac12 years
Rising fuel efficiency standards leading to replacement of clunkers
Rising fuels costs resulting in smaller cars
Automakers likely to increase new models helping drive investment
Aerospace solid order books at the big twohellip
0
250
500
750
1000
1250
1500
1750
1994 1996 1998 2000 2002 2004 2006 2008 2010 2012 2014
Source Company reports
Airbus versus Boeing Orders
Airbus
Boeing
Number of aircraft
Note 2014 annual estimate based on annualized data through July
40
hellipwith APAC to drive long-term growth
Asia will account for almost 32 of global passenger traffic by 2017 compared to 28 in 2012
APAC to account for 40 of plane deliveries over next 20 years
US and Europe sales mainly for replacement of existing fleet
41
Need for efficiency will provide demand supporthellip
A330 revamped for 15 efficiency improvement to compete with Dreamliner 25 new orders on day of announcement
Long-haul efficiency has some ways to go to maintain airline profitability
42
Order backlogs remain high
0
500
1000
1500
2000
2500
3000
3500
1990 1993 1996 1999 2002 2005 2008 2011 2014
Deliveries
Orders
Number of aircraftAirbus amp Boeing Orders amp deliveries
Source Company reports and forecasts
43
Weaker demand for metalshellip
44
hellipand over capacity are weighing on priceshellip
45
hellipand discouraging investment
BHP Capital spending fell 32 in FY14 with another 8 fall expected next year
Rio Tinto Capital spending in FY14 cut faster than initially projected and further cut is budgeted for 2015
This is weighing on equipment makers
Caterpillar reported sales down 9 in the three months to July with sales to mining firms down 33 from the same period a year earlier
Bumper crop has brought down grain prices
47
helliphitting margins and investment
Producers are facing higher costs due to the implementation of Tier 4 engines developed to comply with emissions standards
Weaker margins are leading to farmers cutting back investment spending
John Deere has posted a 5 yy decline in revenues with an 11 decline in its agricultural division
Conclusions amp market implications
Conclusion and business implications
54
bull US economy expected to gradually accelerate through 2014 with support from a dovish Fed
bull Europe expected to recover but more ECB action could be required
bull Chinese economy is gradually rebalancing but banking crisis cannot be discounted
bull Emerging markets quiet for now but structural issue unsolved
bull Geopolitical tensions in the Middle East and Ukraine are being monitored carefully
Thank you
Gregory Daco
Chief US Economist gregorydacooxfordeconomicscom
September 2014
September 10 2014 2014 General Managersrsquo Meeting
Digital Manufacturing
World Class Shop Floor Management Release 5 The Smart Factory Revolution Mr Franz E Gruber Founder amp CEO
Dr Mohamed Abuali COO FORCAM Inc
MTConnect Evolution of a Standard and
Next Generation Interoperability Mr Courtney J Hill Chairman amp President
MTConnect Institute
QampA Session
World Class
Shop Floor Management
The Smart Factory Revolution
Franz E Gruber
Founder amp CEO
Mohamed Abuali
COO
汉语
World Class Shop Floor Management
FORCAM 2014 Page 2
FORCAMlsquos Passion
FORCAM provides proven
manufacturing solutions to
Continuously Improve Productivity
To be the global solutions provider of
the best-in-class Manufacturing
Execution Systems
FORCAM 2014 Page 3
FORCAM ndash 2014 Best Practices Award by Frost amp Sullivan
Frost amp Sullivan
ldquoFORCAM is a plant production software
solution provider that understands and
supports Industry 40 needsrdquo
FORCAM 2014 Page 4
FORCAMrsquos Testimonials and Industry Leadership
FORCAM 2014 Page 5
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
6 B Bartke S Wagner IPI-2
Shop Floor Management Audi - FORCAM FIT 2011-
Bernhard Bartke - Director Components Manufacturing
Stefan Wagner - Director Gear Manufacturing
7 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
bull Collection and recording of Operational Data via a database
(ex Machine States and State Changes)
Machine
Operator
Production Manager
Technical Assistant IT
Plant
Manager
Team Leader
8 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Interfaces
Time
Objectivity of Process Data
9 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Need for Continuous Improvement
bull Objective Information and Communication ndash across ALL levels
bull Transperancy and Visualization - Online
bull Real-time availability of operational data ndash Live Reports
bull Measurable increase in Plant Efficiency (OEE)
10 B Bartke S Wagner IPI-2
Shop Floor Management ndash Realtime bdquoANDONldquo Visualization
bull Web-based Interface Anywhere Anytime Access
bull Real-time Production Status Visualization
In Production
Overflow
Stoppage
Organizational
Stoppage
Idle (Pause)
Tool
Problem
11 B Bartke S Wagner IPI-2
Shop Floor Management Reporting ndash Hierarchical Status Diagrams
bull Reporting for Machines Groups Lines or the whole Plant
Technical
Stoppage In Production
Organizational
Stoppage Pause Overflow
Stoppage
Tool Problem In Setup
12 B Bartke S Wagner IPI-2
Audi Production System (APS)
Leadership Communication
bull Process Control
Standards
bull In Processes
bull Im Products
bull In the Organization
Learning Organization
bull Employee Development
bull Problem-Solving
bull CIP Culture
13 B Bartke S Wagner IPI-2
Shop Floor Management Process Control Panel on the shop floor
OEE Trend
(Day Week Month)
Measures
Quality
Process Control
14 B Bartke S Wagner IPI-2
OEE - Yesterday
Availability Trend
OEE ndash Last Week
OEE ndash Last Month
Naoki Nojiri IPI-25 BDE-Ist Stand 05042011
Shop Floor Management Process Control Panel on the shop floor
15 B Bartke S Wagner IPI-2
Shop Floor Management Management Cockpit
Planned vs Actual
(shift)
Top problems
(challenges)
OEE ndash Last Week
16 B Bartke S Wagner IPI-2
hellipand what have we achieved
17 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development suspension components (OEE Overall Equipment Effectiveness)
Radtraumlger
Start Shop Floor Management with
FORCAM +10
_
18 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development (20+ Increase in OEE in AUDI Stamping Facilities) (OEE Overall Equipment Effectiveness)
Radtraumlger
Start SFM +20
_
Our Beliefs
Respect
Collaboration
Excellence
Integrity
Community
Oct 30th 2013
Lean with Shop Floor Management BorgWarner Turbo Systems Rzeszow
Operator FactoryFrameworktrade Worker Client- Book On
Operator Downtime Reasons
Operator Actual versus Target Performance
TargetPlanned
Throughput
Actual
Performance
Opportunity for
Improvement
Actual
Throughput Machine
Data
ERP
Data
Supervisor Gantt Status
visualzation
Top 5
downtimes
Cip Top 5
Production
orders
Real data
history
Supervisor Cockpit machine
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
Eurozone recovery still ongoing buthellip
8
Strong disinflationary forces in the Eurozone
9
Recovery will be steady rather than spectacular
10
-8
-6
-4
-2
0
2
4
6
1999 2002 2005 2008 2011 2014 2017 2020
Source Oxford EconomicsHaver Analytics
Europe GDP year
UK
Eurozone
Forecast
Current situation not dramatic but full scale conflict hellip
11
-6
-5
-4
-3
-2
-1
0
1
2
3
4
2006 2008 2010 2012 2014 2016 2018
Eurozone GDP year
Source Oxford EconomicsHaver Analytics
BaselineForecast
Military conflict in Ukraine
China Outlook A bumpy landing
China growth to slow as rebalancing continueshellip
13
hellipas debt piles up to worrying levels
14
Real estate sector increasingly at risk
15
Japan Slowing in spite of Abenomics
Consumption tax weighs heavily on growth
17
2013 2014
-40
-30
-20
-10
00
10
20
30
Q3 Q4 Q1 Q2
Private consumptionFixed investmentNet exportsGovernment consumptionStockbuildingGDP
Japan Quarterly GDP contributions
quarterly contribution
Source Cabinet Office of Japan Haver Analytics
-3
-2
-1
0
1
2
3
4
1990 1995 2000 2005 2010 2015
Japan Fiscal policyChange in structural budget balance of GDP
Source International Monetary Fund Haver Analytics
ForecastExpansion
Contraction
Emergers Modest growth with structural issues
19
Does it still make sense to talk about ldquoBRICSrdquo
Some countries more vulnerable than others
20
1 Turkey 1182 S Africa 763 Brazil 404 Thailand 295 Russia 266 Malaysia 187 India 018 Poland 019 Mexico -2010 Indonesia -2511 Korea -8012 Philippines -9113 China -93
Oxford Economics Risk Scorecard
Emerging markets will still outpace developed world
21
US Outlook The US is the cleanest shirt in the laundry basket
GDP on a roller-coaster but employment is better indicator
19
Business surveys pointing to strong growthhellip
24
Consumers are feeling more cheerfulhellip
25
Wages expected to risehellip
26
Key domestic risk is housing activityhellip
27
hellipbut rising income and pent-up demand will help
24
Energy prices remain relatively stable
29
Fed to taper on but hold off on rate hikes
30
This image cannot currently be displayed
First rate hike in 2015Q2
Manufacturing in focus
Manufacturing activity is boominghellip
Further indication that GDP decline is due to unique factors
28
hellipwith encouraging signs from leading indicators
29
US manufacturing has outperformed its peershellip
30
US has made substantial gains in competitiveness
35
Remarkable improvements
Due to productivity gains amp modest wage growthhellip
36
Remarkable improvements
Business sentiment in Europe remains weak while new orders have slowed
37
China amp Brazil have lost their edgehellip
38
Chinese wages have more than doubled over the past decade
Key industries
Loose credit and rising demand for autoshellip
36
hellipshould support productionhellip
20
25
30
35
40
45
50
405060708090
100110120130140150160
Jul-09 Jul-10 Jul-11 Jul-12 Jul-13 Jul-14
2010=100 US$ bn
Output (LHS)
Orders (RHS)
Source Oxford Economics Haver Analytics
US Output and orders
3 month moving average
37
hellipas will opportunities in the Emergers
38
Revamp of car stock to be key long-term driver
Ageing vehicle fleet replacement as economy recovers ndash average age of vehicle on US roads in 11frac12 years
Rising fuel efficiency standards leading to replacement of clunkers
Rising fuels costs resulting in smaller cars
Automakers likely to increase new models helping drive investment
Aerospace solid order books at the big twohellip
0
250
500
750
1000
1250
1500
1750
1994 1996 1998 2000 2002 2004 2006 2008 2010 2012 2014
Source Company reports
Airbus versus Boeing Orders
Airbus
Boeing
Number of aircraft
Note 2014 annual estimate based on annualized data through July
40
hellipwith APAC to drive long-term growth
Asia will account for almost 32 of global passenger traffic by 2017 compared to 28 in 2012
APAC to account for 40 of plane deliveries over next 20 years
US and Europe sales mainly for replacement of existing fleet
41
Need for efficiency will provide demand supporthellip
A330 revamped for 15 efficiency improvement to compete with Dreamliner 25 new orders on day of announcement
Long-haul efficiency has some ways to go to maintain airline profitability
42
Order backlogs remain high
0
500
1000
1500
2000
2500
3000
3500
1990 1993 1996 1999 2002 2005 2008 2011 2014
Deliveries
Orders
Number of aircraftAirbus amp Boeing Orders amp deliveries
Source Company reports and forecasts
43
Weaker demand for metalshellip
44
hellipand over capacity are weighing on priceshellip
45
hellipand discouraging investment
BHP Capital spending fell 32 in FY14 with another 8 fall expected next year
Rio Tinto Capital spending in FY14 cut faster than initially projected and further cut is budgeted for 2015
This is weighing on equipment makers
Caterpillar reported sales down 9 in the three months to July with sales to mining firms down 33 from the same period a year earlier
Bumper crop has brought down grain prices
47
helliphitting margins and investment
Producers are facing higher costs due to the implementation of Tier 4 engines developed to comply with emissions standards
Weaker margins are leading to farmers cutting back investment spending
John Deere has posted a 5 yy decline in revenues with an 11 decline in its agricultural division
Conclusions amp market implications
Conclusion and business implications
54
bull US economy expected to gradually accelerate through 2014 with support from a dovish Fed
bull Europe expected to recover but more ECB action could be required
bull Chinese economy is gradually rebalancing but banking crisis cannot be discounted
bull Emerging markets quiet for now but structural issue unsolved
bull Geopolitical tensions in the Middle East and Ukraine are being monitored carefully
Thank you
Gregory Daco
Chief US Economist gregorydacooxfordeconomicscom
September 2014
September 10 2014 2014 General Managersrsquo Meeting
Digital Manufacturing
World Class Shop Floor Management Release 5 The Smart Factory Revolution Mr Franz E Gruber Founder amp CEO
Dr Mohamed Abuali COO FORCAM Inc
MTConnect Evolution of a Standard and
Next Generation Interoperability Mr Courtney J Hill Chairman amp President
MTConnect Institute
QampA Session
World Class
Shop Floor Management
The Smart Factory Revolution
Franz E Gruber
Founder amp CEO
Mohamed Abuali
COO
汉语
World Class Shop Floor Management
FORCAM 2014 Page 2
FORCAMlsquos Passion
FORCAM provides proven
manufacturing solutions to
Continuously Improve Productivity
To be the global solutions provider of
the best-in-class Manufacturing
Execution Systems
FORCAM 2014 Page 3
FORCAM ndash 2014 Best Practices Award by Frost amp Sullivan
Frost amp Sullivan
ldquoFORCAM is a plant production software
solution provider that understands and
supports Industry 40 needsrdquo
FORCAM 2014 Page 4
FORCAMrsquos Testimonials and Industry Leadership
FORCAM 2014 Page 5
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
6 B Bartke S Wagner IPI-2
Shop Floor Management Audi - FORCAM FIT 2011-
Bernhard Bartke - Director Components Manufacturing
Stefan Wagner - Director Gear Manufacturing
7 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
bull Collection and recording of Operational Data via a database
(ex Machine States and State Changes)
Machine
Operator
Production Manager
Technical Assistant IT
Plant
Manager
Team Leader
8 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Interfaces
Time
Objectivity of Process Data
9 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Need for Continuous Improvement
bull Objective Information and Communication ndash across ALL levels
bull Transperancy and Visualization - Online
bull Real-time availability of operational data ndash Live Reports
bull Measurable increase in Plant Efficiency (OEE)
10 B Bartke S Wagner IPI-2
Shop Floor Management ndash Realtime bdquoANDONldquo Visualization
bull Web-based Interface Anywhere Anytime Access
bull Real-time Production Status Visualization
In Production
Overflow
Stoppage
Organizational
Stoppage
Idle (Pause)
Tool
Problem
11 B Bartke S Wagner IPI-2
Shop Floor Management Reporting ndash Hierarchical Status Diagrams
bull Reporting for Machines Groups Lines or the whole Plant
Technical
Stoppage In Production
Organizational
Stoppage Pause Overflow
Stoppage
Tool Problem In Setup
12 B Bartke S Wagner IPI-2
Audi Production System (APS)
Leadership Communication
bull Process Control
Standards
bull In Processes
bull Im Products
bull In the Organization
Learning Organization
bull Employee Development
bull Problem-Solving
bull CIP Culture
13 B Bartke S Wagner IPI-2
Shop Floor Management Process Control Panel on the shop floor
OEE Trend
(Day Week Month)
Measures
Quality
Process Control
14 B Bartke S Wagner IPI-2
OEE - Yesterday
Availability Trend
OEE ndash Last Week
OEE ndash Last Month
Naoki Nojiri IPI-25 BDE-Ist Stand 05042011
Shop Floor Management Process Control Panel on the shop floor
15 B Bartke S Wagner IPI-2
Shop Floor Management Management Cockpit
Planned vs Actual
(shift)
Top problems
(challenges)
OEE ndash Last Week
16 B Bartke S Wagner IPI-2
hellipand what have we achieved
17 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development suspension components (OEE Overall Equipment Effectiveness)
Radtraumlger
Start Shop Floor Management with
FORCAM +10
_
18 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development (20+ Increase in OEE in AUDI Stamping Facilities) (OEE Overall Equipment Effectiveness)
Radtraumlger
Start SFM +20
_
Our Beliefs
Respect
Collaboration
Excellence
Integrity
Community
Oct 30th 2013
Lean with Shop Floor Management BorgWarner Turbo Systems Rzeszow
Operator FactoryFrameworktrade Worker Client- Book On
Operator Downtime Reasons
Operator Actual versus Target Performance
TargetPlanned
Throughput
Actual
Performance
Opportunity for
Improvement
Actual
Throughput Machine
Data
ERP
Data
Supervisor Gantt Status
visualzation
Top 5
downtimes
Cip Top 5
Production
orders
Real data
history
Supervisor Cockpit machine
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
Strong disinflationary forces in the Eurozone
9
Recovery will be steady rather than spectacular
10
-8
-6
-4
-2
0
2
4
6
1999 2002 2005 2008 2011 2014 2017 2020
Source Oxford EconomicsHaver Analytics
Europe GDP year
UK
Eurozone
Forecast
Current situation not dramatic but full scale conflict hellip
11
-6
-5
-4
-3
-2
-1
0
1
2
3
4
2006 2008 2010 2012 2014 2016 2018
Eurozone GDP year
Source Oxford EconomicsHaver Analytics
BaselineForecast
Military conflict in Ukraine
China Outlook A bumpy landing
China growth to slow as rebalancing continueshellip
13
hellipas debt piles up to worrying levels
14
Real estate sector increasingly at risk
15
Japan Slowing in spite of Abenomics
Consumption tax weighs heavily on growth
17
2013 2014
-40
-30
-20
-10
00
10
20
30
Q3 Q4 Q1 Q2
Private consumptionFixed investmentNet exportsGovernment consumptionStockbuildingGDP
Japan Quarterly GDP contributions
quarterly contribution
Source Cabinet Office of Japan Haver Analytics
-3
-2
-1
0
1
2
3
4
1990 1995 2000 2005 2010 2015
Japan Fiscal policyChange in structural budget balance of GDP
Source International Monetary Fund Haver Analytics
ForecastExpansion
Contraction
Emergers Modest growth with structural issues
19
Does it still make sense to talk about ldquoBRICSrdquo
Some countries more vulnerable than others
20
1 Turkey 1182 S Africa 763 Brazil 404 Thailand 295 Russia 266 Malaysia 187 India 018 Poland 019 Mexico -2010 Indonesia -2511 Korea -8012 Philippines -9113 China -93
Oxford Economics Risk Scorecard
Emerging markets will still outpace developed world
21
US Outlook The US is the cleanest shirt in the laundry basket
GDP on a roller-coaster but employment is better indicator
19
Business surveys pointing to strong growthhellip
24
Consumers are feeling more cheerfulhellip
25
Wages expected to risehellip
26
Key domestic risk is housing activityhellip
27
hellipbut rising income and pent-up demand will help
24
Energy prices remain relatively stable
29
Fed to taper on but hold off on rate hikes
30
This image cannot currently be displayed
First rate hike in 2015Q2
Manufacturing in focus
Manufacturing activity is boominghellip
Further indication that GDP decline is due to unique factors
28
hellipwith encouraging signs from leading indicators
29
US manufacturing has outperformed its peershellip
30
US has made substantial gains in competitiveness
35
Remarkable improvements
Due to productivity gains amp modest wage growthhellip
36
Remarkable improvements
Business sentiment in Europe remains weak while new orders have slowed
37
China amp Brazil have lost their edgehellip
38
Chinese wages have more than doubled over the past decade
Key industries
Loose credit and rising demand for autoshellip
36
hellipshould support productionhellip
20
25
30
35
40
45
50
405060708090
100110120130140150160
Jul-09 Jul-10 Jul-11 Jul-12 Jul-13 Jul-14
2010=100 US$ bn
Output (LHS)
Orders (RHS)
Source Oxford Economics Haver Analytics
US Output and orders
3 month moving average
37
hellipas will opportunities in the Emergers
38
Revamp of car stock to be key long-term driver
Ageing vehicle fleet replacement as economy recovers ndash average age of vehicle on US roads in 11frac12 years
Rising fuel efficiency standards leading to replacement of clunkers
Rising fuels costs resulting in smaller cars
Automakers likely to increase new models helping drive investment
Aerospace solid order books at the big twohellip
0
250
500
750
1000
1250
1500
1750
1994 1996 1998 2000 2002 2004 2006 2008 2010 2012 2014
Source Company reports
Airbus versus Boeing Orders
Airbus
Boeing
Number of aircraft
Note 2014 annual estimate based on annualized data through July
40
hellipwith APAC to drive long-term growth
Asia will account for almost 32 of global passenger traffic by 2017 compared to 28 in 2012
APAC to account for 40 of plane deliveries over next 20 years
US and Europe sales mainly for replacement of existing fleet
41
Need for efficiency will provide demand supporthellip
A330 revamped for 15 efficiency improvement to compete with Dreamliner 25 new orders on day of announcement
Long-haul efficiency has some ways to go to maintain airline profitability
42
Order backlogs remain high
0
500
1000
1500
2000
2500
3000
3500
1990 1993 1996 1999 2002 2005 2008 2011 2014
Deliveries
Orders
Number of aircraftAirbus amp Boeing Orders amp deliveries
Source Company reports and forecasts
43
Weaker demand for metalshellip
44
hellipand over capacity are weighing on priceshellip
45
hellipand discouraging investment
BHP Capital spending fell 32 in FY14 with another 8 fall expected next year
Rio Tinto Capital spending in FY14 cut faster than initially projected and further cut is budgeted for 2015
This is weighing on equipment makers
Caterpillar reported sales down 9 in the three months to July with sales to mining firms down 33 from the same period a year earlier
Bumper crop has brought down grain prices
47
helliphitting margins and investment
Producers are facing higher costs due to the implementation of Tier 4 engines developed to comply with emissions standards
Weaker margins are leading to farmers cutting back investment spending
John Deere has posted a 5 yy decline in revenues with an 11 decline in its agricultural division
Conclusions amp market implications
Conclusion and business implications
54
bull US economy expected to gradually accelerate through 2014 with support from a dovish Fed
bull Europe expected to recover but more ECB action could be required
bull Chinese economy is gradually rebalancing but banking crisis cannot be discounted
bull Emerging markets quiet for now but structural issue unsolved
bull Geopolitical tensions in the Middle East and Ukraine are being monitored carefully
Thank you
Gregory Daco
Chief US Economist gregorydacooxfordeconomicscom
September 2014
September 10 2014 2014 General Managersrsquo Meeting
Digital Manufacturing
World Class Shop Floor Management Release 5 The Smart Factory Revolution Mr Franz E Gruber Founder amp CEO
Dr Mohamed Abuali COO FORCAM Inc
MTConnect Evolution of a Standard and
Next Generation Interoperability Mr Courtney J Hill Chairman amp President
MTConnect Institute
QampA Session
World Class
Shop Floor Management
The Smart Factory Revolution
Franz E Gruber
Founder amp CEO
Mohamed Abuali
COO
汉语
World Class Shop Floor Management
FORCAM 2014 Page 2
FORCAMlsquos Passion
FORCAM provides proven
manufacturing solutions to
Continuously Improve Productivity
To be the global solutions provider of
the best-in-class Manufacturing
Execution Systems
FORCAM 2014 Page 3
FORCAM ndash 2014 Best Practices Award by Frost amp Sullivan
Frost amp Sullivan
ldquoFORCAM is a plant production software
solution provider that understands and
supports Industry 40 needsrdquo
FORCAM 2014 Page 4
FORCAMrsquos Testimonials and Industry Leadership
FORCAM 2014 Page 5
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
6 B Bartke S Wagner IPI-2
Shop Floor Management Audi - FORCAM FIT 2011-
Bernhard Bartke - Director Components Manufacturing
Stefan Wagner - Director Gear Manufacturing
7 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
bull Collection and recording of Operational Data via a database
(ex Machine States and State Changes)
Machine
Operator
Production Manager
Technical Assistant IT
Plant
Manager
Team Leader
8 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Interfaces
Time
Objectivity of Process Data
9 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Need for Continuous Improvement
bull Objective Information and Communication ndash across ALL levels
bull Transperancy and Visualization - Online
bull Real-time availability of operational data ndash Live Reports
bull Measurable increase in Plant Efficiency (OEE)
10 B Bartke S Wagner IPI-2
Shop Floor Management ndash Realtime bdquoANDONldquo Visualization
bull Web-based Interface Anywhere Anytime Access
bull Real-time Production Status Visualization
In Production
Overflow
Stoppage
Organizational
Stoppage
Idle (Pause)
Tool
Problem
11 B Bartke S Wagner IPI-2
Shop Floor Management Reporting ndash Hierarchical Status Diagrams
bull Reporting for Machines Groups Lines or the whole Plant
Technical
Stoppage In Production
Organizational
Stoppage Pause Overflow
Stoppage
Tool Problem In Setup
12 B Bartke S Wagner IPI-2
Audi Production System (APS)
Leadership Communication
bull Process Control
Standards
bull In Processes
bull Im Products
bull In the Organization
Learning Organization
bull Employee Development
bull Problem-Solving
bull CIP Culture
13 B Bartke S Wagner IPI-2
Shop Floor Management Process Control Panel on the shop floor
OEE Trend
(Day Week Month)
Measures
Quality
Process Control
14 B Bartke S Wagner IPI-2
OEE - Yesterday
Availability Trend
OEE ndash Last Week
OEE ndash Last Month
Naoki Nojiri IPI-25 BDE-Ist Stand 05042011
Shop Floor Management Process Control Panel on the shop floor
15 B Bartke S Wagner IPI-2
Shop Floor Management Management Cockpit
Planned vs Actual
(shift)
Top problems
(challenges)
OEE ndash Last Week
16 B Bartke S Wagner IPI-2
hellipand what have we achieved
17 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development suspension components (OEE Overall Equipment Effectiveness)
Radtraumlger
Start Shop Floor Management with
FORCAM +10
_
18 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development (20+ Increase in OEE in AUDI Stamping Facilities) (OEE Overall Equipment Effectiveness)
Radtraumlger
Start SFM +20
_
Our Beliefs
Respect
Collaboration
Excellence
Integrity
Community
Oct 30th 2013
Lean with Shop Floor Management BorgWarner Turbo Systems Rzeszow
Operator FactoryFrameworktrade Worker Client- Book On
Operator Downtime Reasons
Operator Actual versus Target Performance
TargetPlanned
Throughput
Actual
Performance
Opportunity for
Improvement
Actual
Throughput Machine
Data
ERP
Data
Supervisor Gantt Status
visualzation
Top 5
downtimes
Cip Top 5
Production
orders
Real data
history
Supervisor Cockpit machine
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
Recovery will be steady rather than spectacular
10
-8
-6
-4
-2
0
2
4
6
1999 2002 2005 2008 2011 2014 2017 2020
Source Oxford EconomicsHaver Analytics
Europe GDP year
UK
Eurozone
Forecast
Current situation not dramatic but full scale conflict hellip
11
-6
-5
-4
-3
-2
-1
0
1
2
3
4
2006 2008 2010 2012 2014 2016 2018
Eurozone GDP year
Source Oxford EconomicsHaver Analytics
BaselineForecast
Military conflict in Ukraine
China Outlook A bumpy landing
China growth to slow as rebalancing continueshellip
13
hellipas debt piles up to worrying levels
14
Real estate sector increasingly at risk
15
Japan Slowing in spite of Abenomics
Consumption tax weighs heavily on growth
17
2013 2014
-40
-30
-20
-10
00
10
20
30
Q3 Q4 Q1 Q2
Private consumptionFixed investmentNet exportsGovernment consumptionStockbuildingGDP
Japan Quarterly GDP contributions
quarterly contribution
Source Cabinet Office of Japan Haver Analytics
-3
-2
-1
0
1
2
3
4
1990 1995 2000 2005 2010 2015
Japan Fiscal policyChange in structural budget balance of GDP
Source International Monetary Fund Haver Analytics
ForecastExpansion
Contraction
Emergers Modest growth with structural issues
19
Does it still make sense to talk about ldquoBRICSrdquo
Some countries more vulnerable than others
20
1 Turkey 1182 S Africa 763 Brazil 404 Thailand 295 Russia 266 Malaysia 187 India 018 Poland 019 Mexico -2010 Indonesia -2511 Korea -8012 Philippines -9113 China -93
Oxford Economics Risk Scorecard
Emerging markets will still outpace developed world
21
US Outlook The US is the cleanest shirt in the laundry basket
GDP on a roller-coaster but employment is better indicator
19
Business surveys pointing to strong growthhellip
24
Consumers are feeling more cheerfulhellip
25
Wages expected to risehellip
26
Key domestic risk is housing activityhellip
27
hellipbut rising income and pent-up demand will help
24
Energy prices remain relatively stable
29
Fed to taper on but hold off on rate hikes
30
This image cannot currently be displayed
First rate hike in 2015Q2
Manufacturing in focus
Manufacturing activity is boominghellip
Further indication that GDP decline is due to unique factors
28
hellipwith encouraging signs from leading indicators
29
US manufacturing has outperformed its peershellip
30
US has made substantial gains in competitiveness
35
Remarkable improvements
Due to productivity gains amp modest wage growthhellip
36
Remarkable improvements
Business sentiment in Europe remains weak while new orders have slowed
37
China amp Brazil have lost their edgehellip
38
Chinese wages have more than doubled over the past decade
Key industries
Loose credit and rising demand for autoshellip
36
hellipshould support productionhellip
20
25
30
35
40
45
50
405060708090
100110120130140150160
Jul-09 Jul-10 Jul-11 Jul-12 Jul-13 Jul-14
2010=100 US$ bn
Output (LHS)
Orders (RHS)
Source Oxford Economics Haver Analytics
US Output and orders
3 month moving average
37
hellipas will opportunities in the Emergers
38
Revamp of car stock to be key long-term driver
Ageing vehicle fleet replacement as economy recovers ndash average age of vehicle on US roads in 11frac12 years
Rising fuel efficiency standards leading to replacement of clunkers
Rising fuels costs resulting in smaller cars
Automakers likely to increase new models helping drive investment
Aerospace solid order books at the big twohellip
0
250
500
750
1000
1250
1500
1750
1994 1996 1998 2000 2002 2004 2006 2008 2010 2012 2014
Source Company reports
Airbus versus Boeing Orders
Airbus
Boeing
Number of aircraft
Note 2014 annual estimate based on annualized data through July
40
hellipwith APAC to drive long-term growth
Asia will account for almost 32 of global passenger traffic by 2017 compared to 28 in 2012
APAC to account for 40 of plane deliveries over next 20 years
US and Europe sales mainly for replacement of existing fleet
41
Need for efficiency will provide demand supporthellip
A330 revamped for 15 efficiency improvement to compete with Dreamliner 25 new orders on day of announcement
Long-haul efficiency has some ways to go to maintain airline profitability
42
Order backlogs remain high
0
500
1000
1500
2000
2500
3000
3500
1990 1993 1996 1999 2002 2005 2008 2011 2014
Deliveries
Orders
Number of aircraftAirbus amp Boeing Orders amp deliveries
Source Company reports and forecasts
43
Weaker demand for metalshellip
44
hellipand over capacity are weighing on priceshellip
45
hellipand discouraging investment
BHP Capital spending fell 32 in FY14 with another 8 fall expected next year
Rio Tinto Capital spending in FY14 cut faster than initially projected and further cut is budgeted for 2015
This is weighing on equipment makers
Caterpillar reported sales down 9 in the three months to July with sales to mining firms down 33 from the same period a year earlier
Bumper crop has brought down grain prices
47
helliphitting margins and investment
Producers are facing higher costs due to the implementation of Tier 4 engines developed to comply with emissions standards
Weaker margins are leading to farmers cutting back investment spending
John Deere has posted a 5 yy decline in revenues with an 11 decline in its agricultural division
Conclusions amp market implications
Conclusion and business implications
54
bull US economy expected to gradually accelerate through 2014 with support from a dovish Fed
bull Europe expected to recover but more ECB action could be required
bull Chinese economy is gradually rebalancing but banking crisis cannot be discounted
bull Emerging markets quiet for now but structural issue unsolved
bull Geopolitical tensions in the Middle East and Ukraine are being monitored carefully
Thank you
Gregory Daco
Chief US Economist gregorydacooxfordeconomicscom
September 2014
September 10 2014 2014 General Managersrsquo Meeting
Digital Manufacturing
World Class Shop Floor Management Release 5 The Smart Factory Revolution Mr Franz E Gruber Founder amp CEO
Dr Mohamed Abuali COO FORCAM Inc
MTConnect Evolution of a Standard and
Next Generation Interoperability Mr Courtney J Hill Chairman amp President
MTConnect Institute
QampA Session
World Class
Shop Floor Management
The Smart Factory Revolution
Franz E Gruber
Founder amp CEO
Mohamed Abuali
COO
汉语
World Class Shop Floor Management
FORCAM 2014 Page 2
FORCAMlsquos Passion
FORCAM provides proven
manufacturing solutions to
Continuously Improve Productivity
To be the global solutions provider of
the best-in-class Manufacturing
Execution Systems
FORCAM 2014 Page 3
FORCAM ndash 2014 Best Practices Award by Frost amp Sullivan
Frost amp Sullivan
ldquoFORCAM is a plant production software
solution provider that understands and
supports Industry 40 needsrdquo
FORCAM 2014 Page 4
FORCAMrsquos Testimonials and Industry Leadership
FORCAM 2014 Page 5
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
6 B Bartke S Wagner IPI-2
Shop Floor Management Audi - FORCAM FIT 2011-
Bernhard Bartke - Director Components Manufacturing
Stefan Wagner - Director Gear Manufacturing
7 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
bull Collection and recording of Operational Data via a database
(ex Machine States and State Changes)
Machine
Operator
Production Manager
Technical Assistant IT
Plant
Manager
Team Leader
8 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Interfaces
Time
Objectivity of Process Data
9 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Need for Continuous Improvement
bull Objective Information and Communication ndash across ALL levels
bull Transperancy and Visualization - Online
bull Real-time availability of operational data ndash Live Reports
bull Measurable increase in Plant Efficiency (OEE)
10 B Bartke S Wagner IPI-2
Shop Floor Management ndash Realtime bdquoANDONldquo Visualization
bull Web-based Interface Anywhere Anytime Access
bull Real-time Production Status Visualization
In Production
Overflow
Stoppage
Organizational
Stoppage
Idle (Pause)
Tool
Problem
11 B Bartke S Wagner IPI-2
Shop Floor Management Reporting ndash Hierarchical Status Diagrams
bull Reporting for Machines Groups Lines or the whole Plant
Technical
Stoppage In Production
Organizational
Stoppage Pause Overflow
Stoppage
Tool Problem In Setup
12 B Bartke S Wagner IPI-2
Audi Production System (APS)
Leadership Communication
bull Process Control
Standards
bull In Processes
bull Im Products
bull In the Organization
Learning Organization
bull Employee Development
bull Problem-Solving
bull CIP Culture
13 B Bartke S Wagner IPI-2
Shop Floor Management Process Control Panel on the shop floor
OEE Trend
(Day Week Month)
Measures
Quality
Process Control
14 B Bartke S Wagner IPI-2
OEE - Yesterday
Availability Trend
OEE ndash Last Week
OEE ndash Last Month
Naoki Nojiri IPI-25 BDE-Ist Stand 05042011
Shop Floor Management Process Control Panel on the shop floor
15 B Bartke S Wagner IPI-2
Shop Floor Management Management Cockpit
Planned vs Actual
(shift)
Top problems
(challenges)
OEE ndash Last Week
16 B Bartke S Wagner IPI-2
hellipand what have we achieved
17 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development suspension components (OEE Overall Equipment Effectiveness)
Radtraumlger
Start Shop Floor Management with
FORCAM +10
_
18 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development (20+ Increase in OEE in AUDI Stamping Facilities) (OEE Overall Equipment Effectiveness)
Radtraumlger
Start SFM +20
_
Our Beliefs
Respect
Collaboration
Excellence
Integrity
Community
Oct 30th 2013
Lean with Shop Floor Management BorgWarner Turbo Systems Rzeszow
Operator FactoryFrameworktrade Worker Client- Book On
Operator Downtime Reasons
Operator Actual versus Target Performance
TargetPlanned
Throughput
Actual
Performance
Opportunity for
Improvement
Actual
Throughput Machine
Data
ERP
Data
Supervisor Gantt Status
visualzation
Top 5
downtimes
Cip Top 5
Production
orders
Real data
history
Supervisor Cockpit machine
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
Current situation not dramatic but full scale conflict hellip
11
-6
-5
-4
-3
-2
-1
0
1
2
3
4
2006 2008 2010 2012 2014 2016 2018
Eurozone GDP year
Source Oxford EconomicsHaver Analytics
BaselineForecast
Military conflict in Ukraine
China Outlook A bumpy landing
China growth to slow as rebalancing continueshellip
13
hellipas debt piles up to worrying levels
14
Real estate sector increasingly at risk
15
Japan Slowing in spite of Abenomics
Consumption tax weighs heavily on growth
17
2013 2014
-40
-30
-20
-10
00
10
20
30
Q3 Q4 Q1 Q2
Private consumptionFixed investmentNet exportsGovernment consumptionStockbuildingGDP
Japan Quarterly GDP contributions
quarterly contribution
Source Cabinet Office of Japan Haver Analytics
-3
-2
-1
0
1
2
3
4
1990 1995 2000 2005 2010 2015
Japan Fiscal policyChange in structural budget balance of GDP
Source International Monetary Fund Haver Analytics
ForecastExpansion
Contraction
Emergers Modest growth with structural issues
19
Does it still make sense to talk about ldquoBRICSrdquo
Some countries more vulnerable than others
20
1 Turkey 1182 S Africa 763 Brazil 404 Thailand 295 Russia 266 Malaysia 187 India 018 Poland 019 Mexico -2010 Indonesia -2511 Korea -8012 Philippines -9113 China -93
Oxford Economics Risk Scorecard
Emerging markets will still outpace developed world
21
US Outlook The US is the cleanest shirt in the laundry basket
GDP on a roller-coaster but employment is better indicator
19
Business surveys pointing to strong growthhellip
24
Consumers are feeling more cheerfulhellip
25
Wages expected to risehellip
26
Key domestic risk is housing activityhellip
27
hellipbut rising income and pent-up demand will help
24
Energy prices remain relatively stable
29
Fed to taper on but hold off on rate hikes
30
This image cannot currently be displayed
First rate hike in 2015Q2
Manufacturing in focus
Manufacturing activity is boominghellip
Further indication that GDP decline is due to unique factors
28
hellipwith encouraging signs from leading indicators
29
US manufacturing has outperformed its peershellip
30
US has made substantial gains in competitiveness
35
Remarkable improvements
Due to productivity gains amp modest wage growthhellip
36
Remarkable improvements
Business sentiment in Europe remains weak while new orders have slowed
37
China amp Brazil have lost their edgehellip
38
Chinese wages have more than doubled over the past decade
Key industries
Loose credit and rising demand for autoshellip
36
hellipshould support productionhellip
20
25
30
35
40
45
50
405060708090
100110120130140150160
Jul-09 Jul-10 Jul-11 Jul-12 Jul-13 Jul-14
2010=100 US$ bn
Output (LHS)
Orders (RHS)
Source Oxford Economics Haver Analytics
US Output and orders
3 month moving average
37
hellipas will opportunities in the Emergers
38
Revamp of car stock to be key long-term driver
Ageing vehicle fleet replacement as economy recovers ndash average age of vehicle on US roads in 11frac12 years
Rising fuel efficiency standards leading to replacement of clunkers
Rising fuels costs resulting in smaller cars
Automakers likely to increase new models helping drive investment
Aerospace solid order books at the big twohellip
0
250
500
750
1000
1250
1500
1750
1994 1996 1998 2000 2002 2004 2006 2008 2010 2012 2014
Source Company reports
Airbus versus Boeing Orders
Airbus
Boeing
Number of aircraft
Note 2014 annual estimate based on annualized data through July
40
hellipwith APAC to drive long-term growth
Asia will account for almost 32 of global passenger traffic by 2017 compared to 28 in 2012
APAC to account for 40 of plane deliveries over next 20 years
US and Europe sales mainly for replacement of existing fleet
41
Need for efficiency will provide demand supporthellip
A330 revamped for 15 efficiency improvement to compete with Dreamliner 25 new orders on day of announcement
Long-haul efficiency has some ways to go to maintain airline profitability
42
Order backlogs remain high
0
500
1000
1500
2000
2500
3000
3500
1990 1993 1996 1999 2002 2005 2008 2011 2014
Deliveries
Orders
Number of aircraftAirbus amp Boeing Orders amp deliveries
Source Company reports and forecasts
43
Weaker demand for metalshellip
44
hellipand over capacity are weighing on priceshellip
45
hellipand discouraging investment
BHP Capital spending fell 32 in FY14 with another 8 fall expected next year
Rio Tinto Capital spending in FY14 cut faster than initially projected and further cut is budgeted for 2015
This is weighing on equipment makers
Caterpillar reported sales down 9 in the three months to July with sales to mining firms down 33 from the same period a year earlier
Bumper crop has brought down grain prices
47
helliphitting margins and investment
Producers are facing higher costs due to the implementation of Tier 4 engines developed to comply with emissions standards
Weaker margins are leading to farmers cutting back investment spending
John Deere has posted a 5 yy decline in revenues with an 11 decline in its agricultural division
Conclusions amp market implications
Conclusion and business implications
54
bull US economy expected to gradually accelerate through 2014 with support from a dovish Fed
bull Europe expected to recover but more ECB action could be required
bull Chinese economy is gradually rebalancing but banking crisis cannot be discounted
bull Emerging markets quiet for now but structural issue unsolved
bull Geopolitical tensions in the Middle East and Ukraine are being monitored carefully
Thank you
Gregory Daco
Chief US Economist gregorydacooxfordeconomicscom
September 2014
September 10 2014 2014 General Managersrsquo Meeting
Digital Manufacturing
World Class Shop Floor Management Release 5 The Smart Factory Revolution Mr Franz E Gruber Founder amp CEO
Dr Mohamed Abuali COO FORCAM Inc
MTConnect Evolution of a Standard and
Next Generation Interoperability Mr Courtney J Hill Chairman amp President
MTConnect Institute
QampA Session
World Class
Shop Floor Management
The Smart Factory Revolution
Franz E Gruber
Founder amp CEO
Mohamed Abuali
COO
汉语
World Class Shop Floor Management
FORCAM 2014 Page 2
FORCAMlsquos Passion
FORCAM provides proven
manufacturing solutions to
Continuously Improve Productivity
To be the global solutions provider of
the best-in-class Manufacturing
Execution Systems
FORCAM 2014 Page 3
FORCAM ndash 2014 Best Practices Award by Frost amp Sullivan
Frost amp Sullivan
ldquoFORCAM is a plant production software
solution provider that understands and
supports Industry 40 needsrdquo
FORCAM 2014 Page 4
FORCAMrsquos Testimonials and Industry Leadership
FORCAM 2014 Page 5
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
6 B Bartke S Wagner IPI-2
Shop Floor Management Audi - FORCAM FIT 2011-
Bernhard Bartke - Director Components Manufacturing
Stefan Wagner - Director Gear Manufacturing
7 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
bull Collection and recording of Operational Data via a database
(ex Machine States and State Changes)
Machine
Operator
Production Manager
Technical Assistant IT
Plant
Manager
Team Leader
8 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Interfaces
Time
Objectivity of Process Data
9 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Need for Continuous Improvement
bull Objective Information and Communication ndash across ALL levels
bull Transperancy and Visualization - Online
bull Real-time availability of operational data ndash Live Reports
bull Measurable increase in Plant Efficiency (OEE)
10 B Bartke S Wagner IPI-2
Shop Floor Management ndash Realtime bdquoANDONldquo Visualization
bull Web-based Interface Anywhere Anytime Access
bull Real-time Production Status Visualization
In Production
Overflow
Stoppage
Organizational
Stoppage
Idle (Pause)
Tool
Problem
11 B Bartke S Wagner IPI-2
Shop Floor Management Reporting ndash Hierarchical Status Diagrams
bull Reporting for Machines Groups Lines or the whole Plant
Technical
Stoppage In Production
Organizational
Stoppage Pause Overflow
Stoppage
Tool Problem In Setup
12 B Bartke S Wagner IPI-2
Audi Production System (APS)
Leadership Communication
bull Process Control
Standards
bull In Processes
bull Im Products
bull In the Organization
Learning Organization
bull Employee Development
bull Problem-Solving
bull CIP Culture
13 B Bartke S Wagner IPI-2
Shop Floor Management Process Control Panel on the shop floor
OEE Trend
(Day Week Month)
Measures
Quality
Process Control
14 B Bartke S Wagner IPI-2
OEE - Yesterday
Availability Trend
OEE ndash Last Week
OEE ndash Last Month
Naoki Nojiri IPI-25 BDE-Ist Stand 05042011
Shop Floor Management Process Control Panel on the shop floor
15 B Bartke S Wagner IPI-2
Shop Floor Management Management Cockpit
Planned vs Actual
(shift)
Top problems
(challenges)
OEE ndash Last Week
16 B Bartke S Wagner IPI-2
hellipand what have we achieved
17 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development suspension components (OEE Overall Equipment Effectiveness)
Radtraumlger
Start Shop Floor Management with
FORCAM +10
_
18 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development (20+ Increase in OEE in AUDI Stamping Facilities) (OEE Overall Equipment Effectiveness)
Radtraumlger
Start SFM +20
_
Our Beliefs
Respect
Collaboration
Excellence
Integrity
Community
Oct 30th 2013
Lean with Shop Floor Management BorgWarner Turbo Systems Rzeszow
Operator FactoryFrameworktrade Worker Client- Book On
Operator Downtime Reasons
Operator Actual versus Target Performance
TargetPlanned
Throughput
Actual
Performance
Opportunity for
Improvement
Actual
Throughput Machine
Data
ERP
Data
Supervisor Gantt Status
visualzation
Top 5
downtimes
Cip Top 5
Production
orders
Real data
history
Supervisor Cockpit machine
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
China Outlook A bumpy landing
China growth to slow as rebalancing continueshellip
13
hellipas debt piles up to worrying levels
14
Real estate sector increasingly at risk
15
Japan Slowing in spite of Abenomics
Consumption tax weighs heavily on growth
17
2013 2014
-40
-30
-20
-10
00
10
20
30
Q3 Q4 Q1 Q2
Private consumptionFixed investmentNet exportsGovernment consumptionStockbuildingGDP
Japan Quarterly GDP contributions
quarterly contribution
Source Cabinet Office of Japan Haver Analytics
-3
-2
-1
0
1
2
3
4
1990 1995 2000 2005 2010 2015
Japan Fiscal policyChange in structural budget balance of GDP
Source International Monetary Fund Haver Analytics
ForecastExpansion
Contraction
Emergers Modest growth with structural issues
19
Does it still make sense to talk about ldquoBRICSrdquo
Some countries more vulnerable than others
20
1 Turkey 1182 S Africa 763 Brazil 404 Thailand 295 Russia 266 Malaysia 187 India 018 Poland 019 Mexico -2010 Indonesia -2511 Korea -8012 Philippines -9113 China -93
Oxford Economics Risk Scorecard
Emerging markets will still outpace developed world
21
US Outlook The US is the cleanest shirt in the laundry basket
GDP on a roller-coaster but employment is better indicator
19
Business surveys pointing to strong growthhellip
24
Consumers are feeling more cheerfulhellip
25
Wages expected to risehellip
26
Key domestic risk is housing activityhellip
27
hellipbut rising income and pent-up demand will help
24
Energy prices remain relatively stable
29
Fed to taper on but hold off on rate hikes
30
This image cannot currently be displayed
First rate hike in 2015Q2
Manufacturing in focus
Manufacturing activity is boominghellip
Further indication that GDP decline is due to unique factors
28
hellipwith encouraging signs from leading indicators
29
US manufacturing has outperformed its peershellip
30
US has made substantial gains in competitiveness
35
Remarkable improvements
Due to productivity gains amp modest wage growthhellip
36
Remarkable improvements
Business sentiment in Europe remains weak while new orders have slowed
37
China amp Brazil have lost their edgehellip
38
Chinese wages have more than doubled over the past decade
Key industries
Loose credit and rising demand for autoshellip
36
hellipshould support productionhellip
20
25
30
35
40
45
50
405060708090
100110120130140150160
Jul-09 Jul-10 Jul-11 Jul-12 Jul-13 Jul-14
2010=100 US$ bn
Output (LHS)
Orders (RHS)
Source Oxford Economics Haver Analytics
US Output and orders
3 month moving average
37
hellipas will opportunities in the Emergers
38
Revamp of car stock to be key long-term driver
Ageing vehicle fleet replacement as economy recovers ndash average age of vehicle on US roads in 11frac12 years
Rising fuel efficiency standards leading to replacement of clunkers
Rising fuels costs resulting in smaller cars
Automakers likely to increase new models helping drive investment
Aerospace solid order books at the big twohellip
0
250
500
750
1000
1250
1500
1750
1994 1996 1998 2000 2002 2004 2006 2008 2010 2012 2014
Source Company reports
Airbus versus Boeing Orders
Airbus
Boeing
Number of aircraft
Note 2014 annual estimate based on annualized data through July
40
hellipwith APAC to drive long-term growth
Asia will account for almost 32 of global passenger traffic by 2017 compared to 28 in 2012
APAC to account for 40 of plane deliveries over next 20 years
US and Europe sales mainly for replacement of existing fleet
41
Need for efficiency will provide demand supporthellip
A330 revamped for 15 efficiency improvement to compete with Dreamliner 25 new orders on day of announcement
Long-haul efficiency has some ways to go to maintain airline profitability
42
Order backlogs remain high
0
500
1000
1500
2000
2500
3000
3500
1990 1993 1996 1999 2002 2005 2008 2011 2014
Deliveries
Orders
Number of aircraftAirbus amp Boeing Orders amp deliveries
Source Company reports and forecasts
43
Weaker demand for metalshellip
44
hellipand over capacity are weighing on priceshellip
45
hellipand discouraging investment
BHP Capital spending fell 32 in FY14 with another 8 fall expected next year
Rio Tinto Capital spending in FY14 cut faster than initially projected and further cut is budgeted for 2015
This is weighing on equipment makers
Caterpillar reported sales down 9 in the three months to July with sales to mining firms down 33 from the same period a year earlier
Bumper crop has brought down grain prices
47
helliphitting margins and investment
Producers are facing higher costs due to the implementation of Tier 4 engines developed to comply with emissions standards
Weaker margins are leading to farmers cutting back investment spending
John Deere has posted a 5 yy decline in revenues with an 11 decline in its agricultural division
Conclusions amp market implications
Conclusion and business implications
54
bull US economy expected to gradually accelerate through 2014 with support from a dovish Fed
bull Europe expected to recover but more ECB action could be required
bull Chinese economy is gradually rebalancing but banking crisis cannot be discounted
bull Emerging markets quiet for now but structural issue unsolved
bull Geopolitical tensions in the Middle East and Ukraine are being monitored carefully
Thank you
Gregory Daco
Chief US Economist gregorydacooxfordeconomicscom
September 2014
September 10 2014 2014 General Managersrsquo Meeting
Digital Manufacturing
World Class Shop Floor Management Release 5 The Smart Factory Revolution Mr Franz E Gruber Founder amp CEO
Dr Mohamed Abuali COO FORCAM Inc
MTConnect Evolution of a Standard and
Next Generation Interoperability Mr Courtney J Hill Chairman amp President
MTConnect Institute
QampA Session
World Class
Shop Floor Management
The Smart Factory Revolution
Franz E Gruber
Founder amp CEO
Mohamed Abuali
COO
汉语
World Class Shop Floor Management
FORCAM 2014 Page 2
FORCAMlsquos Passion
FORCAM provides proven
manufacturing solutions to
Continuously Improve Productivity
To be the global solutions provider of
the best-in-class Manufacturing
Execution Systems
FORCAM 2014 Page 3
FORCAM ndash 2014 Best Practices Award by Frost amp Sullivan
Frost amp Sullivan
ldquoFORCAM is a plant production software
solution provider that understands and
supports Industry 40 needsrdquo
FORCAM 2014 Page 4
FORCAMrsquos Testimonials and Industry Leadership
FORCAM 2014 Page 5
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
6 B Bartke S Wagner IPI-2
Shop Floor Management Audi - FORCAM FIT 2011-
Bernhard Bartke - Director Components Manufacturing
Stefan Wagner - Director Gear Manufacturing
7 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
bull Collection and recording of Operational Data via a database
(ex Machine States and State Changes)
Machine
Operator
Production Manager
Technical Assistant IT
Plant
Manager
Team Leader
8 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Interfaces
Time
Objectivity of Process Data
9 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Need for Continuous Improvement
bull Objective Information and Communication ndash across ALL levels
bull Transperancy and Visualization - Online
bull Real-time availability of operational data ndash Live Reports
bull Measurable increase in Plant Efficiency (OEE)
10 B Bartke S Wagner IPI-2
Shop Floor Management ndash Realtime bdquoANDONldquo Visualization
bull Web-based Interface Anywhere Anytime Access
bull Real-time Production Status Visualization
In Production
Overflow
Stoppage
Organizational
Stoppage
Idle (Pause)
Tool
Problem
11 B Bartke S Wagner IPI-2
Shop Floor Management Reporting ndash Hierarchical Status Diagrams
bull Reporting for Machines Groups Lines or the whole Plant
Technical
Stoppage In Production
Organizational
Stoppage Pause Overflow
Stoppage
Tool Problem In Setup
12 B Bartke S Wagner IPI-2
Audi Production System (APS)
Leadership Communication
bull Process Control
Standards
bull In Processes
bull Im Products
bull In the Organization
Learning Organization
bull Employee Development
bull Problem-Solving
bull CIP Culture
13 B Bartke S Wagner IPI-2
Shop Floor Management Process Control Panel on the shop floor
OEE Trend
(Day Week Month)
Measures
Quality
Process Control
14 B Bartke S Wagner IPI-2
OEE - Yesterday
Availability Trend
OEE ndash Last Week
OEE ndash Last Month
Naoki Nojiri IPI-25 BDE-Ist Stand 05042011
Shop Floor Management Process Control Panel on the shop floor
15 B Bartke S Wagner IPI-2
Shop Floor Management Management Cockpit
Planned vs Actual
(shift)
Top problems
(challenges)
OEE ndash Last Week
16 B Bartke S Wagner IPI-2
hellipand what have we achieved
17 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development suspension components (OEE Overall Equipment Effectiveness)
Radtraumlger
Start Shop Floor Management with
FORCAM +10
_
18 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development (20+ Increase in OEE in AUDI Stamping Facilities) (OEE Overall Equipment Effectiveness)
Radtraumlger
Start SFM +20
_
Our Beliefs
Respect
Collaboration
Excellence
Integrity
Community
Oct 30th 2013
Lean with Shop Floor Management BorgWarner Turbo Systems Rzeszow
Operator FactoryFrameworktrade Worker Client- Book On
Operator Downtime Reasons
Operator Actual versus Target Performance
TargetPlanned
Throughput
Actual
Performance
Opportunity for
Improvement
Actual
Throughput Machine
Data
ERP
Data
Supervisor Gantt Status
visualzation
Top 5
downtimes
Cip Top 5
Production
orders
Real data
history
Supervisor Cockpit machine
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
China growth to slow as rebalancing continueshellip
13
hellipas debt piles up to worrying levels
14
Real estate sector increasingly at risk
15
Japan Slowing in spite of Abenomics
Consumption tax weighs heavily on growth
17
2013 2014
-40
-30
-20
-10
00
10
20
30
Q3 Q4 Q1 Q2
Private consumptionFixed investmentNet exportsGovernment consumptionStockbuildingGDP
Japan Quarterly GDP contributions
quarterly contribution
Source Cabinet Office of Japan Haver Analytics
-3
-2
-1
0
1
2
3
4
1990 1995 2000 2005 2010 2015
Japan Fiscal policyChange in structural budget balance of GDP
Source International Monetary Fund Haver Analytics
ForecastExpansion
Contraction
Emergers Modest growth with structural issues
19
Does it still make sense to talk about ldquoBRICSrdquo
Some countries more vulnerable than others
20
1 Turkey 1182 S Africa 763 Brazil 404 Thailand 295 Russia 266 Malaysia 187 India 018 Poland 019 Mexico -2010 Indonesia -2511 Korea -8012 Philippines -9113 China -93
Oxford Economics Risk Scorecard
Emerging markets will still outpace developed world
21
US Outlook The US is the cleanest shirt in the laundry basket
GDP on a roller-coaster but employment is better indicator
19
Business surveys pointing to strong growthhellip
24
Consumers are feeling more cheerfulhellip
25
Wages expected to risehellip
26
Key domestic risk is housing activityhellip
27
hellipbut rising income and pent-up demand will help
24
Energy prices remain relatively stable
29
Fed to taper on but hold off on rate hikes
30
This image cannot currently be displayed
First rate hike in 2015Q2
Manufacturing in focus
Manufacturing activity is boominghellip
Further indication that GDP decline is due to unique factors
28
hellipwith encouraging signs from leading indicators
29
US manufacturing has outperformed its peershellip
30
US has made substantial gains in competitiveness
35
Remarkable improvements
Due to productivity gains amp modest wage growthhellip
36
Remarkable improvements
Business sentiment in Europe remains weak while new orders have slowed
37
China amp Brazil have lost their edgehellip
38
Chinese wages have more than doubled over the past decade
Key industries
Loose credit and rising demand for autoshellip
36
hellipshould support productionhellip
20
25
30
35
40
45
50
405060708090
100110120130140150160
Jul-09 Jul-10 Jul-11 Jul-12 Jul-13 Jul-14
2010=100 US$ bn
Output (LHS)
Orders (RHS)
Source Oxford Economics Haver Analytics
US Output and orders
3 month moving average
37
hellipas will opportunities in the Emergers
38
Revamp of car stock to be key long-term driver
Ageing vehicle fleet replacement as economy recovers ndash average age of vehicle on US roads in 11frac12 years
Rising fuel efficiency standards leading to replacement of clunkers
Rising fuels costs resulting in smaller cars
Automakers likely to increase new models helping drive investment
Aerospace solid order books at the big twohellip
0
250
500
750
1000
1250
1500
1750
1994 1996 1998 2000 2002 2004 2006 2008 2010 2012 2014
Source Company reports
Airbus versus Boeing Orders
Airbus
Boeing
Number of aircraft
Note 2014 annual estimate based on annualized data through July
40
hellipwith APAC to drive long-term growth
Asia will account for almost 32 of global passenger traffic by 2017 compared to 28 in 2012
APAC to account for 40 of plane deliveries over next 20 years
US and Europe sales mainly for replacement of existing fleet
41
Need for efficiency will provide demand supporthellip
A330 revamped for 15 efficiency improvement to compete with Dreamliner 25 new orders on day of announcement
Long-haul efficiency has some ways to go to maintain airline profitability
42
Order backlogs remain high
0
500
1000
1500
2000
2500
3000
3500
1990 1993 1996 1999 2002 2005 2008 2011 2014
Deliveries
Orders
Number of aircraftAirbus amp Boeing Orders amp deliveries
Source Company reports and forecasts
43
Weaker demand for metalshellip
44
hellipand over capacity are weighing on priceshellip
45
hellipand discouraging investment
BHP Capital spending fell 32 in FY14 with another 8 fall expected next year
Rio Tinto Capital spending in FY14 cut faster than initially projected and further cut is budgeted for 2015
This is weighing on equipment makers
Caterpillar reported sales down 9 in the three months to July with sales to mining firms down 33 from the same period a year earlier
Bumper crop has brought down grain prices
47
helliphitting margins and investment
Producers are facing higher costs due to the implementation of Tier 4 engines developed to comply with emissions standards
Weaker margins are leading to farmers cutting back investment spending
John Deere has posted a 5 yy decline in revenues with an 11 decline in its agricultural division
Conclusions amp market implications
Conclusion and business implications
54
bull US economy expected to gradually accelerate through 2014 with support from a dovish Fed
bull Europe expected to recover but more ECB action could be required
bull Chinese economy is gradually rebalancing but banking crisis cannot be discounted
bull Emerging markets quiet for now but structural issue unsolved
bull Geopolitical tensions in the Middle East and Ukraine are being monitored carefully
Thank you
Gregory Daco
Chief US Economist gregorydacooxfordeconomicscom
September 2014
September 10 2014 2014 General Managersrsquo Meeting
Digital Manufacturing
World Class Shop Floor Management Release 5 The Smart Factory Revolution Mr Franz E Gruber Founder amp CEO
Dr Mohamed Abuali COO FORCAM Inc
MTConnect Evolution of a Standard and
Next Generation Interoperability Mr Courtney J Hill Chairman amp President
MTConnect Institute
QampA Session
World Class
Shop Floor Management
The Smart Factory Revolution
Franz E Gruber
Founder amp CEO
Mohamed Abuali
COO
汉语
World Class Shop Floor Management
FORCAM 2014 Page 2
FORCAMlsquos Passion
FORCAM provides proven
manufacturing solutions to
Continuously Improve Productivity
To be the global solutions provider of
the best-in-class Manufacturing
Execution Systems
FORCAM 2014 Page 3
FORCAM ndash 2014 Best Practices Award by Frost amp Sullivan
Frost amp Sullivan
ldquoFORCAM is a plant production software
solution provider that understands and
supports Industry 40 needsrdquo
FORCAM 2014 Page 4
FORCAMrsquos Testimonials and Industry Leadership
FORCAM 2014 Page 5
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
6 B Bartke S Wagner IPI-2
Shop Floor Management Audi - FORCAM FIT 2011-
Bernhard Bartke - Director Components Manufacturing
Stefan Wagner - Director Gear Manufacturing
7 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
bull Collection and recording of Operational Data via a database
(ex Machine States and State Changes)
Machine
Operator
Production Manager
Technical Assistant IT
Plant
Manager
Team Leader
8 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Interfaces
Time
Objectivity of Process Data
9 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Need for Continuous Improvement
bull Objective Information and Communication ndash across ALL levels
bull Transperancy and Visualization - Online
bull Real-time availability of operational data ndash Live Reports
bull Measurable increase in Plant Efficiency (OEE)
10 B Bartke S Wagner IPI-2
Shop Floor Management ndash Realtime bdquoANDONldquo Visualization
bull Web-based Interface Anywhere Anytime Access
bull Real-time Production Status Visualization
In Production
Overflow
Stoppage
Organizational
Stoppage
Idle (Pause)
Tool
Problem
11 B Bartke S Wagner IPI-2
Shop Floor Management Reporting ndash Hierarchical Status Diagrams
bull Reporting for Machines Groups Lines or the whole Plant
Technical
Stoppage In Production
Organizational
Stoppage Pause Overflow
Stoppage
Tool Problem In Setup
12 B Bartke S Wagner IPI-2
Audi Production System (APS)
Leadership Communication
bull Process Control
Standards
bull In Processes
bull Im Products
bull In the Organization
Learning Organization
bull Employee Development
bull Problem-Solving
bull CIP Culture
13 B Bartke S Wagner IPI-2
Shop Floor Management Process Control Panel on the shop floor
OEE Trend
(Day Week Month)
Measures
Quality
Process Control
14 B Bartke S Wagner IPI-2
OEE - Yesterday
Availability Trend
OEE ndash Last Week
OEE ndash Last Month
Naoki Nojiri IPI-25 BDE-Ist Stand 05042011
Shop Floor Management Process Control Panel on the shop floor
15 B Bartke S Wagner IPI-2
Shop Floor Management Management Cockpit
Planned vs Actual
(shift)
Top problems
(challenges)
OEE ndash Last Week
16 B Bartke S Wagner IPI-2
hellipand what have we achieved
17 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development suspension components (OEE Overall Equipment Effectiveness)
Radtraumlger
Start Shop Floor Management with
FORCAM +10
_
18 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development (20+ Increase in OEE in AUDI Stamping Facilities) (OEE Overall Equipment Effectiveness)
Radtraumlger
Start SFM +20
_
Our Beliefs
Respect
Collaboration
Excellence
Integrity
Community
Oct 30th 2013
Lean with Shop Floor Management BorgWarner Turbo Systems Rzeszow
Operator FactoryFrameworktrade Worker Client- Book On
Operator Downtime Reasons
Operator Actual versus Target Performance
TargetPlanned
Throughput
Actual
Performance
Opportunity for
Improvement
Actual
Throughput Machine
Data
ERP
Data
Supervisor Gantt Status
visualzation
Top 5
downtimes
Cip Top 5
Production
orders
Real data
history
Supervisor Cockpit machine
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
hellipas debt piles up to worrying levels
14
Real estate sector increasingly at risk
15
Japan Slowing in spite of Abenomics
Consumption tax weighs heavily on growth
17
2013 2014
-40
-30
-20
-10
00
10
20
30
Q3 Q4 Q1 Q2
Private consumptionFixed investmentNet exportsGovernment consumptionStockbuildingGDP
Japan Quarterly GDP contributions
quarterly contribution
Source Cabinet Office of Japan Haver Analytics
-3
-2
-1
0
1
2
3
4
1990 1995 2000 2005 2010 2015
Japan Fiscal policyChange in structural budget balance of GDP
Source International Monetary Fund Haver Analytics
ForecastExpansion
Contraction
Emergers Modest growth with structural issues
19
Does it still make sense to talk about ldquoBRICSrdquo
Some countries more vulnerable than others
20
1 Turkey 1182 S Africa 763 Brazil 404 Thailand 295 Russia 266 Malaysia 187 India 018 Poland 019 Mexico -2010 Indonesia -2511 Korea -8012 Philippines -9113 China -93
Oxford Economics Risk Scorecard
Emerging markets will still outpace developed world
21
US Outlook The US is the cleanest shirt in the laundry basket
GDP on a roller-coaster but employment is better indicator
19
Business surveys pointing to strong growthhellip
24
Consumers are feeling more cheerfulhellip
25
Wages expected to risehellip
26
Key domestic risk is housing activityhellip
27
hellipbut rising income and pent-up demand will help
24
Energy prices remain relatively stable
29
Fed to taper on but hold off on rate hikes
30
This image cannot currently be displayed
First rate hike in 2015Q2
Manufacturing in focus
Manufacturing activity is boominghellip
Further indication that GDP decline is due to unique factors
28
hellipwith encouraging signs from leading indicators
29
US manufacturing has outperformed its peershellip
30
US has made substantial gains in competitiveness
35
Remarkable improvements
Due to productivity gains amp modest wage growthhellip
36
Remarkable improvements
Business sentiment in Europe remains weak while new orders have slowed
37
China amp Brazil have lost their edgehellip
38
Chinese wages have more than doubled over the past decade
Key industries
Loose credit and rising demand for autoshellip
36
hellipshould support productionhellip
20
25
30
35
40
45
50
405060708090
100110120130140150160
Jul-09 Jul-10 Jul-11 Jul-12 Jul-13 Jul-14
2010=100 US$ bn
Output (LHS)
Orders (RHS)
Source Oxford Economics Haver Analytics
US Output and orders
3 month moving average
37
hellipas will opportunities in the Emergers
38
Revamp of car stock to be key long-term driver
Ageing vehicle fleet replacement as economy recovers ndash average age of vehicle on US roads in 11frac12 years
Rising fuel efficiency standards leading to replacement of clunkers
Rising fuels costs resulting in smaller cars
Automakers likely to increase new models helping drive investment
Aerospace solid order books at the big twohellip
0
250
500
750
1000
1250
1500
1750
1994 1996 1998 2000 2002 2004 2006 2008 2010 2012 2014
Source Company reports
Airbus versus Boeing Orders
Airbus
Boeing
Number of aircraft
Note 2014 annual estimate based on annualized data through July
40
hellipwith APAC to drive long-term growth
Asia will account for almost 32 of global passenger traffic by 2017 compared to 28 in 2012
APAC to account for 40 of plane deliveries over next 20 years
US and Europe sales mainly for replacement of existing fleet
41
Need for efficiency will provide demand supporthellip
A330 revamped for 15 efficiency improvement to compete with Dreamliner 25 new orders on day of announcement
Long-haul efficiency has some ways to go to maintain airline profitability
42
Order backlogs remain high
0
500
1000
1500
2000
2500
3000
3500
1990 1993 1996 1999 2002 2005 2008 2011 2014
Deliveries
Orders
Number of aircraftAirbus amp Boeing Orders amp deliveries
Source Company reports and forecasts
43
Weaker demand for metalshellip
44
hellipand over capacity are weighing on priceshellip
45
hellipand discouraging investment
BHP Capital spending fell 32 in FY14 with another 8 fall expected next year
Rio Tinto Capital spending in FY14 cut faster than initially projected and further cut is budgeted for 2015
This is weighing on equipment makers
Caterpillar reported sales down 9 in the three months to July with sales to mining firms down 33 from the same period a year earlier
Bumper crop has brought down grain prices
47
helliphitting margins and investment
Producers are facing higher costs due to the implementation of Tier 4 engines developed to comply with emissions standards
Weaker margins are leading to farmers cutting back investment spending
John Deere has posted a 5 yy decline in revenues with an 11 decline in its agricultural division
Conclusions amp market implications
Conclusion and business implications
54
bull US economy expected to gradually accelerate through 2014 with support from a dovish Fed
bull Europe expected to recover but more ECB action could be required
bull Chinese economy is gradually rebalancing but banking crisis cannot be discounted
bull Emerging markets quiet for now but structural issue unsolved
bull Geopolitical tensions in the Middle East and Ukraine are being monitored carefully
Thank you
Gregory Daco
Chief US Economist gregorydacooxfordeconomicscom
September 2014
September 10 2014 2014 General Managersrsquo Meeting
Digital Manufacturing
World Class Shop Floor Management Release 5 The Smart Factory Revolution Mr Franz E Gruber Founder amp CEO
Dr Mohamed Abuali COO FORCAM Inc
MTConnect Evolution of a Standard and
Next Generation Interoperability Mr Courtney J Hill Chairman amp President
MTConnect Institute
QampA Session
World Class
Shop Floor Management
The Smart Factory Revolution
Franz E Gruber
Founder amp CEO
Mohamed Abuali
COO
汉语
World Class Shop Floor Management
FORCAM 2014 Page 2
FORCAMlsquos Passion
FORCAM provides proven
manufacturing solutions to
Continuously Improve Productivity
To be the global solutions provider of
the best-in-class Manufacturing
Execution Systems
FORCAM 2014 Page 3
FORCAM ndash 2014 Best Practices Award by Frost amp Sullivan
Frost amp Sullivan
ldquoFORCAM is a plant production software
solution provider that understands and
supports Industry 40 needsrdquo
FORCAM 2014 Page 4
FORCAMrsquos Testimonials and Industry Leadership
FORCAM 2014 Page 5
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
6 B Bartke S Wagner IPI-2
Shop Floor Management Audi - FORCAM FIT 2011-
Bernhard Bartke - Director Components Manufacturing
Stefan Wagner - Director Gear Manufacturing
7 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
bull Collection and recording of Operational Data via a database
(ex Machine States and State Changes)
Machine
Operator
Production Manager
Technical Assistant IT
Plant
Manager
Team Leader
8 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Interfaces
Time
Objectivity of Process Data
9 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Need for Continuous Improvement
bull Objective Information and Communication ndash across ALL levels
bull Transperancy and Visualization - Online
bull Real-time availability of operational data ndash Live Reports
bull Measurable increase in Plant Efficiency (OEE)
10 B Bartke S Wagner IPI-2
Shop Floor Management ndash Realtime bdquoANDONldquo Visualization
bull Web-based Interface Anywhere Anytime Access
bull Real-time Production Status Visualization
In Production
Overflow
Stoppage
Organizational
Stoppage
Idle (Pause)
Tool
Problem
11 B Bartke S Wagner IPI-2
Shop Floor Management Reporting ndash Hierarchical Status Diagrams
bull Reporting for Machines Groups Lines or the whole Plant
Technical
Stoppage In Production
Organizational
Stoppage Pause Overflow
Stoppage
Tool Problem In Setup
12 B Bartke S Wagner IPI-2
Audi Production System (APS)
Leadership Communication
bull Process Control
Standards
bull In Processes
bull Im Products
bull In the Organization
Learning Organization
bull Employee Development
bull Problem-Solving
bull CIP Culture
13 B Bartke S Wagner IPI-2
Shop Floor Management Process Control Panel on the shop floor
OEE Trend
(Day Week Month)
Measures
Quality
Process Control
14 B Bartke S Wagner IPI-2
OEE - Yesterday
Availability Trend
OEE ndash Last Week
OEE ndash Last Month
Naoki Nojiri IPI-25 BDE-Ist Stand 05042011
Shop Floor Management Process Control Panel on the shop floor
15 B Bartke S Wagner IPI-2
Shop Floor Management Management Cockpit
Planned vs Actual
(shift)
Top problems
(challenges)
OEE ndash Last Week
16 B Bartke S Wagner IPI-2
hellipand what have we achieved
17 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development suspension components (OEE Overall Equipment Effectiveness)
Radtraumlger
Start Shop Floor Management with
FORCAM +10
_
18 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development (20+ Increase in OEE in AUDI Stamping Facilities) (OEE Overall Equipment Effectiveness)
Radtraumlger
Start SFM +20
_
Our Beliefs
Respect
Collaboration
Excellence
Integrity
Community
Oct 30th 2013
Lean with Shop Floor Management BorgWarner Turbo Systems Rzeszow
Operator FactoryFrameworktrade Worker Client- Book On
Operator Downtime Reasons
Operator Actual versus Target Performance
TargetPlanned
Throughput
Actual
Performance
Opportunity for
Improvement
Actual
Throughput Machine
Data
ERP
Data
Supervisor Gantt Status
visualzation
Top 5
downtimes
Cip Top 5
Production
orders
Real data
history
Supervisor Cockpit machine
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
Real estate sector increasingly at risk
15
Japan Slowing in spite of Abenomics
Consumption tax weighs heavily on growth
17
2013 2014
-40
-30
-20
-10
00
10
20
30
Q3 Q4 Q1 Q2
Private consumptionFixed investmentNet exportsGovernment consumptionStockbuildingGDP
Japan Quarterly GDP contributions
quarterly contribution
Source Cabinet Office of Japan Haver Analytics
-3
-2
-1
0
1
2
3
4
1990 1995 2000 2005 2010 2015
Japan Fiscal policyChange in structural budget balance of GDP
Source International Monetary Fund Haver Analytics
ForecastExpansion
Contraction
Emergers Modest growth with structural issues
19
Does it still make sense to talk about ldquoBRICSrdquo
Some countries more vulnerable than others
20
1 Turkey 1182 S Africa 763 Brazil 404 Thailand 295 Russia 266 Malaysia 187 India 018 Poland 019 Mexico -2010 Indonesia -2511 Korea -8012 Philippines -9113 China -93
Oxford Economics Risk Scorecard
Emerging markets will still outpace developed world
21
US Outlook The US is the cleanest shirt in the laundry basket
GDP on a roller-coaster but employment is better indicator
19
Business surveys pointing to strong growthhellip
24
Consumers are feeling more cheerfulhellip
25
Wages expected to risehellip
26
Key domestic risk is housing activityhellip
27
hellipbut rising income and pent-up demand will help
24
Energy prices remain relatively stable
29
Fed to taper on but hold off on rate hikes
30
This image cannot currently be displayed
First rate hike in 2015Q2
Manufacturing in focus
Manufacturing activity is boominghellip
Further indication that GDP decline is due to unique factors
28
hellipwith encouraging signs from leading indicators
29
US manufacturing has outperformed its peershellip
30
US has made substantial gains in competitiveness
35
Remarkable improvements
Due to productivity gains amp modest wage growthhellip
36
Remarkable improvements
Business sentiment in Europe remains weak while new orders have slowed
37
China amp Brazil have lost their edgehellip
38
Chinese wages have more than doubled over the past decade
Key industries
Loose credit and rising demand for autoshellip
36
hellipshould support productionhellip
20
25
30
35
40
45
50
405060708090
100110120130140150160
Jul-09 Jul-10 Jul-11 Jul-12 Jul-13 Jul-14
2010=100 US$ bn
Output (LHS)
Orders (RHS)
Source Oxford Economics Haver Analytics
US Output and orders
3 month moving average
37
hellipas will opportunities in the Emergers
38
Revamp of car stock to be key long-term driver
Ageing vehicle fleet replacement as economy recovers ndash average age of vehicle on US roads in 11frac12 years
Rising fuel efficiency standards leading to replacement of clunkers
Rising fuels costs resulting in smaller cars
Automakers likely to increase new models helping drive investment
Aerospace solid order books at the big twohellip
0
250
500
750
1000
1250
1500
1750
1994 1996 1998 2000 2002 2004 2006 2008 2010 2012 2014
Source Company reports
Airbus versus Boeing Orders
Airbus
Boeing
Number of aircraft
Note 2014 annual estimate based on annualized data through July
40
hellipwith APAC to drive long-term growth
Asia will account for almost 32 of global passenger traffic by 2017 compared to 28 in 2012
APAC to account for 40 of plane deliveries over next 20 years
US and Europe sales mainly for replacement of existing fleet
41
Need for efficiency will provide demand supporthellip
A330 revamped for 15 efficiency improvement to compete with Dreamliner 25 new orders on day of announcement
Long-haul efficiency has some ways to go to maintain airline profitability
42
Order backlogs remain high
0
500
1000
1500
2000
2500
3000
3500
1990 1993 1996 1999 2002 2005 2008 2011 2014
Deliveries
Orders
Number of aircraftAirbus amp Boeing Orders amp deliveries
Source Company reports and forecasts
43
Weaker demand for metalshellip
44
hellipand over capacity are weighing on priceshellip
45
hellipand discouraging investment
BHP Capital spending fell 32 in FY14 with another 8 fall expected next year
Rio Tinto Capital spending in FY14 cut faster than initially projected and further cut is budgeted for 2015
This is weighing on equipment makers
Caterpillar reported sales down 9 in the three months to July with sales to mining firms down 33 from the same period a year earlier
Bumper crop has brought down grain prices
47
helliphitting margins and investment
Producers are facing higher costs due to the implementation of Tier 4 engines developed to comply with emissions standards
Weaker margins are leading to farmers cutting back investment spending
John Deere has posted a 5 yy decline in revenues with an 11 decline in its agricultural division
Conclusions amp market implications
Conclusion and business implications
54
bull US economy expected to gradually accelerate through 2014 with support from a dovish Fed
bull Europe expected to recover but more ECB action could be required
bull Chinese economy is gradually rebalancing but banking crisis cannot be discounted
bull Emerging markets quiet for now but structural issue unsolved
bull Geopolitical tensions in the Middle East and Ukraine are being monitored carefully
Thank you
Gregory Daco
Chief US Economist gregorydacooxfordeconomicscom
September 2014
September 10 2014 2014 General Managersrsquo Meeting
Digital Manufacturing
World Class Shop Floor Management Release 5 The Smart Factory Revolution Mr Franz E Gruber Founder amp CEO
Dr Mohamed Abuali COO FORCAM Inc
MTConnect Evolution of a Standard and
Next Generation Interoperability Mr Courtney J Hill Chairman amp President
MTConnect Institute
QampA Session
World Class
Shop Floor Management
The Smart Factory Revolution
Franz E Gruber
Founder amp CEO
Mohamed Abuali
COO
汉语
World Class Shop Floor Management
FORCAM 2014 Page 2
FORCAMlsquos Passion
FORCAM provides proven
manufacturing solutions to
Continuously Improve Productivity
To be the global solutions provider of
the best-in-class Manufacturing
Execution Systems
FORCAM 2014 Page 3
FORCAM ndash 2014 Best Practices Award by Frost amp Sullivan
Frost amp Sullivan
ldquoFORCAM is a plant production software
solution provider that understands and
supports Industry 40 needsrdquo
FORCAM 2014 Page 4
FORCAMrsquos Testimonials and Industry Leadership
FORCAM 2014 Page 5
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
6 B Bartke S Wagner IPI-2
Shop Floor Management Audi - FORCAM FIT 2011-
Bernhard Bartke - Director Components Manufacturing
Stefan Wagner - Director Gear Manufacturing
7 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
bull Collection and recording of Operational Data via a database
(ex Machine States and State Changes)
Machine
Operator
Production Manager
Technical Assistant IT
Plant
Manager
Team Leader
8 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Interfaces
Time
Objectivity of Process Data
9 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Need for Continuous Improvement
bull Objective Information and Communication ndash across ALL levels
bull Transperancy and Visualization - Online
bull Real-time availability of operational data ndash Live Reports
bull Measurable increase in Plant Efficiency (OEE)
10 B Bartke S Wagner IPI-2
Shop Floor Management ndash Realtime bdquoANDONldquo Visualization
bull Web-based Interface Anywhere Anytime Access
bull Real-time Production Status Visualization
In Production
Overflow
Stoppage
Organizational
Stoppage
Idle (Pause)
Tool
Problem
11 B Bartke S Wagner IPI-2
Shop Floor Management Reporting ndash Hierarchical Status Diagrams
bull Reporting for Machines Groups Lines or the whole Plant
Technical
Stoppage In Production
Organizational
Stoppage Pause Overflow
Stoppage
Tool Problem In Setup
12 B Bartke S Wagner IPI-2
Audi Production System (APS)
Leadership Communication
bull Process Control
Standards
bull In Processes
bull Im Products
bull In the Organization
Learning Organization
bull Employee Development
bull Problem-Solving
bull CIP Culture
13 B Bartke S Wagner IPI-2
Shop Floor Management Process Control Panel on the shop floor
OEE Trend
(Day Week Month)
Measures
Quality
Process Control
14 B Bartke S Wagner IPI-2
OEE - Yesterday
Availability Trend
OEE ndash Last Week
OEE ndash Last Month
Naoki Nojiri IPI-25 BDE-Ist Stand 05042011
Shop Floor Management Process Control Panel on the shop floor
15 B Bartke S Wagner IPI-2
Shop Floor Management Management Cockpit
Planned vs Actual
(shift)
Top problems
(challenges)
OEE ndash Last Week
16 B Bartke S Wagner IPI-2
hellipand what have we achieved
17 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development suspension components (OEE Overall Equipment Effectiveness)
Radtraumlger
Start Shop Floor Management with
FORCAM +10
_
18 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development (20+ Increase in OEE in AUDI Stamping Facilities) (OEE Overall Equipment Effectiveness)
Radtraumlger
Start SFM +20
_
Our Beliefs
Respect
Collaboration
Excellence
Integrity
Community
Oct 30th 2013
Lean with Shop Floor Management BorgWarner Turbo Systems Rzeszow
Operator FactoryFrameworktrade Worker Client- Book On
Operator Downtime Reasons
Operator Actual versus Target Performance
TargetPlanned
Throughput
Actual
Performance
Opportunity for
Improvement
Actual
Throughput Machine
Data
ERP
Data
Supervisor Gantt Status
visualzation
Top 5
downtimes
Cip Top 5
Production
orders
Real data
history
Supervisor Cockpit machine
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
Japan Slowing in spite of Abenomics
Consumption tax weighs heavily on growth
17
2013 2014
-40
-30
-20
-10
00
10
20
30
Q3 Q4 Q1 Q2
Private consumptionFixed investmentNet exportsGovernment consumptionStockbuildingGDP
Japan Quarterly GDP contributions
quarterly contribution
Source Cabinet Office of Japan Haver Analytics
-3
-2
-1
0
1
2
3
4
1990 1995 2000 2005 2010 2015
Japan Fiscal policyChange in structural budget balance of GDP
Source International Monetary Fund Haver Analytics
ForecastExpansion
Contraction
Emergers Modest growth with structural issues
19
Does it still make sense to talk about ldquoBRICSrdquo
Some countries more vulnerable than others
20
1 Turkey 1182 S Africa 763 Brazil 404 Thailand 295 Russia 266 Malaysia 187 India 018 Poland 019 Mexico -2010 Indonesia -2511 Korea -8012 Philippines -9113 China -93
Oxford Economics Risk Scorecard
Emerging markets will still outpace developed world
21
US Outlook The US is the cleanest shirt in the laundry basket
GDP on a roller-coaster but employment is better indicator
19
Business surveys pointing to strong growthhellip
24
Consumers are feeling more cheerfulhellip
25
Wages expected to risehellip
26
Key domestic risk is housing activityhellip
27
hellipbut rising income and pent-up demand will help
24
Energy prices remain relatively stable
29
Fed to taper on but hold off on rate hikes
30
This image cannot currently be displayed
First rate hike in 2015Q2
Manufacturing in focus
Manufacturing activity is boominghellip
Further indication that GDP decline is due to unique factors
28
hellipwith encouraging signs from leading indicators
29
US manufacturing has outperformed its peershellip
30
US has made substantial gains in competitiveness
35
Remarkable improvements
Due to productivity gains amp modest wage growthhellip
36
Remarkable improvements
Business sentiment in Europe remains weak while new orders have slowed
37
China amp Brazil have lost their edgehellip
38
Chinese wages have more than doubled over the past decade
Key industries
Loose credit and rising demand for autoshellip
36
hellipshould support productionhellip
20
25
30
35
40
45
50
405060708090
100110120130140150160
Jul-09 Jul-10 Jul-11 Jul-12 Jul-13 Jul-14
2010=100 US$ bn
Output (LHS)
Orders (RHS)
Source Oxford Economics Haver Analytics
US Output and orders
3 month moving average
37
hellipas will opportunities in the Emergers
38
Revamp of car stock to be key long-term driver
Ageing vehicle fleet replacement as economy recovers ndash average age of vehicle on US roads in 11frac12 years
Rising fuel efficiency standards leading to replacement of clunkers
Rising fuels costs resulting in smaller cars
Automakers likely to increase new models helping drive investment
Aerospace solid order books at the big twohellip
0
250
500
750
1000
1250
1500
1750
1994 1996 1998 2000 2002 2004 2006 2008 2010 2012 2014
Source Company reports
Airbus versus Boeing Orders
Airbus
Boeing
Number of aircraft
Note 2014 annual estimate based on annualized data through July
40
hellipwith APAC to drive long-term growth
Asia will account for almost 32 of global passenger traffic by 2017 compared to 28 in 2012
APAC to account for 40 of plane deliveries over next 20 years
US and Europe sales mainly for replacement of existing fleet
41
Need for efficiency will provide demand supporthellip
A330 revamped for 15 efficiency improvement to compete with Dreamliner 25 new orders on day of announcement
Long-haul efficiency has some ways to go to maintain airline profitability
42
Order backlogs remain high
0
500
1000
1500
2000
2500
3000
3500
1990 1993 1996 1999 2002 2005 2008 2011 2014
Deliveries
Orders
Number of aircraftAirbus amp Boeing Orders amp deliveries
Source Company reports and forecasts
43
Weaker demand for metalshellip
44
hellipand over capacity are weighing on priceshellip
45
hellipand discouraging investment
BHP Capital spending fell 32 in FY14 with another 8 fall expected next year
Rio Tinto Capital spending in FY14 cut faster than initially projected and further cut is budgeted for 2015
This is weighing on equipment makers
Caterpillar reported sales down 9 in the three months to July with sales to mining firms down 33 from the same period a year earlier
Bumper crop has brought down grain prices
47
helliphitting margins and investment
Producers are facing higher costs due to the implementation of Tier 4 engines developed to comply with emissions standards
Weaker margins are leading to farmers cutting back investment spending
John Deere has posted a 5 yy decline in revenues with an 11 decline in its agricultural division
Conclusions amp market implications
Conclusion and business implications
54
bull US economy expected to gradually accelerate through 2014 with support from a dovish Fed
bull Europe expected to recover but more ECB action could be required
bull Chinese economy is gradually rebalancing but banking crisis cannot be discounted
bull Emerging markets quiet for now but structural issue unsolved
bull Geopolitical tensions in the Middle East and Ukraine are being monitored carefully
Thank you
Gregory Daco
Chief US Economist gregorydacooxfordeconomicscom
September 2014
September 10 2014 2014 General Managersrsquo Meeting
Digital Manufacturing
World Class Shop Floor Management Release 5 The Smart Factory Revolution Mr Franz E Gruber Founder amp CEO
Dr Mohamed Abuali COO FORCAM Inc
MTConnect Evolution of a Standard and
Next Generation Interoperability Mr Courtney J Hill Chairman amp President
MTConnect Institute
QampA Session
World Class
Shop Floor Management
The Smart Factory Revolution
Franz E Gruber
Founder amp CEO
Mohamed Abuali
COO
汉语
World Class Shop Floor Management
FORCAM 2014 Page 2
FORCAMlsquos Passion
FORCAM provides proven
manufacturing solutions to
Continuously Improve Productivity
To be the global solutions provider of
the best-in-class Manufacturing
Execution Systems
FORCAM 2014 Page 3
FORCAM ndash 2014 Best Practices Award by Frost amp Sullivan
Frost amp Sullivan
ldquoFORCAM is a plant production software
solution provider that understands and
supports Industry 40 needsrdquo
FORCAM 2014 Page 4
FORCAMrsquos Testimonials and Industry Leadership
FORCAM 2014 Page 5
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
6 B Bartke S Wagner IPI-2
Shop Floor Management Audi - FORCAM FIT 2011-
Bernhard Bartke - Director Components Manufacturing
Stefan Wagner - Director Gear Manufacturing
7 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
bull Collection and recording of Operational Data via a database
(ex Machine States and State Changes)
Machine
Operator
Production Manager
Technical Assistant IT
Plant
Manager
Team Leader
8 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Interfaces
Time
Objectivity of Process Data
9 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Need for Continuous Improvement
bull Objective Information and Communication ndash across ALL levels
bull Transperancy and Visualization - Online
bull Real-time availability of operational data ndash Live Reports
bull Measurable increase in Plant Efficiency (OEE)
10 B Bartke S Wagner IPI-2
Shop Floor Management ndash Realtime bdquoANDONldquo Visualization
bull Web-based Interface Anywhere Anytime Access
bull Real-time Production Status Visualization
In Production
Overflow
Stoppage
Organizational
Stoppage
Idle (Pause)
Tool
Problem
11 B Bartke S Wagner IPI-2
Shop Floor Management Reporting ndash Hierarchical Status Diagrams
bull Reporting for Machines Groups Lines or the whole Plant
Technical
Stoppage In Production
Organizational
Stoppage Pause Overflow
Stoppage
Tool Problem In Setup
12 B Bartke S Wagner IPI-2
Audi Production System (APS)
Leadership Communication
bull Process Control
Standards
bull In Processes
bull Im Products
bull In the Organization
Learning Organization
bull Employee Development
bull Problem-Solving
bull CIP Culture
13 B Bartke S Wagner IPI-2
Shop Floor Management Process Control Panel on the shop floor
OEE Trend
(Day Week Month)
Measures
Quality
Process Control
14 B Bartke S Wagner IPI-2
OEE - Yesterday
Availability Trend
OEE ndash Last Week
OEE ndash Last Month
Naoki Nojiri IPI-25 BDE-Ist Stand 05042011
Shop Floor Management Process Control Panel on the shop floor
15 B Bartke S Wagner IPI-2
Shop Floor Management Management Cockpit
Planned vs Actual
(shift)
Top problems
(challenges)
OEE ndash Last Week
16 B Bartke S Wagner IPI-2
hellipand what have we achieved
17 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development suspension components (OEE Overall Equipment Effectiveness)
Radtraumlger
Start Shop Floor Management with
FORCAM +10
_
18 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development (20+ Increase in OEE in AUDI Stamping Facilities) (OEE Overall Equipment Effectiveness)
Radtraumlger
Start SFM +20
_
Our Beliefs
Respect
Collaboration
Excellence
Integrity
Community
Oct 30th 2013
Lean with Shop Floor Management BorgWarner Turbo Systems Rzeszow
Operator FactoryFrameworktrade Worker Client- Book On
Operator Downtime Reasons
Operator Actual versus Target Performance
TargetPlanned
Throughput
Actual
Performance
Opportunity for
Improvement
Actual
Throughput Machine
Data
ERP
Data
Supervisor Gantt Status
visualzation
Top 5
downtimes
Cip Top 5
Production
orders
Real data
history
Supervisor Cockpit machine
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
Consumption tax weighs heavily on growth
17
2013 2014
-40
-30
-20
-10
00
10
20
30
Q3 Q4 Q1 Q2
Private consumptionFixed investmentNet exportsGovernment consumptionStockbuildingGDP
Japan Quarterly GDP contributions
quarterly contribution
Source Cabinet Office of Japan Haver Analytics
-3
-2
-1
0
1
2
3
4
1990 1995 2000 2005 2010 2015
Japan Fiscal policyChange in structural budget balance of GDP
Source International Monetary Fund Haver Analytics
ForecastExpansion
Contraction
Emergers Modest growth with structural issues
19
Does it still make sense to talk about ldquoBRICSrdquo
Some countries more vulnerable than others
20
1 Turkey 1182 S Africa 763 Brazil 404 Thailand 295 Russia 266 Malaysia 187 India 018 Poland 019 Mexico -2010 Indonesia -2511 Korea -8012 Philippines -9113 China -93
Oxford Economics Risk Scorecard
Emerging markets will still outpace developed world
21
US Outlook The US is the cleanest shirt in the laundry basket
GDP on a roller-coaster but employment is better indicator
19
Business surveys pointing to strong growthhellip
24
Consumers are feeling more cheerfulhellip
25
Wages expected to risehellip
26
Key domestic risk is housing activityhellip
27
hellipbut rising income and pent-up demand will help
24
Energy prices remain relatively stable
29
Fed to taper on but hold off on rate hikes
30
This image cannot currently be displayed
First rate hike in 2015Q2
Manufacturing in focus
Manufacturing activity is boominghellip
Further indication that GDP decline is due to unique factors
28
hellipwith encouraging signs from leading indicators
29
US manufacturing has outperformed its peershellip
30
US has made substantial gains in competitiveness
35
Remarkable improvements
Due to productivity gains amp modest wage growthhellip
36
Remarkable improvements
Business sentiment in Europe remains weak while new orders have slowed
37
China amp Brazil have lost their edgehellip
38
Chinese wages have more than doubled over the past decade
Key industries
Loose credit and rising demand for autoshellip
36
hellipshould support productionhellip
20
25
30
35
40
45
50
405060708090
100110120130140150160
Jul-09 Jul-10 Jul-11 Jul-12 Jul-13 Jul-14
2010=100 US$ bn
Output (LHS)
Orders (RHS)
Source Oxford Economics Haver Analytics
US Output and orders
3 month moving average
37
hellipas will opportunities in the Emergers
38
Revamp of car stock to be key long-term driver
Ageing vehicle fleet replacement as economy recovers ndash average age of vehicle on US roads in 11frac12 years
Rising fuel efficiency standards leading to replacement of clunkers
Rising fuels costs resulting in smaller cars
Automakers likely to increase new models helping drive investment
Aerospace solid order books at the big twohellip
0
250
500
750
1000
1250
1500
1750
1994 1996 1998 2000 2002 2004 2006 2008 2010 2012 2014
Source Company reports
Airbus versus Boeing Orders
Airbus
Boeing
Number of aircraft
Note 2014 annual estimate based on annualized data through July
40
hellipwith APAC to drive long-term growth
Asia will account for almost 32 of global passenger traffic by 2017 compared to 28 in 2012
APAC to account for 40 of plane deliveries over next 20 years
US and Europe sales mainly for replacement of existing fleet
41
Need for efficiency will provide demand supporthellip
A330 revamped for 15 efficiency improvement to compete with Dreamliner 25 new orders on day of announcement
Long-haul efficiency has some ways to go to maintain airline profitability
42
Order backlogs remain high
0
500
1000
1500
2000
2500
3000
3500
1990 1993 1996 1999 2002 2005 2008 2011 2014
Deliveries
Orders
Number of aircraftAirbus amp Boeing Orders amp deliveries
Source Company reports and forecasts
43
Weaker demand for metalshellip
44
hellipand over capacity are weighing on priceshellip
45
hellipand discouraging investment
BHP Capital spending fell 32 in FY14 with another 8 fall expected next year
Rio Tinto Capital spending in FY14 cut faster than initially projected and further cut is budgeted for 2015
This is weighing on equipment makers
Caterpillar reported sales down 9 in the three months to July with sales to mining firms down 33 from the same period a year earlier
Bumper crop has brought down grain prices
47
helliphitting margins and investment
Producers are facing higher costs due to the implementation of Tier 4 engines developed to comply with emissions standards
Weaker margins are leading to farmers cutting back investment spending
John Deere has posted a 5 yy decline in revenues with an 11 decline in its agricultural division
Conclusions amp market implications
Conclusion and business implications
54
bull US economy expected to gradually accelerate through 2014 with support from a dovish Fed
bull Europe expected to recover but more ECB action could be required
bull Chinese economy is gradually rebalancing but banking crisis cannot be discounted
bull Emerging markets quiet for now but structural issue unsolved
bull Geopolitical tensions in the Middle East and Ukraine are being monitored carefully
Thank you
Gregory Daco
Chief US Economist gregorydacooxfordeconomicscom
September 2014
September 10 2014 2014 General Managersrsquo Meeting
Digital Manufacturing
World Class Shop Floor Management Release 5 The Smart Factory Revolution Mr Franz E Gruber Founder amp CEO
Dr Mohamed Abuali COO FORCAM Inc
MTConnect Evolution of a Standard and
Next Generation Interoperability Mr Courtney J Hill Chairman amp President
MTConnect Institute
QampA Session
World Class
Shop Floor Management
The Smart Factory Revolution
Franz E Gruber
Founder amp CEO
Mohamed Abuali
COO
汉语
World Class Shop Floor Management
FORCAM 2014 Page 2
FORCAMlsquos Passion
FORCAM provides proven
manufacturing solutions to
Continuously Improve Productivity
To be the global solutions provider of
the best-in-class Manufacturing
Execution Systems
FORCAM 2014 Page 3
FORCAM ndash 2014 Best Practices Award by Frost amp Sullivan
Frost amp Sullivan
ldquoFORCAM is a plant production software
solution provider that understands and
supports Industry 40 needsrdquo
FORCAM 2014 Page 4
FORCAMrsquos Testimonials and Industry Leadership
FORCAM 2014 Page 5
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
6 B Bartke S Wagner IPI-2
Shop Floor Management Audi - FORCAM FIT 2011-
Bernhard Bartke - Director Components Manufacturing
Stefan Wagner - Director Gear Manufacturing
7 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
bull Collection and recording of Operational Data via a database
(ex Machine States and State Changes)
Machine
Operator
Production Manager
Technical Assistant IT
Plant
Manager
Team Leader
8 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Interfaces
Time
Objectivity of Process Data
9 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Need for Continuous Improvement
bull Objective Information and Communication ndash across ALL levels
bull Transperancy and Visualization - Online
bull Real-time availability of operational data ndash Live Reports
bull Measurable increase in Plant Efficiency (OEE)
10 B Bartke S Wagner IPI-2
Shop Floor Management ndash Realtime bdquoANDONldquo Visualization
bull Web-based Interface Anywhere Anytime Access
bull Real-time Production Status Visualization
In Production
Overflow
Stoppage
Organizational
Stoppage
Idle (Pause)
Tool
Problem
11 B Bartke S Wagner IPI-2
Shop Floor Management Reporting ndash Hierarchical Status Diagrams
bull Reporting for Machines Groups Lines or the whole Plant
Technical
Stoppage In Production
Organizational
Stoppage Pause Overflow
Stoppage
Tool Problem In Setup
12 B Bartke S Wagner IPI-2
Audi Production System (APS)
Leadership Communication
bull Process Control
Standards
bull In Processes
bull Im Products
bull In the Organization
Learning Organization
bull Employee Development
bull Problem-Solving
bull CIP Culture
13 B Bartke S Wagner IPI-2
Shop Floor Management Process Control Panel on the shop floor
OEE Trend
(Day Week Month)
Measures
Quality
Process Control
14 B Bartke S Wagner IPI-2
OEE - Yesterday
Availability Trend
OEE ndash Last Week
OEE ndash Last Month
Naoki Nojiri IPI-25 BDE-Ist Stand 05042011
Shop Floor Management Process Control Panel on the shop floor
15 B Bartke S Wagner IPI-2
Shop Floor Management Management Cockpit
Planned vs Actual
(shift)
Top problems
(challenges)
OEE ndash Last Week
16 B Bartke S Wagner IPI-2
hellipand what have we achieved
17 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development suspension components (OEE Overall Equipment Effectiveness)
Radtraumlger
Start Shop Floor Management with
FORCAM +10
_
18 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development (20+ Increase in OEE in AUDI Stamping Facilities) (OEE Overall Equipment Effectiveness)
Radtraumlger
Start SFM +20
_
Our Beliefs
Respect
Collaboration
Excellence
Integrity
Community
Oct 30th 2013
Lean with Shop Floor Management BorgWarner Turbo Systems Rzeszow
Operator FactoryFrameworktrade Worker Client- Book On
Operator Downtime Reasons
Operator Actual versus Target Performance
TargetPlanned
Throughput
Actual
Performance
Opportunity for
Improvement
Actual
Throughput Machine
Data
ERP
Data
Supervisor Gantt Status
visualzation
Top 5
downtimes
Cip Top 5
Production
orders
Real data
history
Supervisor Cockpit machine
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
Emergers Modest growth with structural issues
19
Does it still make sense to talk about ldquoBRICSrdquo
Some countries more vulnerable than others
20
1 Turkey 1182 S Africa 763 Brazil 404 Thailand 295 Russia 266 Malaysia 187 India 018 Poland 019 Mexico -2010 Indonesia -2511 Korea -8012 Philippines -9113 China -93
Oxford Economics Risk Scorecard
Emerging markets will still outpace developed world
21
US Outlook The US is the cleanest shirt in the laundry basket
GDP on a roller-coaster but employment is better indicator
19
Business surveys pointing to strong growthhellip
24
Consumers are feeling more cheerfulhellip
25
Wages expected to risehellip
26
Key domestic risk is housing activityhellip
27
hellipbut rising income and pent-up demand will help
24
Energy prices remain relatively stable
29
Fed to taper on but hold off on rate hikes
30
This image cannot currently be displayed
First rate hike in 2015Q2
Manufacturing in focus
Manufacturing activity is boominghellip
Further indication that GDP decline is due to unique factors
28
hellipwith encouraging signs from leading indicators
29
US manufacturing has outperformed its peershellip
30
US has made substantial gains in competitiveness
35
Remarkable improvements
Due to productivity gains amp modest wage growthhellip
36
Remarkable improvements
Business sentiment in Europe remains weak while new orders have slowed
37
China amp Brazil have lost their edgehellip
38
Chinese wages have more than doubled over the past decade
Key industries
Loose credit and rising demand for autoshellip
36
hellipshould support productionhellip
20
25
30
35
40
45
50
405060708090
100110120130140150160
Jul-09 Jul-10 Jul-11 Jul-12 Jul-13 Jul-14
2010=100 US$ bn
Output (LHS)
Orders (RHS)
Source Oxford Economics Haver Analytics
US Output and orders
3 month moving average
37
hellipas will opportunities in the Emergers
38
Revamp of car stock to be key long-term driver
Ageing vehicle fleet replacement as economy recovers ndash average age of vehicle on US roads in 11frac12 years
Rising fuel efficiency standards leading to replacement of clunkers
Rising fuels costs resulting in smaller cars
Automakers likely to increase new models helping drive investment
Aerospace solid order books at the big twohellip
0
250
500
750
1000
1250
1500
1750
1994 1996 1998 2000 2002 2004 2006 2008 2010 2012 2014
Source Company reports
Airbus versus Boeing Orders
Airbus
Boeing
Number of aircraft
Note 2014 annual estimate based on annualized data through July
40
hellipwith APAC to drive long-term growth
Asia will account for almost 32 of global passenger traffic by 2017 compared to 28 in 2012
APAC to account for 40 of plane deliveries over next 20 years
US and Europe sales mainly for replacement of existing fleet
41
Need for efficiency will provide demand supporthellip
A330 revamped for 15 efficiency improvement to compete with Dreamliner 25 new orders on day of announcement
Long-haul efficiency has some ways to go to maintain airline profitability
42
Order backlogs remain high
0
500
1000
1500
2000
2500
3000
3500
1990 1993 1996 1999 2002 2005 2008 2011 2014
Deliveries
Orders
Number of aircraftAirbus amp Boeing Orders amp deliveries
Source Company reports and forecasts
43
Weaker demand for metalshellip
44
hellipand over capacity are weighing on priceshellip
45
hellipand discouraging investment
BHP Capital spending fell 32 in FY14 with another 8 fall expected next year
Rio Tinto Capital spending in FY14 cut faster than initially projected and further cut is budgeted for 2015
This is weighing on equipment makers
Caterpillar reported sales down 9 in the three months to July with sales to mining firms down 33 from the same period a year earlier
Bumper crop has brought down grain prices
47
helliphitting margins and investment
Producers are facing higher costs due to the implementation of Tier 4 engines developed to comply with emissions standards
Weaker margins are leading to farmers cutting back investment spending
John Deere has posted a 5 yy decline in revenues with an 11 decline in its agricultural division
Conclusions amp market implications
Conclusion and business implications
54
bull US economy expected to gradually accelerate through 2014 with support from a dovish Fed
bull Europe expected to recover but more ECB action could be required
bull Chinese economy is gradually rebalancing but banking crisis cannot be discounted
bull Emerging markets quiet for now but structural issue unsolved
bull Geopolitical tensions in the Middle East and Ukraine are being monitored carefully
Thank you
Gregory Daco
Chief US Economist gregorydacooxfordeconomicscom
September 2014
September 10 2014 2014 General Managersrsquo Meeting
Digital Manufacturing
World Class Shop Floor Management Release 5 The Smart Factory Revolution Mr Franz E Gruber Founder amp CEO
Dr Mohamed Abuali COO FORCAM Inc
MTConnect Evolution of a Standard and
Next Generation Interoperability Mr Courtney J Hill Chairman amp President
MTConnect Institute
QampA Session
World Class
Shop Floor Management
The Smart Factory Revolution
Franz E Gruber
Founder amp CEO
Mohamed Abuali
COO
汉语
World Class Shop Floor Management
FORCAM 2014 Page 2
FORCAMlsquos Passion
FORCAM provides proven
manufacturing solutions to
Continuously Improve Productivity
To be the global solutions provider of
the best-in-class Manufacturing
Execution Systems
FORCAM 2014 Page 3
FORCAM ndash 2014 Best Practices Award by Frost amp Sullivan
Frost amp Sullivan
ldquoFORCAM is a plant production software
solution provider that understands and
supports Industry 40 needsrdquo
FORCAM 2014 Page 4
FORCAMrsquos Testimonials and Industry Leadership
FORCAM 2014 Page 5
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
6 B Bartke S Wagner IPI-2
Shop Floor Management Audi - FORCAM FIT 2011-
Bernhard Bartke - Director Components Manufacturing
Stefan Wagner - Director Gear Manufacturing
7 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
bull Collection and recording of Operational Data via a database
(ex Machine States and State Changes)
Machine
Operator
Production Manager
Technical Assistant IT
Plant
Manager
Team Leader
8 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Interfaces
Time
Objectivity of Process Data
9 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Need for Continuous Improvement
bull Objective Information and Communication ndash across ALL levels
bull Transperancy and Visualization - Online
bull Real-time availability of operational data ndash Live Reports
bull Measurable increase in Plant Efficiency (OEE)
10 B Bartke S Wagner IPI-2
Shop Floor Management ndash Realtime bdquoANDONldquo Visualization
bull Web-based Interface Anywhere Anytime Access
bull Real-time Production Status Visualization
In Production
Overflow
Stoppage
Organizational
Stoppage
Idle (Pause)
Tool
Problem
11 B Bartke S Wagner IPI-2
Shop Floor Management Reporting ndash Hierarchical Status Diagrams
bull Reporting for Machines Groups Lines or the whole Plant
Technical
Stoppage In Production
Organizational
Stoppage Pause Overflow
Stoppage
Tool Problem In Setup
12 B Bartke S Wagner IPI-2
Audi Production System (APS)
Leadership Communication
bull Process Control
Standards
bull In Processes
bull Im Products
bull In the Organization
Learning Organization
bull Employee Development
bull Problem-Solving
bull CIP Culture
13 B Bartke S Wagner IPI-2
Shop Floor Management Process Control Panel on the shop floor
OEE Trend
(Day Week Month)
Measures
Quality
Process Control
14 B Bartke S Wagner IPI-2
OEE - Yesterday
Availability Trend
OEE ndash Last Week
OEE ndash Last Month
Naoki Nojiri IPI-25 BDE-Ist Stand 05042011
Shop Floor Management Process Control Panel on the shop floor
15 B Bartke S Wagner IPI-2
Shop Floor Management Management Cockpit
Planned vs Actual
(shift)
Top problems
(challenges)
OEE ndash Last Week
16 B Bartke S Wagner IPI-2
hellipand what have we achieved
17 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development suspension components (OEE Overall Equipment Effectiveness)
Radtraumlger
Start Shop Floor Management with
FORCAM +10
_
18 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development (20+ Increase in OEE in AUDI Stamping Facilities) (OEE Overall Equipment Effectiveness)
Radtraumlger
Start SFM +20
_
Our Beliefs
Respect
Collaboration
Excellence
Integrity
Community
Oct 30th 2013
Lean with Shop Floor Management BorgWarner Turbo Systems Rzeszow
Operator FactoryFrameworktrade Worker Client- Book On
Operator Downtime Reasons
Operator Actual versus Target Performance
TargetPlanned
Throughput
Actual
Performance
Opportunity for
Improvement
Actual
Throughput Machine
Data
ERP
Data
Supervisor Gantt Status
visualzation
Top 5
downtimes
Cip Top 5
Production
orders
Real data
history
Supervisor Cockpit machine
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
19
Does it still make sense to talk about ldquoBRICSrdquo
Some countries more vulnerable than others
20
1 Turkey 1182 S Africa 763 Brazil 404 Thailand 295 Russia 266 Malaysia 187 India 018 Poland 019 Mexico -2010 Indonesia -2511 Korea -8012 Philippines -9113 China -93
Oxford Economics Risk Scorecard
Emerging markets will still outpace developed world
21
US Outlook The US is the cleanest shirt in the laundry basket
GDP on a roller-coaster but employment is better indicator
19
Business surveys pointing to strong growthhellip
24
Consumers are feeling more cheerfulhellip
25
Wages expected to risehellip
26
Key domestic risk is housing activityhellip
27
hellipbut rising income and pent-up demand will help
24
Energy prices remain relatively stable
29
Fed to taper on but hold off on rate hikes
30
This image cannot currently be displayed
First rate hike in 2015Q2
Manufacturing in focus
Manufacturing activity is boominghellip
Further indication that GDP decline is due to unique factors
28
hellipwith encouraging signs from leading indicators
29
US manufacturing has outperformed its peershellip
30
US has made substantial gains in competitiveness
35
Remarkable improvements
Due to productivity gains amp modest wage growthhellip
36
Remarkable improvements
Business sentiment in Europe remains weak while new orders have slowed
37
China amp Brazil have lost their edgehellip
38
Chinese wages have more than doubled over the past decade
Key industries
Loose credit and rising demand for autoshellip
36
hellipshould support productionhellip
20
25
30
35
40
45
50
405060708090
100110120130140150160
Jul-09 Jul-10 Jul-11 Jul-12 Jul-13 Jul-14
2010=100 US$ bn
Output (LHS)
Orders (RHS)
Source Oxford Economics Haver Analytics
US Output and orders
3 month moving average
37
hellipas will opportunities in the Emergers
38
Revamp of car stock to be key long-term driver
Ageing vehicle fleet replacement as economy recovers ndash average age of vehicle on US roads in 11frac12 years
Rising fuel efficiency standards leading to replacement of clunkers
Rising fuels costs resulting in smaller cars
Automakers likely to increase new models helping drive investment
Aerospace solid order books at the big twohellip
0
250
500
750
1000
1250
1500
1750
1994 1996 1998 2000 2002 2004 2006 2008 2010 2012 2014
Source Company reports
Airbus versus Boeing Orders
Airbus
Boeing
Number of aircraft
Note 2014 annual estimate based on annualized data through July
40
hellipwith APAC to drive long-term growth
Asia will account for almost 32 of global passenger traffic by 2017 compared to 28 in 2012
APAC to account for 40 of plane deliveries over next 20 years
US and Europe sales mainly for replacement of existing fleet
41
Need for efficiency will provide demand supporthellip
A330 revamped for 15 efficiency improvement to compete with Dreamliner 25 new orders on day of announcement
Long-haul efficiency has some ways to go to maintain airline profitability
42
Order backlogs remain high
0
500
1000
1500
2000
2500
3000
3500
1990 1993 1996 1999 2002 2005 2008 2011 2014
Deliveries
Orders
Number of aircraftAirbus amp Boeing Orders amp deliveries
Source Company reports and forecasts
43
Weaker demand for metalshellip
44
hellipand over capacity are weighing on priceshellip
45
hellipand discouraging investment
BHP Capital spending fell 32 in FY14 with another 8 fall expected next year
Rio Tinto Capital spending in FY14 cut faster than initially projected and further cut is budgeted for 2015
This is weighing on equipment makers
Caterpillar reported sales down 9 in the three months to July with sales to mining firms down 33 from the same period a year earlier
Bumper crop has brought down grain prices
47
helliphitting margins and investment
Producers are facing higher costs due to the implementation of Tier 4 engines developed to comply with emissions standards
Weaker margins are leading to farmers cutting back investment spending
John Deere has posted a 5 yy decline in revenues with an 11 decline in its agricultural division
Conclusions amp market implications
Conclusion and business implications
54
bull US economy expected to gradually accelerate through 2014 with support from a dovish Fed
bull Europe expected to recover but more ECB action could be required
bull Chinese economy is gradually rebalancing but banking crisis cannot be discounted
bull Emerging markets quiet for now but structural issue unsolved
bull Geopolitical tensions in the Middle East and Ukraine are being monitored carefully
Thank you
Gregory Daco
Chief US Economist gregorydacooxfordeconomicscom
September 2014
September 10 2014 2014 General Managersrsquo Meeting
Digital Manufacturing
World Class Shop Floor Management Release 5 The Smart Factory Revolution Mr Franz E Gruber Founder amp CEO
Dr Mohamed Abuali COO FORCAM Inc
MTConnect Evolution of a Standard and
Next Generation Interoperability Mr Courtney J Hill Chairman amp President
MTConnect Institute
QampA Session
World Class
Shop Floor Management
The Smart Factory Revolution
Franz E Gruber
Founder amp CEO
Mohamed Abuali
COO
汉语
World Class Shop Floor Management
FORCAM 2014 Page 2
FORCAMlsquos Passion
FORCAM provides proven
manufacturing solutions to
Continuously Improve Productivity
To be the global solutions provider of
the best-in-class Manufacturing
Execution Systems
FORCAM 2014 Page 3
FORCAM ndash 2014 Best Practices Award by Frost amp Sullivan
Frost amp Sullivan
ldquoFORCAM is a plant production software
solution provider that understands and
supports Industry 40 needsrdquo
FORCAM 2014 Page 4
FORCAMrsquos Testimonials and Industry Leadership
FORCAM 2014 Page 5
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
6 B Bartke S Wagner IPI-2
Shop Floor Management Audi - FORCAM FIT 2011-
Bernhard Bartke - Director Components Manufacturing
Stefan Wagner - Director Gear Manufacturing
7 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
bull Collection and recording of Operational Data via a database
(ex Machine States and State Changes)
Machine
Operator
Production Manager
Technical Assistant IT
Plant
Manager
Team Leader
8 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Interfaces
Time
Objectivity of Process Data
9 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Need for Continuous Improvement
bull Objective Information and Communication ndash across ALL levels
bull Transperancy and Visualization - Online
bull Real-time availability of operational data ndash Live Reports
bull Measurable increase in Plant Efficiency (OEE)
10 B Bartke S Wagner IPI-2
Shop Floor Management ndash Realtime bdquoANDONldquo Visualization
bull Web-based Interface Anywhere Anytime Access
bull Real-time Production Status Visualization
In Production
Overflow
Stoppage
Organizational
Stoppage
Idle (Pause)
Tool
Problem
11 B Bartke S Wagner IPI-2
Shop Floor Management Reporting ndash Hierarchical Status Diagrams
bull Reporting for Machines Groups Lines or the whole Plant
Technical
Stoppage In Production
Organizational
Stoppage Pause Overflow
Stoppage
Tool Problem In Setup
12 B Bartke S Wagner IPI-2
Audi Production System (APS)
Leadership Communication
bull Process Control
Standards
bull In Processes
bull Im Products
bull In the Organization
Learning Organization
bull Employee Development
bull Problem-Solving
bull CIP Culture
13 B Bartke S Wagner IPI-2
Shop Floor Management Process Control Panel on the shop floor
OEE Trend
(Day Week Month)
Measures
Quality
Process Control
14 B Bartke S Wagner IPI-2
OEE - Yesterday
Availability Trend
OEE ndash Last Week
OEE ndash Last Month
Naoki Nojiri IPI-25 BDE-Ist Stand 05042011
Shop Floor Management Process Control Panel on the shop floor
15 B Bartke S Wagner IPI-2
Shop Floor Management Management Cockpit
Planned vs Actual
(shift)
Top problems
(challenges)
OEE ndash Last Week
16 B Bartke S Wagner IPI-2
hellipand what have we achieved
17 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development suspension components (OEE Overall Equipment Effectiveness)
Radtraumlger
Start Shop Floor Management with
FORCAM +10
_
18 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development (20+ Increase in OEE in AUDI Stamping Facilities) (OEE Overall Equipment Effectiveness)
Radtraumlger
Start SFM +20
_
Our Beliefs
Respect
Collaboration
Excellence
Integrity
Community
Oct 30th 2013
Lean with Shop Floor Management BorgWarner Turbo Systems Rzeszow
Operator FactoryFrameworktrade Worker Client- Book On
Operator Downtime Reasons
Operator Actual versus Target Performance
TargetPlanned
Throughput
Actual
Performance
Opportunity for
Improvement
Actual
Throughput Machine
Data
ERP
Data
Supervisor Gantt Status
visualzation
Top 5
downtimes
Cip Top 5
Production
orders
Real data
history
Supervisor Cockpit machine
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
Some countries more vulnerable than others
20
1 Turkey 1182 S Africa 763 Brazil 404 Thailand 295 Russia 266 Malaysia 187 India 018 Poland 019 Mexico -2010 Indonesia -2511 Korea -8012 Philippines -9113 China -93
Oxford Economics Risk Scorecard
Emerging markets will still outpace developed world
21
US Outlook The US is the cleanest shirt in the laundry basket
GDP on a roller-coaster but employment is better indicator
19
Business surveys pointing to strong growthhellip
24
Consumers are feeling more cheerfulhellip
25
Wages expected to risehellip
26
Key domestic risk is housing activityhellip
27
hellipbut rising income and pent-up demand will help
24
Energy prices remain relatively stable
29
Fed to taper on but hold off on rate hikes
30
This image cannot currently be displayed
First rate hike in 2015Q2
Manufacturing in focus
Manufacturing activity is boominghellip
Further indication that GDP decline is due to unique factors
28
hellipwith encouraging signs from leading indicators
29
US manufacturing has outperformed its peershellip
30
US has made substantial gains in competitiveness
35
Remarkable improvements
Due to productivity gains amp modest wage growthhellip
36
Remarkable improvements
Business sentiment in Europe remains weak while new orders have slowed
37
China amp Brazil have lost their edgehellip
38
Chinese wages have more than doubled over the past decade
Key industries
Loose credit and rising demand for autoshellip
36
hellipshould support productionhellip
20
25
30
35
40
45
50
405060708090
100110120130140150160
Jul-09 Jul-10 Jul-11 Jul-12 Jul-13 Jul-14
2010=100 US$ bn
Output (LHS)
Orders (RHS)
Source Oxford Economics Haver Analytics
US Output and orders
3 month moving average
37
hellipas will opportunities in the Emergers
38
Revamp of car stock to be key long-term driver
Ageing vehicle fleet replacement as economy recovers ndash average age of vehicle on US roads in 11frac12 years
Rising fuel efficiency standards leading to replacement of clunkers
Rising fuels costs resulting in smaller cars
Automakers likely to increase new models helping drive investment
Aerospace solid order books at the big twohellip
0
250
500
750
1000
1250
1500
1750
1994 1996 1998 2000 2002 2004 2006 2008 2010 2012 2014
Source Company reports
Airbus versus Boeing Orders
Airbus
Boeing
Number of aircraft
Note 2014 annual estimate based on annualized data through July
40
hellipwith APAC to drive long-term growth
Asia will account for almost 32 of global passenger traffic by 2017 compared to 28 in 2012
APAC to account for 40 of plane deliveries over next 20 years
US and Europe sales mainly for replacement of existing fleet
41
Need for efficiency will provide demand supporthellip
A330 revamped for 15 efficiency improvement to compete with Dreamliner 25 new orders on day of announcement
Long-haul efficiency has some ways to go to maintain airline profitability
42
Order backlogs remain high
0
500
1000
1500
2000
2500
3000
3500
1990 1993 1996 1999 2002 2005 2008 2011 2014
Deliveries
Orders
Number of aircraftAirbus amp Boeing Orders amp deliveries
Source Company reports and forecasts
43
Weaker demand for metalshellip
44
hellipand over capacity are weighing on priceshellip
45
hellipand discouraging investment
BHP Capital spending fell 32 in FY14 with another 8 fall expected next year
Rio Tinto Capital spending in FY14 cut faster than initially projected and further cut is budgeted for 2015
This is weighing on equipment makers
Caterpillar reported sales down 9 in the three months to July with sales to mining firms down 33 from the same period a year earlier
Bumper crop has brought down grain prices
47
helliphitting margins and investment
Producers are facing higher costs due to the implementation of Tier 4 engines developed to comply with emissions standards
Weaker margins are leading to farmers cutting back investment spending
John Deere has posted a 5 yy decline in revenues with an 11 decline in its agricultural division
Conclusions amp market implications
Conclusion and business implications
54
bull US economy expected to gradually accelerate through 2014 with support from a dovish Fed
bull Europe expected to recover but more ECB action could be required
bull Chinese economy is gradually rebalancing but banking crisis cannot be discounted
bull Emerging markets quiet for now but structural issue unsolved
bull Geopolitical tensions in the Middle East and Ukraine are being monitored carefully
Thank you
Gregory Daco
Chief US Economist gregorydacooxfordeconomicscom
September 2014
September 10 2014 2014 General Managersrsquo Meeting
Digital Manufacturing
World Class Shop Floor Management Release 5 The Smart Factory Revolution Mr Franz E Gruber Founder amp CEO
Dr Mohamed Abuali COO FORCAM Inc
MTConnect Evolution of a Standard and
Next Generation Interoperability Mr Courtney J Hill Chairman amp President
MTConnect Institute
QampA Session
World Class
Shop Floor Management
The Smart Factory Revolution
Franz E Gruber
Founder amp CEO
Mohamed Abuali
COO
汉语
World Class Shop Floor Management
FORCAM 2014 Page 2
FORCAMlsquos Passion
FORCAM provides proven
manufacturing solutions to
Continuously Improve Productivity
To be the global solutions provider of
the best-in-class Manufacturing
Execution Systems
FORCAM 2014 Page 3
FORCAM ndash 2014 Best Practices Award by Frost amp Sullivan
Frost amp Sullivan
ldquoFORCAM is a plant production software
solution provider that understands and
supports Industry 40 needsrdquo
FORCAM 2014 Page 4
FORCAMrsquos Testimonials and Industry Leadership
FORCAM 2014 Page 5
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
6 B Bartke S Wagner IPI-2
Shop Floor Management Audi - FORCAM FIT 2011-
Bernhard Bartke - Director Components Manufacturing
Stefan Wagner - Director Gear Manufacturing
7 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
bull Collection and recording of Operational Data via a database
(ex Machine States and State Changes)
Machine
Operator
Production Manager
Technical Assistant IT
Plant
Manager
Team Leader
8 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Interfaces
Time
Objectivity of Process Data
9 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Need for Continuous Improvement
bull Objective Information and Communication ndash across ALL levels
bull Transperancy and Visualization - Online
bull Real-time availability of operational data ndash Live Reports
bull Measurable increase in Plant Efficiency (OEE)
10 B Bartke S Wagner IPI-2
Shop Floor Management ndash Realtime bdquoANDONldquo Visualization
bull Web-based Interface Anywhere Anytime Access
bull Real-time Production Status Visualization
In Production
Overflow
Stoppage
Organizational
Stoppage
Idle (Pause)
Tool
Problem
11 B Bartke S Wagner IPI-2
Shop Floor Management Reporting ndash Hierarchical Status Diagrams
bull Reporting for Machines Groups Lines or the whole Plant
Technical
Stoppage In Production
Organizational
Stoppage Pause Overflow
Stoppage
Tool Problem In Setup
12 B Bartke S Wagner IPI-2
Audi Production System (APS)
Leadership Communication
bull Process Control
Standards
bull In Processes
bull Im Products
bull In the Organization
Learning Organization
bull Employee Development
bull Problem-Solving
bull CIP Culture
13 B Bartke S Wagner IPI-2
Shop Floor Management Process Control Panel on the shop floor
OEE Trend
(Day Week Month)
Measures
Quality
Process Control
14 B Bartke S Wagner IPI-2
OEE - Yesterday
Availability Trend
OEE ndash Last Week
OEE ndash Last Month
Naoki Nojiri IPI-25 BDE-Ist Stand 05042011
Shop Floor Management Process Control Panel on the shop floor
15 B Bartke S Wagner IPI-2
Shop Floor Management Management Cockpit
Planned vs Actual
(shift)
Top problems
(challenges)
OEE ndash Last Week
16 B Bartke S Wagner IPI-2
hellipand what have we achieved
17 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development suspension components (OEE Overall Equipment Effectiveness)
Radtraumlger
Start Shop Floor Management with
FORCAM +10
_
18 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development (20+ Increase in OEE in AUDI Stamping Facilities) (OEE Overall Equipment Effectiveness)
Radtraumlger
Start SFM +20
_
Our Beliefs
Respect
Collaboration
Excellence
Integrity
Community
Oct 30th 2013
Lean with Shop Floor Management BorgWarner Turbo Systems Rzeszow
Operator FactoryFrameworktrade Worker Client- Book On
Operator Downtime Reasons
Operator Actual versus Target Performance
TargetPlanned
Throughput
Actual
Performance
Opportunity for
Improvement
Actual
Throughput Machine
Data
ERP
Data
Supervisor Gantt Status
visualzation
Top 5
downtimes
Cip Top 5
Production
orders
Real data
history
Supervisor Cockpit machine
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
Emerging markets will still outpace developed world
21
US Outlook The US is the cleanest shirt in the laundry basket
GDP on a roller-coaster but employment is better indicator
19
Business surveys pointing to strong growthhellip
24
Consumers are feeling more cheerfulhellip
25
Wages expected to risehellip
26
Key domestic risk is housing activityhellip
27
hellipbut rising income and pent-up demand will help
24
Energy prices remain relatively stable
29
Fed to taper on but hold off on rate hikes
30
This image cannot currently be displayed
First rate hike in 2015Q2
Manufacturing in focus
Manufacturing activity is boominghellip
Further indication that GDP decline is due to unique factors
28
hellipwith encouraging signs from leading indicators
29
US manufacturing has outperformed its peershellip
30
US has made substantial gains in competitiveness
35
Remarkable improvements
Due to productivity gains amp modest wage growthhellip
36
Remarkable improvements
Business sentiment in Europe remains weak while new orders have slowed
37
China amp Brazil have lost their edgehellip
38
Chinese wages have more than doubled over the past decade
Key industries
Loose credit and rising demand for autoshellip
36
hellipshould support productionhellip
20
25
30
35
40
45
50
405060708090
100110120130140150160
Jul-09 Jul-10 Jul-11 Jul-12 Jul-13 Jul-14
2010=100 US$ bn
Output (LHS)
Orders (RHS)
Source Oxford Economics Haver Analytics
US Output and orders
3 month moving average
37
hellipas will opportunities in the Emergers
38
Revamp of car stock to be key long-term driver
Ageing vehicle fleet replacement as economy recovers ndash average age of vehicle on US roads in 11frac12 years
Rising fuel efficiency standards leading to replacement of clunkers
Rising fuels costs resulting in smaller cars
Automakers likely to increase new models helping drive investment
Aerospace solid order books at the big twohellip
0
250
500
750
1000
1250
1500
1750
1994 1996 1998 2000 2002 2004 2006 2008 2010 2012 2014
Source Company reports
Airbus versus Boeing Orders
Airbus
Boeing
Number of aircraft
Note 2014 annual estimate based on annualized data through July
40
hellipwith APAC to drive long-term growth
Asia will account for almost 32 of global passenger traffic by 2017 compared to 28 in 2012
APAC to account for 40 of plane deliveries over next 20 years
US and Europe sales mainly for replacement of existing fleet
41
Need for efficiency will provide demand supporthellip
A330 revamped for 15 efficiency improvement to compete with Dreamliner 25 new orders on day of announcement
Long-haul efficiency has some ways to go to maintain airline profitability
42
Order backlogs remain high
0
500
1000
1500
2000
2500
3000
3500
1990 1993 1996 1999 2002 2005 2008 2011 2014
Deliveries
Orders
Number of aircraftAirbus amp Boeing Orders amp deliveries
Source Company reports and forecasts
43
Weaker demand for metalshellip
44
hellipand over capacity are weighing on priceshellip
45
hellipand discouraging investment
BHP Capital spending fell 32 in FY14 with another 8 fall expected next year
Rio Tinto Capital spending in FY14 cut faster than initially projected and further cut is budgeted for 2015
This is weighing on equipment makers
Caterpillar reported sales down 9 in the three months to July with sales to mining firms down 33 from the same period a year earlier
Bumper crop has brought down grain prices
47
helliphitting margins and investment
Producers are facing higher costs due to the implementation of Tier 4 engines developed to comply with emissions standards
Weaker margins are leading to farmers cutting back investment spending
John Deere has posted a 5 yy decline in revenues with an 11 decline in its agricultural division
Conclusions amp market implications
Conclusion and business implications
54
bull US economy expected to gradually accelerate through 2014 with support from a dovish Fed
bull Europe expected to recover but more ECB action could be required
bull Chinese economy is gradually rebalancing but banking crisis cannot be discounted
bull Emerging markets quiet for now but structural issue unsolved
bull Geopolitical tensions in the Middle East and Ukraine are being monitored carefully
Thank you
Gregory Daco
Chief US Economist gregorydacooxfordeconomicscom
September 2014
September 10 2014 2014 General Managersrsquo Meeting
Digital Manufacturing
World Class Shop Floor Management Release 5 The Smart Factory Revolution Mr Franz E Gruber Founder amp CEO
Dr Mohamed Abuali COO FORCAM Inc
MTConnect Evolution of a Standard and
Next Generation Interoperability Mr Courtney J Hill Chairman amp President
MTConnect Institute
QampA Session
World Class
Shop Floor Management
The Smart Factory Revolution
Franz E Gruber
Founder amp CEO
Mohamed Abuali
COO
汉语
World Class Shop Floor Management
FORCAM 2014 Page 2
FORCAMlsquos Passion
FORCAM provides proven
manufacturing solutions to
Continuously Improve Productivity
To be the global solutions provider of
the best-in-class Manufacturing
Execution Systems
FORCAM 2014 Page 3
FORCAM ndash 2014 Best Practices Award by Frost amp Sullivan
Frost amp Sullivan
ldquoFORCAM is a plant production software
solution provider that understands and
supports Industry 40 needsrdquo
FORCAM 2014 Page 4
FORCAMrsquos Testimonials and Industry Leadership
FORCAM 2014 Page 5
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
6 B Bartke S Wagner IPI-2
Shop Floor Management Audi - FORCAM FIT 2011-
Bernhard Bartke - Director Components Manufacturing
Stefan Wagner - Director Gear Manufacturing
7 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
bull Collection and recording of Operational Data via a database
(ex Machine States and State Changes)
Machine
Operator
Production Manager
Technical Assistant IT
Plant
Manager
Team Leader
8 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Interfaces
Time
Objectivity of Process Data
9 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Need for Continuous Improvement
bull Objective Information and Communication ndash across ALL levels
bull Transperancy and Visualization - Online
bull Real-time availability of operational data ndash Live Reports
bull Measurable increase in Plant Efficiency (OEE)
10 B Bartke S Wagner IPI-2
Shop Floor Management ndash Realtime bdquoANDONldquo Visualization
bull Web-based Interface Anywhere Anytime Access
bull Real-time Production Status Visualization
In Production
Overflow
Stoppage
Organizational
Stoppage
Idle (Pause)
Tool
Problem
11 B Bartke S Wagner IPI-2
Shop Floor Management Reporting ndash Hierarchical Status Diagrams
bull Reporting for Machines Groups Lines or the whole Plant
Technical
Stoppage In Production
Organizational
Stoppage Pause Overflow
Stoppage
Tool Problem In Setup
12 B Bartke S Wagner IPI-2
Audi Production System (APS)
Leadership Communication
bull Process Control
Standards
bull In Processes
bull Im Products
bull In the Organization
Learning Organization
bull Employee Development
bull Problem-Solving
bull CIP Culture
13 B Bartke S Wagner IPI-2
Shop Floor Management Process Control Panel on the shop floor
OEE Trend
(Day Week Month)
Measures
Quality
Process Control
14 B Bartke S Wagner IPI-2
OEE - Yesterday
Availability Trend
OEE ndash Last Week
OEE ndash Last Month
Naoki Nojiri IPI-25 BDE-Ist Stand 05042011
Shop Floor Management Process Control Panel on the shop floor
15 B Bartke S Wagner IPI-2
Shop Floor Management Management Cockpit
Planned vs Actual
(shift)
Top problems
(challenges)
OEE ndash Last Week
16 B Bartke S Wagner IPI-2
hellipand what have we achieved
17 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development suspension components (OEE Overall Equipment Effectiveness)
Radtraumlger
Start Shop Floor Management with
FORCAM +10
_
18 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development (20+ Increase in OEE in AUDI Stamping Facilities) (OEE Overall Equipment Effectiveness)
Radtraumlger
Start SFM +20
_
Our Beliefs
Respect
Collaboration
Excellence
Integrity
Community
Oct 30th 2013
Lean with Shop Floor Management BorgWarner Turbo Systems Rzeszow
Operator FactoryFrameworktrade Worker Client- Book On
Operator Downtime Reasons
Operator Actual versus Target Performance
TargetPlanned
Throughput
Actual
Performance
Opportunity for
Improvement
Actual
Throughput Machine
Data
ERP
Data
Supervisor Gantt Status
visualzation
Top 5
downtimes
Cip Top 5
Production
orders
Real data
history
Supervisor Cockpit machine
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
US Outlook The US is the cleanest shirt in the laundry basket
GDP on a roller-coaster but employment is better indicator
19
Business surveys pointing to strong growthhellip
24
Consumers are feeling more cheerfulhellip
25
Wages expected to risehellip
26
Key domestic risk is housing activityhellip
27
hellipbut rising income and pent-up demand will help
24
Energy prices remain relatively stable
29
Fed to taper on but hold off on rate hikes
30
This image cannot currently be displayed
First rate hike in 2015Q2
Manufacturing in focus
Manufacturing activity is boominghellip
Further indication that GDP decline is due to unique factors
28
hellipwith encouraging signs from leading indicators
29
US manufacturing has outperformed its peershellip
30
US has made substantial gains in competitiveness
35
Remarkable improvements
Due to productivity gains amp modest wage growthhellip
36
Remarkable improvements
Business sentiment in Europe remains weak while new orders have slowed
37
China amp Brazil have lost their edgehellip
38
Chinese wages have more than doubled over the past decade
Key industries
Loose credit and rising demand for autoshellip
36
hellipshould support productionhellip
20
25
30
35
40
45
50
405060708090
100110120130140150160
Jul-09 Jul-10 Jul-11 Jul-12 Jul-13 Jul-14
2010=100 US$ bn
Output (LHS)
Orders (RHS)
Source Oxford Economics Haver Analytics
US Output and orders
3 month moving average
37
hellipas will opportunities in the Emergers
38
Revamp of car stock to be key long-term driver
Ageing vehicle fleet replacement as economy recovers ndash average age of vehicle on US roads in 11frac12 years
Rising fuel efficiency standards leading to replacement of clunkers
Rising fuels costs resulting in smaller cars
Automakers likely to increase new models helping drive investment
Aerospace solid order books at the big twohellip
0
250
500
750
1000
1250
1500
1750
1994 1996 1998 2000 2002 2004 2006 2008 2010 2012 2014
Source Company reports
Airbus versus Boeing Orders
Airbus
Boeing
Number of aircraft
Note 2014 annual estimate based on annualized data through July
40
hellipwith APAC to drive long-term growth
Asia will account for almost 32 of global passenger traffic by 2017 compared to 28 in 2012
APAC to account for 40 of plane deliveries over next 20 years
US and Europe sales mainly for replacement of existing fleet
41
Need for efficiency will provide demand supporthellip
A330 revamped for 15 efficiency improvement to compete with Dreamliner 25 new orders on day of announcement
Long-haul efficiency has some ways to go to maintain airline profitability
42
Order backlogs remain high
0
500
1000
1500
2000
2500
3000
3500
1990 1993 1996 1999 2002 2005 2008 2011 2014
Deliveries
Orders
Number of aircraftAirbus amp Boeing Orders amp deliveries
Source Company reports and forecasts
43
Weaker demand for metalshellip
44
hellipand over capacity are weighing on priceshellip
45
hellipand discouraging investment
BHP Capital spending fell 32 in FY14 with another 8 fall expected next year
Rio Tinto Capital spending in FY14 cut faster than initially projected and further cut is budgeted for 2015
This is weighing on equipment makers
Caterpillar reported sales down 9 in the three months to July with sales to mining firms down 33 from the same period a year earlier
Bumper crop has brought down grain prices
47
helliphitting margins and investment
Producers are facing higher costs due to the implementation of Tier 4 engines developed to comply with emissions standards
Weaker margins are leading to farmers cutting back investment spending
John Deere has posted a 5 yy decline in revenues with an 11 decline in its agricultural division
Conclusions amp market implications
Conclusion and business implications
54
bull US economy expected to gradually accelerate through 2014 with support from a dovish Fed
bull Europe expected to recover but more ECB action could be required
bull Chinese economy is gradually rebalancing but banking crisis cannot be discounted
bull Emerging markets quiet for now but structural issue unsolved
bull Geopolitical tensions in the Middle East and Ukraine are being monitored carefully
Thank you
Gregory Daco
Chief US Economist gregorydacooxfordeconomicscom
September 2014
September 10 2014 2014 General Managersrsquo Meeting
Digital Manufacturing
World Class Shop Floor Management Release 5 The Smart Factory Revolution Mr Franz E Gruber Founder amp CEO
Dr Mohamed Abuali COO FORCAM Inc
MTConnect Evolution of a Standard and
Next Generation Interoperability Mr Courtney J Hill Chairman amp President
MTConnect Institute
QampA Session
World Class
Shop Floor Management
The Smart Factory Revolution
Franz E Gruber
Founder amp CEO
Mohamed Abuali
COO
汉语
World Class Shop Floor Management
FORCAM 2014 Page 2
FORCAMlsquos Passion
FORCAM provides proven
manufacturing solutions to
Continuously Improve Productivity
To be the global solutions provider of
the best-in-class Manufacturing
Execution Systems
FORCAM 2014 Page 3
FORCAM ndash 2014 Best Practices Award by Frost amp Sullivan
Frost amp Sullivan
ldquoFORCAM is a plant production software
solution provider that understands and
supports Industry 40 needsrdquo
FORCAM 2014 Page 4
FORCAMrsquos Testimonials and Industry Leadership
FORCAM 2014 Page 5
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
6 B Bartke S Wagner IPI-2
Shop Floor Management Audi - FORCAM FIT 2011-
Bernhard Bartke - Director Components Manufacturing
Stefan Wagner - Director Gear Manufacturing
7 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
bull Collection and recording of Operational Data via a database
(ex Machine States and State Changes)
Machine
Operator
Production Manager
Technical Assistant IT
Plant
Manager
Team Leader
8 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Interfaces
Time
Objectivity of Process Data
9 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Need for Continuous Improvement
bull Objective Information and Communication ndash across ALL levels
bull Transperancy and Visualization - Online
bull Real-time availability of operational data ndash Live Reports
bull Measurable increase in Plant Efficiency (OEE)
10 B Bartke S Wagner IPI-2
Shop Floor Management ndash Realtime bdquoANDONldquo Visualization
bull Web-based Interface Anywhere Anytime Access
bull Real-time Production Status Visualization
In Production
Overflow
Stoppage
Organizational
Stoppage
Idle (Pause)
Tool
Problem
11 B Bartke S Wagner IPI-2
Shop Floor Management Reporting ndash Hierarchical Status Diagrams
bull Reporting for Machines Groups Lines or the whole Plant
Technical
Stoppage In Production
Organizational
Stoppage Pause Overflow
Stoppage
Tool Problem In Setup
12 B Bartke S Wagner IPI-2
Audi Production System (APS)
Leadership Communication
bull Process Control
Standards
bull In Processes
bull Im Products
bull In the Organization
Learning Organization
bull Employee Development
bull Problem-Solving
bull CIP Culture
13 B Bartke S Wagner IPI-2
Shop Floor Management Process Control Panel on the shop floor
OEE Trend
(Day Week Month)
Measures
Quality
Process Control
14 B Bartke S Wagner IPI-2
OEE - Yesterday
Availability Trend
OEE ndash Last Week
OEE ndash Last Month
Naoki Nojiri IPI-25 BDE-Ist Stand 05042011
Shop Floor Management Process Control Panel on the shop floor
15 B Bartke S Wagner IPI-2
Shop Floor Management Management Cockpit
Planned vs Actual
(shift)
Top problems
(challenges)
OEE ndash Last Week
16 B Bartke S Wagner IPI-2
hellipand what have we achieved
17 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development suspension components (OEE Overall Equipment Effectiveness)
Radtraumlger
Start Shop Floor Management with
FORCAM +10
_
18 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development (20+ Increase in OEE in AUDI Stamping Facilities) (OEE Overall Equipment Effectiveness)
Radtraumlger
Start SFM +20
_
Our Beliefs
Respect
Collaboration
Excellence
Integrity
Community
Oct 30th 2013
Lean with Shop Floor Management BorgWarner Turbo Systems Rzeszow
Operator FactoryFrameworktrade Worker Client- Book On
Operator Downtime Reasons
Operator Actual versus Target Performance
TargetPlanned
Throughput
Actual
Performance
Opportunity for
Improvement
Actual
Throughput Machine
Data
ERP
Data
Supervisor Gantt Status
visualzation
Top 5
downtimes
Cip Top 5
Production
orders
Real data
history
Supervisor Cockpit machine
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
GDP on a roller-coaster but employment is better indicator
19
Business surveys pointing to strong growthhellip
24
Consumers are feeling more cheerfulhellip
25
Wages expected to risehellip
26
Key domestic risk is housing activityhellip
27
hellipbut rising income and pent-up demand will help
24
Energy prices remain relatively stable
29
Fed to taper on but hold off on rate hikes
30
This image cannot currently be displayed
First rate hike in 2015Q2
Manufacturing in focus
Manufacturing activity is boominghellip
Further indication that GDP decline is due to unique factors
28
hellipwith encouraging signs from leading indicators
29
US manufacturing has outperformed its peershellip
30
US has made substantial gains in competitiveness
35
Remarkable improvements
Due to productivity gains amp modest wage growthhellip
36
Remarkable improvements
Business sentiment in Europe remains weak while new orders have slowed
37
China amp Brazil have lost their edgehellip
38
Chinese wages have more than doubled over the past decade
Key industries
Loose credit and rising demand for autoshellip
36
hellipshould support productionhellip
20
25
30
35
40
45
50
405060708090
100110120130140150160
Jul-09 Jul-10 Jul-11 Jul-12 Jul-13 Jul-14
2010=100 US$ bn
Output (LHS)
Orders (RHS)
Source Oxford Economics Haver Analytics
US Output and orders
3 month moving average
37
hellipas will opportunities in the Emergers
38
Revamp of car stock to be key long-term driver
Ageing vehicle fleet replacement as economy recovers ndash average age of vehicle on US roads in 11frac12 years
Rising fuel efficiency standards leading to replacement of clunkers
Rising fuels costs resulting in smaller cars
Automakers likely to increase new models helping drive investment
Aerospace solid order books at the big twohellip
0
250
500
750
1000
1250
1500
1750
1994 1996 1998 2000 2002 2004 2006 2008 2010 2012 2014
Source Company reports
Airbus versus Boeing Orders
Airbus
Boeing
Number of aircraft
Note 2014 annual estimate based on annualized data through July
40
hellipwith APAC to drive long-term growth
Asia will account for almost 32 of global passenger traffic by 2017 compared to 28 in 2012
APAC to account for 40 of plane deliveries over next 20 years
US and Europe sales mainly for replacement of existing fleet
41
Need for efficiency will provide demand supporthellip
A330 revamped for 15 efficiency improvement to compete with Dreamliner 25 new orders on day of announcement
Long-haul efficiency has some ways to go to maintain airline profitability
42
Order backlogs remain high
0
500
1000
1500
2000
2500
3000
3500
1990 1993 1996 1999 2002 2005 2008 2011 2014
Deliveries
Orders
Number of aircraftAirbus amp Boeing Orders amp deliveries
Source Company reports and forecasts
43
Weaker demand for metalshellip
44
hellipand over capacity are weighing on priceshellip
45
hellipand discouraging investment
BHP Capital spending fell 32 in FY14 with another 8 fall expected next year
Rio Tinto Capital spending in FY14 cut faster than initially projected and further cut is budgeted for 2015
This is weighing on equipment makers
Caterpillar reported sales down 9 in the three months to July with sales to mining firms down 33 from the same period a year earlier
Bumper crop has brought down grain prices
47
helliphitting margins and investment
Producers are facing higher costs due to the implementation of Tier 4 engines developed to comply with emissions standards
Weaker margins are leading to farmers cutting back investment spending
John Deere has posted a 5 yy decline in revenues with an 11 decline in its agricultural division
Conclusions amp market implications
Conclusion and business implications
54
bull US economy expected to gradually accelerate through 2014 with support from a dovish Fed
bull Europe expected to recover but more ECB action could be required
bull Chinese economy is gradually rebalancing but banking crisis cannot be discounted
bull Emerging markets quiet for now but structural issue unsolved
bull Geopolitical tensions in the Middle East and Ukraine are being monitored carefully
Thank you
Gregory Daco
Chief US Economist gregorydacooxfordeconomicscom
September 2014
September 10 2014 2014 General Managersrsquo Meeting
Digital Manufacturing
World Class Shop Floor Management Release 5 The Smart Factory Revolution Mr Franz E Gruber Founder amp CEO
Dr Mohamed Abuali COO FORCAM Inc
MTConnect Evolution of a Standard and
Next Generation Interoperability Mr Courtney J Hill Chairman amp President
MTConnect Institute
QampA Session
World Class
Shop Floor Management
The Smart Factory Revolution
Franz E Gruber
Founder amp CEO
Mohamed Abuali
COO
汉语
World Class Shop Floor Management
FORCAM 2014 Page 2
FORCAMlsquos Passion
FORCAM provides proven
manufacturing solutions to
Continuously Improve Productivity
To be the global solutions provider of
the best-in-class Manufacturing
Execution Systems
FORCAM 2014 Page 3
FORCAM ndash 2014 Best Practices Award by Frost amp Sullivan
Frost amp Sullivan
ldquoFORCAM is a plant production software
solution provider that understands and
supports Industry 40 needsrdquo
FORCAM 2014 Page 4
FORCAMrsquos Testimonials and Industry Leadership
FORCAM 2014 Page 5
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
6 B Bartke S Wagner IPI-2
Shop Floor Management Audi - FORCAM FIT 2011-
Bernhard Bartke - Director Components Manufacturing
Stefan Wagner - Director Gear Manufacturing
7 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
bull Collection and recording of Operational Data via a database
(ex Machine States and State Changes)
Machine
Operator
Production Manager
Technical Assistant IT
Plant
Manager
Team Leader
8 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Interfaces
Time
Objectivity of Process Data
9 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Need for Continuous Improvement
bull Objective Information and Communication ndash across ALL levels
bull Transperancy and Visualization - Online
bull Real-time availability of operational data ndash Live Reports
bull Measurable increase in Plant Efficiency (OEE)
10 B Bartke S Wagner IPI-2
Shop Floor Management ndash Realtime bdquoANDONldquo Visualization
bull Web-based Interface Anywhere Anytime Access
bull Real-time Production Status Visualization
In Production
Overflow
Stoppage
Organizational
Stoppage
Idle (Pause)
Tool
Problem
11 B Bartke S Wagner IPI-2
Shop Floor Management Reporting ndash Hierarchical Status Diagrams
bull Reporting for Machines Groups Lines or the whole Plant
Technical
Stoppage In Production
Organizational
Stoppage Pause Overflow
Stoppage
Tool Problem In Setup
12 B Bartke S Wagner IPI-2
Audi Production System (APS)
Leadership Communication
bull Process Control
Standards
bull In Processes
bull Im Products
bull In the Organization
Learning Organization
bull Employee Development
bull Problem-Solving
bull CIP Culture
13 B Bartke S Wagner IPI-2
Shop Floor Management Process Control Panel on the shop floor
OEE Trend
(Day Week Month)
Measures
Quality
Process Control
14 B Bartke S Wagner IPI-2
OEE - Yesterday
Availability Trend
OEE ndash Last Week
OEE ndash Last Month
Naoki Nojiri IPI-25 BDE-Ist Stand 05042011
Shop Floor Management Process Control Panel on the shop floor
15 B Bartke S Wagner IPI-2
Shop Floor Management Management Cockpit
Planned vs Actual
(shift)
Top problems
(challenges)
OEE ndash Last Week
16 B Bartke S Wagner IPI-2
hellipand what have we achieved
17 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development suspension components (OEE Overall Equipment Effectiveness)
Radtraumlger
Start Shop Floor Management with
FORCAM +10
_
18 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development (20+ Increase in OEE in AUDI Stamping Facilities) (OEE Overall Equipment Effectiveness)
Radtraumlger
Start SFM +20
_
Our Beliefs
Respect
Collaboration
Excellence
Integrity
Community
Oct 30th 2013
Lean with Shop Floor Management BorgWarner Turbo Systems Rzeszow
Operator FactoryFrameworktrade Worker Client- Book On
Operator Downtime Reasons
Operator Actual versus Target Performance
TargetPlanned
Throughput
Actual
Performance
Opportunity for
Improvement
Actual
Throughput Machine
Data
ERP
Data
Supervisor Gantt Status
visualzation
Top 5
downtimes
Cip Top 5
Production
orders
Real data
history
Supervisor Cockpit machine
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
Business surveys pointing to strong growthhellip
24
Consumers are feeling more cheerfulhellip
25
Wages expected to risehellip
26
Key domestic risk is housing activityhellip
27
hellipbut rising income and pent-up demand will help
24
Energy prices remain relatively stable
29
Fed to taper on but hold off on rate hikes
30
This image cannot currently be displayed
First rate hike in 2015Q2
Manufacturing in focus
Manufacturing activity is boominghellip
Further indication that GDP decline is due to unique factors
28
hellipwith encouraging signs from leading indicators
29
US manufacturing has outperformed its peershellip
30
US has made substantial gains in competitiveness
35
Remarkable improvements
Due to productivity gains amp modest wage growthhellip
36
Remarkable improvements
Business sentiment in Europe remains weak while new orders have slowed
37
China amp Brazil have lost their edgehellip
38
Chinese wages have more than doubled over the past decade
Key industries
Loose credit and rising demand for autoshellip
36
hellipshould support productionhellip
20
25
30
35
40
45
50
405060708090
100110120130140150160
Jul-09 Jul-10 Jul-11 Jul-12 Jul-13 Jul-14
2010=100 US$ bn
Output (LHS)
Orders (RHS)
Source Oxford Economics Haver Analytics
US Output and orders
3 month moving average
37
hellipas will opportunities in the Emergers
38
Revamp of car stock to be key long-term driver
Ageing vehicle fleet replacement as economy recovers ndash average age of vehicle on US roads in 11frac12 years
Rising fuel efficiency standards leading to replacement of clunkers
Rising fuels costs resulting in smaller cars
Automakers likely to increase new models helping drive investment
Aerospace solid order books at the big twohellip
0
250
500
750
1000
1250
1500
1750
1994 1996 1998 2000 2002 2004 2006 2008 2010 2012 2014
Source Company reports
Airbus versus Boeing Orders
Airbus
Boeing
Number of aircraft
Note 2014 annual estimate based on annualized data through July
40
hellipwith APAC to drive long-term growth
Asia will account for almost 32 of global passenger traffic by 2017 compared to 28 in 2012
APAC to account for 40 of plane deliveries over next 20 years
US and Europe sales mainly for replacement of existing fleet
41
Need for efficiency will provide demand supporthellip
A330 revamped for 15 efficiency improvement to compete with Dreamliner 25 new orders on day of announcement
Long-haul efficiency has some ways to go to maintain airline profitability
42
Order backlogs remain high
0
500
1000
1500
2000
2500
3000
3500
1990 1993 1996 1999 2002 2005 2008 2011 2014
Deliveries
Orders
Number of aircraftAirbus amp Boeing Orders amp deliveries
Source Company reports and forecasts
43
Weaker demand for metalshellip
44
hellipand over capacity are weighing on priceshellip
45
hellipand discouraging investment
BHP Capital spending fell 32 in FY14 with another 8 fall expected next year
Rio Tinto Capital spending in FY14 cut faster than initially projected and further cut is budgeted for 2015
This is weighing on equipment makers
Caterpillar reported sales down 9 in the three months to July with sales to mining firms down 33 from the same period a year earlier
Bumper crop has brought down grain prices
47
helliphitting margins and investment
Producers are facing higher costs due to the implementation of Tier 4 engines developed to comply with emissions standards
Weaker margins are leading to farmers cutting back investment spending
John Deere has posted a 5 yy decline in revenues with an 11 decline in its agricultural division
Conclusions amp market implications
Conclusion and business implications
54
bull US economy expected to gradually accelerate through 2014 with support from a dovish Fed
bull Europe expected to recover but more ECB action could be required
bull Chinese economy is gradually rebalancing but banking crisis cannot be discounted
bull Emerging markets quiet for now but structural issue unsolved
bull Geopolitical tensions in the Middle East and Ukraine are being monitored carefully
Thank you
Gregory Daco
Chief US Economist gregorydacooxfordeconomicscom
September 2014
September 10 2014 2014 General Managersrsquo Meeting
Digital Manufacturing
World Class Shop Floor Management Release 5 The Smart Factory Revolution Mr Franz E Gruber Founder amp CEO
Dr Mohamed Abuali COO FORCAM Inc
MTConnect Evolution of a Standard and
Next Generation Interoperability Mr Courtney J Hill Chairman amp President
MTConnect Institute
QampA Session
World Class
Shop Floor Management
The Smart Factory Revolution
Franz E Gruber
Founder amp CEO
Mohamed Abuali
COO
汉语
World Class Shop Floor Management
FORCAM 2014 Page 2
FORCAMlsquos Passion
FORCAM provides proven
manufacturing solutions to
Continuously Improve Productivity
To be the global solutions provider of
the best-in-class Manufacturing
Execution Systems
FORCAM 2014 Page 3
FORCAM ndash 2014 Best Practices Award by Frost amp Sullivan
Frost amp Sullivan
ldquoFORCAM is a plant production software
solution provider that understands and
supports Industry 40 needsrdquo
FORCAM 2014 Page 4
FORCAMrsquos Testimonials and Industry Leadership
FORCAM 2014 Page 5
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
6 B Bartke S Wagner IPI-2
Shop Floor Management Audi - FORCAM FIT 2011-
Bernhard Bartke - Director Components Manufacturing
Stefan Wagner - Director Gear Manufacturing
7 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
bull Collection and recording of Operational Data via a database
(ex Machine States and State Changes)
Machine
Operator
Production Manager
Technical Assistant IT
Plant
Manager
Team Leader
8 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Interfaces
Time
Objectivity of Process Data
9 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Need for Continuous Improvement
bull Objective Information and Communication ndash across ALL levels
bull Transperancy and Visualization - Online
bull Real-time availability of operational data ndash Live Reports
bull Measurable increase in Plant Efficiency (OEE)
10 B Bartke S Wagner IPI-2
Shop Floor Management ndash Realtime bdquoANDONldquo Visualization
bull Web-based Interface Anywhere Anytime Access
bull Real-time Production Status Visualization
In Production
Overflow
Stoppage
Organizational
Stoppage
Idle (Pause)
Tool
Problem
11 B Bartke S Wagner IPI-2
Shop Floor Management Reporting ndash Hierarchical Status Diagrams
bull Reporting for Machines Groups Lines or the whole Plant
Technical
Stoppage In Production
Organizational
Stoppage Pause Overflow
Stoppage
Tool Problem In Setup
12 B Bartke S Wagner IPI-2
Audi Production System (APS)
Leadership Communication
bull Process Control
Standards
bull In Processes
bull Im Products
bull In the Organization
Learning Organization
bull Employee Development
bull Problem-Solving
bull CIP Culture
13 B Bartke S Wagner IPI-2
Shop Floor Management Process Control Panel on the shop floor
OEE Trend
(Day Week Month)
Measures
Quality
Process Control
14 B Bartke S Wagner IPI-2
OEE - Yesterday
Availability Trend
OEE ndash Last Week
OEE ndash Last Month
Naoki Nojiri IPI-25 BDE-Ist Stand 05042011
Shop Floor Management Process Control Panel on the shop floor
15 B Bartke S Wagner IPI-2
Shop Floor Management Management Cockpit
Planned vs Actual
(shift)
Top problems
(challenges)
OEE ndash Last Week
16 B Bartke S Wagner IPI-2
hellipand what have we achieved
17 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development suspension components (OEE Overall Equipment Effectiveness)
Radtraumlger
Start Shop Floor Management with
FORCAM +10
_
18 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development (20+ Increase in OEE in AUDI Stamping Facilities) (OEE Overall Equipment Effectiveness)
Radtraumlger
Start SFM +20
_
Our Beliefs
Respect
Collaboration
Excellence
Integrity
Community
Oct 30th 2013
Lean with Shop Floor Management BorgWarner Turbo Systems Rzeszow
Operator FactoryFrameworktrade Worker Client- Book On
Operator Downtime Reasons
Operator Actual versus Target Performance
TargetPlanned
Throughput
Actual
Performance
Opportunity for
Improvement
Actual
Throughput Machine
Data
ERP
Data
Supervisor Gantt Status
visualzation
Top 5
downtimes
Cip Top 5
Production
orders
Real data
history
Supervisor Cockpit machine
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
Consumers are feeling more cheerfulhellip
25
Wages expected to risehellip
26
Key domestic risk is housing activityhellip
27
hellipbut rising income and pent-up demand will help
24
Energy prices remain relatively stable
29
Fed to taper on but hold off on rate hikes
30
This image cannot currently be displayed
First rate hike in 2015Q2
Manufacturing in focus
Manufacturing activity is boominghellip
Further indication that GDP decline is due to unique factors
28
hellipwith encouraging signs from leading indicators
29
US manufacturing has outperformed its peershellip
30
US has made substantial gains in competitiveness
35
Remarkable improvements
Due to productivity gains amp modest wage growthhellip
36
Remarkable improvements
Business sentiment in Europe remains weak while new orders have slowed
37
China amp Brazil have lost their edgehellip
38
Chinese wages have more than doubled over the past decade
Key industries
Loose credit and rising demand for autoshellip
36
hellipshould support productionhellip
20
25
30
35
40
45
50
405060708090
100110120130140150160
Jul-09 Jul-10 Jul-11 Jul-12 Jul-13 Jul-14
2010=100 US$ bn
Output (LHS)
Orders (RHS)
Source Oxford Economics Haver Analytics
US Output and orders
3 month moving average
37
hellipas will opportunities in the Emergers
38
Revamp of car stock to be key long-term driver
Ageing vehicle fleet replacement as economy recovers ndash average age of vehicle on US roads in 11frac12 years
Rising fuel efficiency standards leading to replacement of clunkers
Rising fuels costs resulting in smaller cars
Automakers likely to increase new models helping drive investment
Aerospace solid order books at the big twohellip
0
250
500
750
1000
1250
1500
1750
1994 1996 1998 2000 2002 2004 2006 2008 2010 2012 2014
Source Company reports
Airbus versus Boeing Orders
Airbus
Boeing
Number of aircraft
Note 2014 annual estimate based on annualized data through July
40
hellipwith APAC to drive long-term growth
Asia will account for almost 32 of global passenger traffic by 2017 compared to 28 in 2012
APAC to account for 40 of plane deliveries over next 20 years
US and Europe sales mainly for replacement of existing fleet
41
Need for efficiency will provide demand supporthellip
A330 revamped for 15 efficiency improvement to compete with Dreamliner 25 new orders on day of announcement
Long-haul efficiency has some ways to go to maintain airline profitability
42
Order backlogs remain high
0
500
1000
1500
2000
2500
3000
3500
1990 1993 1996 1999 2002 2005 2008 2011 2014
Deliveries
Orders
Number of aircraftAirbus amp Boeing Orders amp deliveries
Source Company reports and forecasts
43
Weaker demand for metalshellip
44
hellipand over capacity are weighing on priceshellip
45
hellipand discouraging investment
BHP Capital spending fell 32 in FY14 with another 8 fall expected next year
Rio Tinto Capital spending in FY14 cut faster than initially projected and further cut is budgeted for 2015
This is weighing on equipment makers
Caterpillar reported sales down 9 in the three months to July with sales to mining firms down 33 from the same period a year earlier
Bumper crop has brought down grain prices
47
helliphitting margins and investment
Producers are facing higher costs due to the implementation of Tier 4 engines developed to comply with emissions standards
Weaker margins are leading to farmers cutting back investment spending
John Deere has posted a 5 yy decline in revenues with an 11 decline in its agricultural division
Conclusions amp market implications
Conclusion and business implications
54
bull US economy expected to gradually accelerate through 2014 with support from a dovish Fed
bull Europe expected to recover but more ECB action could be required
bull Chinese economy is gradually rebalancing but banking crisis cannot be discounted
bull Emerging markets quiet for now but structural issue unsolved
bull Geopolitical tensions in the Middle East and Ukraine are being monitored carefully
Thank you
Gregory Daco
Chief US Economist gregorydacooxfordeconomicscom
September 2014
September 10 2014 2014 General Managersrsquo Meeting
Digital Manufacturing
World Class Shop Floor Management Release 5 The Smart Factory Revolution Mr Franz E Gruber Founder amp CEO
Dr Mohamed Abuali COO FORCAM Inc
MTConnect Evolution of a Standard and
Next Generation Interoperability Mr Courtney J Hill Chairman amp President
MTConnect Institute
QampA Session
World Class
Shop Floor Management
The Smart Factory Revolution
Franz E Gruber
Founder amp CEO
Mohamed Abuali
COO
汉语
World Class Shop Floor Management
FORCAM 2014 Page 2
FORCAMlsquos Passion
FORCAM provides proven
manufacturing solutions to
Continuously Improve Productivity
To be the global solutions provider of
the best-in-class Manufacturing
Execution Systems
FORCAM 2014 Page 3
FORCAM ndash 2014 Best Practices Award by Frost amp Sullivan
Frost amp Sullivan
ldquoFORCAM is a plant production software
solution provider that understands and
supports Industry 40 needsrdquo
FORCAM 2014 Page 4
FORCAMrsquos Testimonials and Industry Leadership
FORCAM 2014 Page 5
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
6 B Bartke S Wagner IPI-2
Shop Floor Management Audi - FORCAM FIT 2011-
Bernhard Bartke - Director Components Manufacturing
Stefan Wagner - Director Gear Manufacturing
7 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
bull Collection and recording of Operational Data via a database
(ex Machine States and State Changes)
Machine
Operator
Production Manager
Technical Assistant IT
Plant
Manager
Team Leader
8 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Interfaces
Time
Objectivity of Process Data
9 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Need for Continuous Improvement
bull Objective Information and Communication ndash across ALL levels
bull Transperancy and Visualization - Online
bull Real-time availability of operational data ndash Live Reports
bull Measurable increase in Plant Efficiency (OEE)
10 B Bartke S Wagner IPI-2
Shop Floor Management ndash Realtime bdquoANDONldquo Visualization
bull Web-based Interface Anywhere Anytime Access
bull Real-time Production Status Visualization
In Production
Overflow
Stoppage
Organizational
Stoppage
Idle (Pause)
Tool
Problem
11 B Bartke S Wagner IPI-2
Shop Floor Management Reporting ndash Hierarchical Status Diagrams
bull Reporting for Machines Groups Lines or the whole Plant
Technical
Stoppage In Production
Organizational
Stoppage Pause Overflow
Stoppage
Tool Problem In Setup
12 B Bartke S Wagner IPI-2
Audi Production System (APS)
Leadership Communication
bull Process Control
Standards
bull In Processes
bull Im Products
bull In the Organization
Learning Organization
bull Employee Development
bull Problem-Solving
bull CIP Culture
13 B Bartke S Wagner IPI-2
Shop Floor Management Process Control Panel on the shop floor
OEE Trend
(Day Week Month)
Measures
Quality
Process Control
14 B Bartke S Wagner IPI-2
OEE - Yesterday
Availability Trend
OEE ndash Last Week
OEE ndash Last Month
Naoki Nojiri IPI-25 BDE-Ist Stand 05042011
Shop Floor Management Process Control Panel on the shop floor
15 B Bartke S Wagner IPI-2
Shop Floor Management Management Cockpit
Planned vs Actual
(shift)
Top problems
(challenges)
OEE ndash Last Week
16 B Bartke S Wagner IPI-2
hellipand what have we achieved
17 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development suspension components (OEE Overall Equipment Effectiveness)
Radtraumlger
Start Shop Floor Management with
FORCAM +10
_
18 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development (20+ Increase in OEE in AUDI Stamping Facilities) (OEE Overall Equipment Effectiveness)
Radtraumlger
Start SFM +20
_
Our Beliefs
Respect
Collaboration
Excellence
Integrity
Community
Oct 30th 2013
Lean with Shop Floor Management BorgWarner Turbo Systems Rzeszow
Operator FactoryFrameworktrade Worker Client- Book On
Operator Downtime Reasons
Operator Actual versus Target Performance
TargetPlanned
Throughput
Actual
Performance
Opportunity for
Improvement
Actual
Throughput Machine
Data
ERP
Data
Supervisor Gantt Status
visualzation
Top 5
downtimes
Cip Top 5
Production
orders
Real data
history
Supervisor Cockpit machine
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
Wages expected to risehellip
26
Key domestic risk is housing activityhellip
27
hellipbut rising income and pent-up demand will help
24
Energy prices remain relatively stable
29
Fed to taper on but hold off on rate hikes
30
This image cannot currently be displayed
First rate hike in 2015Q2
Manufacturing in focus
Manufacturing activity is boominghellip
Further indication that GDP decline is due to unique factors
28
hellipwith encouraging signs from leading indicators
29
US manufacturing has outperformed its peershellip
30
US has made substantial gains in competitiveness
35
Remarkable improvements
Due to productivity gains amp modest wage growthhellip
36
Remarkable improvements
Business sentiment in Europe remains weak while new orders have slowed
37
China amp Brazil have lost their edgehellip
38
Chinese wages have more than doubled over the past decade
Key industries
Loose credit and rising demand for autoshellip
36
hellipshould support productionhellip
20
25
30
35
40
45
50
405060708090
100110120130140150160
Jul-09 Jul-10 Jul-11 Jul-12 Jul-13 Jul-14
2010=100 US$ bn
Output (LHS)
Orders (RHS)
Source Oxford Economics Haver Analytics
US Output and orders
3 month moving average
37
hellipas will opportunities in the Emergers
38
Revamp of car stock to be key long-term driver
Ageing vehicle fleet replacement as economy recovers ndash average age of vehicle on US roads in 11frac12 years
Rising fuel efficiency standards leading to replacement of clunkers
Rising fuels costs resulting in smaller cars
Automakers likely to increase new models helping drive investment
Aerospace solid order books at the big twohellip
0
250
500
750
1000
1250
1500
1750
1994 1996 1998 2000 2002 2004 2006 2008 2010 2012 2014
Source Company reports
Airbus versus Boeing Orders
Airbus
Boeing
Number of aircraft
Note 2014 annual estimate based on annualized data through July
40
hellipwith APAC to drive long-term growth
Asia will account for almost 32 of global passenger traffic by 2017 compared to 28 in 2012
APAC to account for 40 of plane deliveries over next 20 years
US and Europe sales mainly for replacement of existing fleet
41
Need for efficiency will provide demand supporthellip
A330 revamped for 15 efficiency improvement to compete with Dreamliner 25 new orders on day of announcement
Long-haul efficiency has some ways to go to maintain airline profitability
42
Order backlogs remain high
0
500
1000
1500
2000
2500
3000
3500
1990 1993 1996 1999 2002 2005 2008 2011 2014
Deliveries
Orders
Number of aircraftAirbus amp Boeing Orders amp deliveries
Source Company reports and forecasts
43
Weaker demand for metalshellip
44
hellipand over capacity are weighing on priceshellip
45
hellipand discouraging investment
BHP Capital spending fell 32 in FY14 with another 8 fall expected next year
Rio Tinto Capital spending in FY14 cut faster than initially projected and further cut is budgeted for 2015
This is weighing on equipment makers
Caterpillar reported sales down 9 in the three months to July with sales to mining firms down 33 from the same period a year earlier
Bumper crop has brought down grain prices
47
helliphitting margins and investment
Producers are facing higher costs due to the implementation of Tier 4 engines developed to comply with emissions standards
Weaker margins are leading to farmers cutting back investment spending
John Deere has posted a 5 yy decline in revenues with an 11 decline in its agricultural division
Conclusions amp market implications
Conclusion and business implications
54
bull US economy expected to gradually accelerate through 2014 with support from a dovish Fed
bull Europe expected to recover but more ECB action could be required
bull Chinese economy is gradually rebalancing but banking crisis cannot be discounted
bull Emerging markets quiet for now but structural issue unsolved
bull Geopolitical tensions in the Middle East and Ukraine are being monitored carefully
Thank you
Gregory Daco
Chief US Economist gregorydacooxfordeconomicscom
September 2014
September 10 2014 2014 General Managersrsquo Meeting
Digital Manufacturing
World Class Shop Floor Management Release 5 The Smart Factory Revolution Mr Franz E Gruber Founder amp CEO
Dr Mohamed Abuali COO FORCAM Inc
MTConnect Evolution of a Standard and
Next Generation Interoperability Mr Courtney J Hill Chairman amp President
MTConnect Institute
QampA Session
World Class
Shop Floor Management
The Smart Factory Revolution
Franz E Gruber
Founder amp CEO
Mohamed Abuali
COO
汉语
World Class Shop Floor Management
FORCAM 2014 Page 2
FORCAMlsquos Passion
FORCAM provides proven
manufacturing solutions to
Continuously Improve Productivity
To be the global solutions provider of
the best-in-class Manufacturing
Execution Systems
FORCAM 2014 Page 3
FORCAM ndash 2014 Best Practices Award by Frost amp Sullivan
Frost amp Sullivan
ldquoFORCAM is a plant production software
solution provider that understands and
supports Industry 40 needsrdquo
FORCAM 2014 Page 4
FORCAMrsquos Testimonials and Industry Leadership
FORCAM 2014 Page 5
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
6 B Bartke S Wagner IPI-2
Shop Floor Management Audi - FORCAM FIT 2011-
Bernhard Bartke - Director Components Manufacturing
Stefan Wagner - Director Gear Manufacturing
7 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
bull Collection and recording of Operational Data via a database
(ex Machine States and State Changes)
Machine
Operator
Production Manager
Technical Assistant IT
Plant
Manager
Team Leader
8 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Interfaces
Time
Objectivity of Process Data
9 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Need for Continuous Improvement
bull Objective Information and Communication ndash across ALL levels
bull Transperancy and Visualization - Online
bull Real-time availability of operational data ndash Live Reports
bull Measurable increase in Plant Efficiency (OEE)
10 B Bartke S Wagner IPI-2
Shop Floor Management ndash Realtime bdquoANDONldquo Visualization
bull Web-based Interface Anywhere Anytime Access
bull Real-time Production Status Visualization
In Production
Overflow
Stoppage
Organizational
Stoppage
Idle (Pause)
Tool
Problem
11 B Bartke S Wagner IPI-2
Shop Floor Management Reporting ndash Hierarchical Status Diagrams
bull Reporting for Machines Groups Lines or the whole Plant
Technical
Stoppage In Production
Organizational
Stoppage Pause Overflow
Stoppage
Tool Problem In Setup
12 B Bartke S Wagner IPI-2
Audi Production System (APS)
Leadership Communication
bull Process Control
Standards
bull In Processes
bull Im Products
bull In the Organization
Learning Organization
bull Employee Development
bull Problem-Solving
bull CIP Culture
13 B Bartke S Wagner IPI-2
Shop Floor Management Process Control Panel on the shop floor
OEE Trend
(Day Week Month)
Measures
Quality
Process Control
14 B Bartke S Wagner IPI-2
OEE - Yesterday
Availability Trend
OEE ndash Last Week
OEE ndash Last Month
Naoki Nojiri IPI-25 BDE-Ist Stand 05042011
Shop Floor Management Process Control Panel on the shop floor
15 B Bartke S Wagner IPI-2
Shop Floor Management Management Cockpit
Planned vs Actual
(shift)
Top problems
(challenges)
OEE ndash Last Week
16 B Bartke S Wagner IPI-2
hellipand what have we achieved
17 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development suspension components (OEE Overall Equipment Effectiveness)
Radtraumlger
Start Shop Floor Management with
FORCAM +10
_
18 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development (20+ Increase in OEE in AUDI Stamping Facilities) (OEE Overall Equipment Effectiveness)
Radtraumlger
Start SFM +20
_
Our Beliefs
Respect
Collaboration
Excellence
Integrity
Community
Oct 30th 2013
Lean with Shop Floor Management BorgWarner Turbo Systems Rzeszow
Operator FactoryFrameworktrade Worker Client- Book On
Operator Downtime Reasons
Operator Actual versus Target Performance
TargetPlanned
Throughput
Actual
Performance
Opportunity for
Improvement
Actual
Throughput Machine
Data
ERP
Data
Supervisor Gantt Status
visualzation
Top 5
downtimes
Cip Top 5
Production
orders
Real data
history
Supervisor Cockpit machine
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
Key domestic risk is housing activityhellip
27
hellipbut rising income and pent-up demand will help
24
Energy prices remain relatively stable
29
Fed to taper on but hold off on rate hikes
30
This image cannot currently be displayed
First rate hike in 2015Q2
Manufacturing in focus
Manufacturing activity is boominghellip
Further indication that GDP decline is due to unique factors
28
hellipwith encouraging signs from leading indicators
29
US manufacturing has outperformed its peershellip
30
US has made substantial gains in competitiveness
35
Remarkable improvements
Due to productivity gains amp modest wage growthhellip
36
Remarkable improvements
Business sentiment in Europe remains weak while new orders have slowed
37
China amp Brazil have lost their edgehellip
38
Chinese wages have more than doubled over the past decade
Key industries
Loose credit and rising demand for autoshellip
36
hellipshould support productionhellip
20
25
30
35
40
45
50
405060708090
100110120130140150160
Jul-09 Jul-10 Jul-11 Jul-12 Jul-13 Jul-14
2010=100 US$ bn
Output (LHS)
Orders (RHS)
Source Oxford Economics Haver Analytics
US Output and orders
3 month moving average
37
hellipas will opportunities in the Emergers
38
Revamp of car stock to be key long-term driver
Ageing vehicle fleet replacement as economy recovers ndash average age of vehicle on US roads in 11frac12 years
Rising fuel efficiency standards leading to replacement of clunkers
Rising fuels costs resulting in smaller cars
Automakers likely to increase new models helping drive investment
Aerospace solid order books at the big twohellip
0
250
500
750
1000
1250
1500
1750
1994 1996 1998 2000 2002 2004 2006 2008 2010 2012 2014
Source Company reports
Airbus versus Boeing Orders
Airbus
Boeing
Number of aircraft
Note 2014 annual estimate based on annualized data through July
40
hellipwith APAC to drive long-term growth
Asia will account for almost 32 of global passenger traffic by 2017 compared to 28 in 2012
APAC to account for 40 of plane deliveries over next 20 years
US and Europe sales mainly for replacement of existing fleet
41
Need for efficiency will provide demand supporthellip
A330 revamped for 15 efficiency improvement to compete with Dreamliner 25 new orders on day of announcement
Long-haul efficiency has some ways to go to maintain airline profitability
42
Order backlogs remain high
0
500
1000
1500
2000
2500
3000
3500
1990 1993 1996 1999 2002 2005 2008 2011 2014
Deliveries
Orders
Number of aircraftAirbus amp Boeing Orders amp deliveries
Source Company reports and forecasts
43
Weaker demand for metalshellip
44
hellipand over capacity are weighing on priceshellip
45
hellipand discouraging investment
BHP Capital spending fell 32 in FY14 with another 8 fall expected next year
Rio Tinto Capital spending in FY14 cut faster than initially projected and further cut is budgeted for 2015
This is weighing on equipment makers
Caterpillar reported sales down 9 in the three months to July with sales to mining firms down 33 from the same period a year earlier
Bumper crop has brought down grain prices
47
helliphitting margins and investment
Producers are facing higher costs due to the implementation of Tier 4 engines developed to comply with emissions standards
Weaker margins are leading to farmers cutting back investment spending
John Deere has posted a 5 yy decline in revenues with an 11 decline in its agricultural division
Conclusions amp market implications
Conclusion and business implications
54
bull US economy expected to gradually accelerate through 2014 with support from a dovish Fed
bull Europe expected to recover but more ECB action could be required
bull Chinese economy is gradually rebalancing but banking crisis cannot be discounted
bull Emerging markets quiet for now but structural issue unsolved
bull Geopolitical tensions in the Middle East and Ukraine are being monitored carefully
Thank you
Gregory Daco
Chief US Economist gregorydacooxfordeconomicscom
September 2014
September 10 2014 2014 General Managersrsquo Meeting
Digital Manufacturing
World Class Shop Floor Management Release 5 The Smart Factory Revolution Mr Franz E Gruber Founder amp CEO
Dr Mohamed Abuali COO FORCAM Inc
MTConnect Evolution of a Standard and
Next Generation Interoperability Mr Courtney J Hill Chairman amp President
MTConnect Institute
QampA Session
World Class
Shop Floor Management
The Smart Factory Revolution
Franz E Gruber
Founder amp CEO
Mohamed Abuali
COO
汉语
World Class Shop Floor Management
FORCAM 2014 Page 2
FORCAMlsquos Passion
FORCAM provides proven
manufacturing solutions to
Continuously Improve Productivity
To be the global solutions provider of
the best-in-class Manufacturing
Execution Systems
FORCAM 2014 Page 3
FORCAM ndash 2014 Best Practices Award by Frost amp Sullivan
Frost amp Sullivan
ldquoFORCAM is a plant production software
solution provider that understands and
supports Industry 40 needsrdquo
FORCAM 2014 Page 4
FORCAMrsquos Testimonials and Industry Leadership
FORCAM 2014 Page 5
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
6 B Bartke S Wagner IPI-2
Shop Floor Management Audi - FORCAM FIT 2011-
Bernhard Bartke - Director Components Manufacturing
Stefan Wagner - Director Gear Manufacturing
7 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
bull Collection and recording of Operational Data via a database
(ex Machine States and State Changes)
Machine
Operator
Production Manager
Technical Assistant IT
Plant
Manager
Team Leader
8 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Interfaces
Time
Objectivity of Process Data
9 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Need for Continuous Improvement
bull Objective Information and Communication ndash across ALL levels
bull Transperancy and Visualization - Online
bull Real-time availability of operational data ndash Live Reports
bull Measurable increase in Plant Efficiency (OEE)
10 B Bartke S Wagner IPI-2
Shop Floor Management ndash Realtime bdquoANDONldquo Visualization
bull Web-based Interface Anywhere Anytime Access
bull Real-time Production Status Visualization
In Production
Overflow
Stoppage
Organizational
Stoppage
Idle (Pause)
Tool
Problem
11 B Bartke S Wagner IPI-2
Shop Floor Management Reporting ndash Hierarchical Status Diagrams
bull Reporting for Machines Groups Lines or the whole Plant
Technical
Stoppage In Production
Organizational
Stoppage Pause Overflow
Stoppage
Tool Problem In Setup
12 B Bartke S Wagner IPI-2
Audi Production System (APS)
Leadership Communication
bull Process Control
Standards
bull In Processes
bull Im Products
bull In the Organization
Learning Organization
bull Employee Development
bull Problem-Solving
bull CIP Culture
13 B Bartke S Wagner IPI-2
Shop Floor Management Process Control Panel on the shop floor
OEE Trend
(Day Week Month)
Measures
Quality
Process Control
14 B Bartke S Wagner IPI-2
OEE - Yesterday
Availability Trend
OEE ndash Last Week
OEE ndash Last Month
Naoki Nojiri IPI-25 BDE-Ist Stand 05042011
Shop Floor Management Process Control Panel on the shop floor
15 B Bartke S Wagner IPI-2
Shop Floor Management Management Cockpit
Planned vs Actual
(shift)
Top problems
(challenges)
OEE ndash Last Week
16 B Bartke S Wagner IPI-2
hellipand what have we achieved
17 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development suspension components (OEE Overall Equipment Effectiveness)
Radtraumlger
Start Shop Floor Management with
FORCAM +10
_
18 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development (20+ Increase in OEE in AUDI Stamping Facilities) (OEE Overall Equipment Effectiveness)
Radtraumlger
Start SFM +20
_
Our Beliefs
Respect
Collaboration
Excellence
Integrity
Community
Oct 30th 2013
Lean with Shop Floor Management BorgWarner Turbo Systems Rzeszow
Operator FactoryFrameworktrade Worker Client- Book On
Operator Downtime Reasons
Operator Actual versus Target Performance
TargetPlanned
Throughput
Actual
Performance
Opportunity for
Improvement
Actual
Throughput Machine
Data
ERP
Data
Supervisor Gantt Status
visualzation
Top 5
downtimes
Cip Top 5
Production
orders
Real data
history
Supervisor Cockpit machine
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
hellipbut rising income and pent-up demand will help
24
Energy prices remain relatively stable
29
Fed to taper on but hold off on rate hikes
30
This image cannot currently be displayed
First rate hike in 2015Q2
Manufacturing in focus
Manufacturing activity is boominghellip
Further indication that GDP decline is due to unique factors
28
hellipwith encouraging signs from leading indicators
29
US manufacturing has outperformed its peershellip
30
US has made substantial gains in competitiveness
35
Remarkable improvements
Due to productivity gains amp modest wage growthhellip
36
Remarkable improvements
Business sentiment in Europe remains weak while new orders have slowed
37
China amp Brazil have lost their edgehellip
38
Chinese wages have more than doubled over the past decade
Key industries
Loose credit and rising demand for autoshellip
36
hellipshould support productionhellip
20
25
30
35
40
45
50
405060708090
100110120130140150160
Jul-09 Jul-10 Jul-11 Jul-12 Jul-13 Jul-14
2010=100 US$ bn
Output (LHS)
Orders (RHS)
Source Oxford Economics Haver Analytics
US Output and orders
3 month moving average
37
hellipas will opportunities in the Emergers
38
Revamp of car stock to be key long-term driver
Ageing vehicle fleet replacement as economy recovers ndash average age of vehicle on US roads in 11frac12 years
Rising fuel efficiency standards leading to replacement of clunkers
Rising fuels costs resulting in smaller cars
Automakers likely to increase new models helping drive investment
Aerospace solid order books at the big twohellip
0
250
500
750
1000
1250
1500
1750
1994 1996 1998 2000 2002 2004 2006 2008 2010 2012 2014
Source Company reports
Airbus versus Boeing Orders
Airbus
Boeing
Number of aircraft
Note 2014 annual estimate based on annualized data through July
40
hellipwith APAC to drive long-term growth
Asia will account for almost 32 of global passenger traffic by 2017 compared to 28 in 2012
APAC to account for 40 of plane deliveries over next 20 years
US and Europe sales mainly for replacement of existing fleet
41
Need for efficiency will provide demand supporthellip
A330 revamped for 15 efficiency improvement to compete with Dreamliner 25 new orders on day of announcement
Long-haul efficiency has some ways to go to maintain airline profitability
42
Order backlogs remain high
0
500
1000
1500
2000
2500
3000
3500
1990 1993 1996 1999 2002 2005 2008 2011 2014
Deliveries
Orders
Number of aircraftAirbus amp Boeing Orders amp deliveries
Source Company reports and forecasts
43
Weaker demand for metalshellip
44
hellipand over capacity are weighing on priceshellip
45
hellipand discouraging investment
BHP Capital spending fell 32 in FY14 with another 8 fall expected next year
Rio Tinto Capital spending in FY14 cut faster than initially projected and further cut is budgeted for 2015
This is weighing on equipment makers
Caterpillar reported sales down 9 in the three months to July with sales to mining firms down 33 from the same period a year earlier
Bumper crop has brought down grain prices
47
helliphitting margins and investment
Producers are facing higher costs due to the implementation of Tier 4 engines developed to comply with emissions standards
Weaker margins are leading to farmers cutting back investment spending
John Deere has posted a 5 yy decline in revenues with an 11 decline in its agricultural division
Conclusions amp market implications
Conclusion and business implications
54
bull US economy expected to gradually accelerate through 2014 with support from a dovish Fed
bull Europe expected to recover but more ECB action could be required
bull Chinese economy is gradually rebalancing but banking crisis cannot be discounted
bull Emerging markets quiet for now but structural issue unsolved
bull Geopolitical tensions in the Middle East and Ukraine are being monitored carefully
Thank you
Gregory Daco
Chief US Economist gregorydacooxfordeconomicscom
September 2014
September 10 2014 2014 General Managersrsquo Meeting
Digital Manufacturing
World Class Shop Floor Management Release 5 The Smart Factory Revolution Mr Franz E Gruber Founder amp CEO
Dr Mohamed Abuali COO FORCAM Inc
MTConnect Evolution of a Standard and
Next Generation Interoperability Mr Courtney J Hill Chairman amp President
MTConnect Institute
QampA Session
World Class
Shop Floor Management
The Smart Factory Revolution
Franz E Gruber
Founder amp CEO
Mohamed Abuali
COO
汉语
World Class Shop Floor Management
FORCAM 2014 Page 2
FORCAMlsquos Passion
FORCAM provides proven
manufacturing solutions to
Continuously Improve Productivity
To be the global solutions provider of
the best-in-class Manufacturing
Execution Systems
FORCAM 2014 Page 3
FORCAM ndash 2014 Best Practices Award by Frost amp Sullivan
Frost amp Sullivan
ldquoFORCAM is a plant production software
solution provider that understands and
supports Industry 40 needsrdquo
FORCAM 2014 Page 4
FORCAMrsquos Testimonials and Industry Leadership
FORCAM 2014 Page 5
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
6 B Bartke S Wagner IPI-2
Shop Floor Management Audi - FORCAM FIT 2011-
Bernhard Bartke - Director Components Manufacturing
Stefan Wagner - Director Gear Manufacturing
7 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
bull Collection and recording of Operational Data via a database
(ex Machine States and State Changes)
Machine
Operator
Production Manager
Technical Assistant IT
Plant
Manager
Team Leader
8 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Interfaces
Time
Objectivity of Process Data
9 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Need for Continuous Improvement
bull Objective Information and Communication ndash across ALL levels
bull Transperancy and Visualization - Online
bull Real-time availability of operational data ndash Live Reports
bull Measurable increase in Plant Efficiency (OEE)
10 B Bartke S Wagner IPI-2
Shop Floor Management ndash Realtime bdquoANDONldquo Visualization
bull Web-based Interface Anywhere Anytime Access
bull Real-time Production Status Visualization
In Production
Overflow
Stoppage
Organizational
Stoppage
Idle (Pause)
Tool
Problem
11 B Bartke S Wagner IPI-2
Shop Floor Management Reporting ndash Hierarchical Status Diagrams
bull Reporting for Machines Groups Lines or the whole Plant
Technical
Stoppage In Production
Organizational
Stoppage Pause Overflow
Stoppage
Tool Problem In Setup
12 B Bartke S Wagner IPI-2
Audi Production System (APS)
Leadership Communication
bull Process Control
Standards
bull In Processes
bull Im Products
bull In the Organization
Learning Organization
bull Employee Development
bull Problem-Solving
bull CIP Culture
13 B Bartke S Wagner IPI-2
Shop Floor Management Process Control Panel on the shop floor
OEE Trend
(Day Week Month)
Measures
Quality
Process Control
14 B Bartke S Wagner IPI-2
OEE - Yesterday
Availability Trend
OEE ndash Last Week
OEE ndash Last Month
Naoki Nojiri IPI-25 BDE-Ist Stand 05042011
Shop Floor Management Process Control Panel on the shop floor
15 B Bartke S Wagner IPI-2
Shop Floor Management Management Cockpit
Planned vs Actual
(shift)
Top problems
(challenges)
OEE ndash Last Week
16 B Bartke S Wagner IPI-2
hellipand what have we achieved
17 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development suspension components (OEE Overall Equipment Effectiveness)
Radtraumlger
Start Shop Floor Management with
FORCAM +10
_
18 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development (20+ Increase in OEE in AUDI Stamping Facilities) (OEE Overall Equipment Effectiveness)
Radtraumlger
Start SFM +20
_
Our Beliefs
Respect
Collaboration
Excellence
Integrity
Community
Oct 30th 2013
Lean with Shop Floor Management BorgWarner Turbo Systems Rzeszow
Operator FactoryFrameworktrade Worker Client- Book On
Operator Downtime Reasons
Operator Actual versus Target Performance
TargetPlanned
Throughput
Actual
Performance
Opportunity for
Improvement
Actual
Throughput Machine
Data
ERP
Data
Supervisor Gantt Status
visualzation
Top 5
downtimes
Cip Top 5
Production
orders
Real data
history
Supervisor Cockpit machine
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
Energy prices remain relatively stable
29
Fed to taper on but hold off on rate hikes
30
This image cannot currently be displayed
First rate hike in 2015Q2
Manufacturing in focus
Manufacturing activity is boominghellip
Further indication that GDP decline is due to unique factors
28
hellipwith encouraging signs from leading indicators
29
US manufacturing has outperformed its peershellip
30
US has made substantial gains in competitiveness
35
Remarkable improvements
Due to productivity gains amp modest wage growthhellip
36
Remarkable improvements
Business sentiment in Europe remains weak while new orders have slowed
37
China amp Brazil have lost their edgehellip
38
Chinese wages have more than doubled over the past decade
Key industries
Loose credit and rising demand for autoshellip
36
hellipshould support productionhellip
20
25
30
35
40
45
50
405060708090
100110120130140150160
Jul-09 Jul-10 Jul-11 Jul-12 Jul-13 Jul-14
2010=100 US$ bn
Output (LHS)
Orders (RHS)
Source Oxford Economics Haver Analytics
US Output and orders
3 month moving average
37
hellipas will opportunities in the Emergers
38
Revamp of car stock to be key long-term driver
Ageing vehicle fleet replacement as economy recovers ndash average age of vehicle on US roads in 11frac12 years
Rising fuel efficiency standards leading to replacement of clunkers
Rising fuels costs resulting in smaller cars
Automakers likely to increase new models helping drive investment
Aerospace solid order books at the big twohellip
0
250
500
750
1000
1250
1500
1750
1994 1996 1998 2000 2002 2004 2006 2008 2010 2012 2014
Source Company reports
Airbus versus Boeing Orders
Airbus
Boeing
Number of aircraft
Note 2014 annual estimate based on annualized data through July
40
hellipwith APAC to drive long-term growth
Asia will account for almost 32 of global passenger traffic by 2017 compared to 28 in 2012
APAC to account for 40 of plane deliveries over next 20 years
US and Europe sales mainly for replacement of existing fleet
41
Need for efficiency will provide demand supporthellip
A330 revamped for 15 efficiency improvement to compete with Dreamliner 25 new orders on day of announcement
Long-haul efficiency has some ways to go to maintain airline profitability
42
Order backlogs remain high
0
500
1000
1500
2000
2500
3000
3500
1990 1993 1996 1999 2002 2005 2008 2011 2014
Deliveries
Orders
Number of aircraftAirbus amp Boeing Orders amp deliveries
Source Company reports and forecasts
43
Weaker demand for metalshellip
44
hellipand over capacity are weighing on priceshellip
45
hellipand discouraging investment
BHP Capital spending fell 32 in FY14 with another 8 fall expected next year
Rio Tinto Capital spending in FY14 cut faster than initially projected and further cut is budgeted for 2015
This is weighing on equipment makers
Caterpillar reported sales down 9 in the three months to July with sales to mining firms down 33 from the same period a year earlier
Bumper crop has brought down grain prices
47
helliphitting margins and investment
Producers are facing higher costs due to the implementation of Tier 4 engines developed to comply with emissions standards
Weaker margins are leading to farmers cutting back investment spending
John Deere has posted a 5 yy decline in revenues with an 11 decline in its agricultural division
Conclusions amp market implications
Conclusion and business implications
54
bull US economy expected to gradually accelerate through 2014 with support from a dovish Fed
bull Europe expected to recover but more ECB action could be required
bull Chinese economy is gradually rebalancing but banking crisis cannot be discounted
bull Emerging markets quiet for now but structural issue unsolved
bull Geopolitical tensions in the Middle East and Ukraine are being monitored carefully
Thank you
Gregory Daco
Chief US Economist gregorydacooxfordeconomicscom
September 2014
September 10 2014 2014 General Managersrsquo Meeting
Digital Manufacturing
World Class Shop Floor Management Release 5 The Smart Factory Revolution Mr Franz E Gruber Founder amp CEO
Dr Mohamed Abuali COO FORCAM Inc
MTConnect Evolution of a Standard and
Next Generation Interoperability Mr Courtney J Hill Chairman amp President
MTConnect Institute
QampA Session
World Class
Shop Floor Management
The Smart Factory Revolution
Franz E Gruber
Founder amp CEO
Mohamed Abuali
COO
汉语
World Class Shop Floor Management
FORCAM 2014 Page 2
FORCAMlsquos Passion
FORCAM provides proven
manufacturing solutions to
Continuously Improve Productivity
To be the global solutions provider of
the best-in-class Manufacturing
Execution Systems
FORCAM 2014 Page 3
FORCAM ndash 2014 Best Practices Award by Frost amp Sullivan
Frost amp Sullivan
ldquoFORCAM is a plant production software
solution provider that understands and
supports Industry 40 needsrdquo
FORCAM 2014 Page 4
FORCAMrsquos Testimonials and Industry Leadership
FORCAM 2014 Page 5
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
6 B Bartke S Wagner IPI-2
Shop Floor Management Audi - FORCAM FIT 2011-
Bernhard Bartke - Director Components Manufacturing
Stefan Wagner - Director Gear Manufacturing
7 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
bull Collection and recording of Operational Data via a database
(ex Machine States and State Changes)
Machine
Operator
Production Manager
Technical Assistant IT
Plant
Manager
Team Leader
8 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Interfaces
Time
Objectivity of Process Data
9 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Need for Continuous Improvement
bull Objective Information and Communication ndash across ALL levels
bull Transperancy and Visualization - Online
bull Real-time availability of operational data ndash Live Reports
bull Measurable increase in Plant Efficiency (OEE)
10 B Bartke S Wagner IPI-2
Shop Floor Management ndash Realtime bdquoANDONldquo Visualization
bull Web-based Interface Anywhere Anytime Access
bull Real-time Production Status Visualization
In Production
Overflow
Stoppage
Organizational
Stoppage
Idle (Pause)
Tool
Problem
11 B Bartke S Wagner IPI-2
Shop Floor Management Reporting ndash Hierarchical Status Diagrams
bull Reporting for Machines Groups Lines or the whole Plant
Technical
Stoppage In Production
Organizational
Stoppage Pause Overflow
Stoppage
Tool Problem In Setup
12 B Bartke S Wagner IPI-2
Audi Production System (APS)
Leadership Communication
bull Process Control
Standards
bull In Processes
bull Im Products
bull In the Organization
Learning Organization
bull Employee Development
bull Problem-Solving
bull CIP Culture
13 B Bartke S Wagner IPI-2
Shop Floor Management Process Control Panel on the shop floor
OEE Trend
(Day Week Month)
Measures
Quality
Process Control
14 B Bartke S Wagner IPI-2
OEE - Yesterday
Availability Trend
OEE ndash Last Week
OEE ndash Last Month
Naoki Nojiri IPI-25 BDE-Ist Stand 05042011
Shop Floor Management Process Control Panel on the shop floor
15 B Bartke S Wagner IPI-2
Shop Floor Management Management Cockpit
Planned vs Actual
(shift)
Top problems
(challenges)
OEE ndash Last Week
16 B Bartke S Wagner IPI-2
hellipand what have we achieved
17 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development suspension components (OEE Overall Equipment Effectiveness)
Radtraumlger
Start Shop Floor Management with
FORCAM +10
_
18 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development (20+ Increase in OEE in AUDI Stamping Facilities) (OEE Overall Equipment Effectiveness)
Radtraumlger
Start SFM +20
_
Our Beliefs
Respect
Collaboration
Excellence
Integrity
Community
Oct 30th 2013
Lean with Shop Floor Management BorgWarner Turbo Systems Rzeszow
Operator FactoryFrameworktrade Worker Client- Book On
Operator Downtime Reasons
Operator Actual versus Target Performance
TargetPlanned
Throughput
Actual
Performance
Opportunity for
Improvement
Actual
Throughput Machine
Data
ERP
Data
Supervisor Gantt Status
visualzation
Top 5
downtimes
Cip Top 5
Production
orders
Real data
history
Supervisor Cockpit machine
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
Fed to taper on but hold off on rate hikes
30
This image cannot currently be displayed
First rate hike in 2015Q2
Manufacturing in focus
Manufacturing activity is boominghellip
Further indication that GDP decline is due to unique factors
28
hellipwith encouraging signs from leading indicators
29
US manufacturing has outperformed its peershellip
30
US has made substantial gains in competitiveness
35
Remarkable improvements
Due to productivity gains amp modest wage growthhellip
36
Remarkable improvements
Business sentiment in Europe remains weak while new orders have slowed
37
China amp Brazil have lost their edgehellip
38
Chinese wages have more than doubled over the past decade
Key industries
Loose credit and rising demand for autoshellip
36
hellipshould support productionhellip
20
25
30
35
40
45
50
405060708090
100110120130140150160
Jul-09 Jul-10 Jul-11 Jul-12 Jul-13 Jul-14
2010=100 US$ bn
Output (LHS)
Orders (RHS)
Source Oxford Economics Haver Analytics
US Output and orders
3 month moving average
37
hellipas will opportunities in the Emergers
38
Revamp of car stock to be key long-term driver
Ageing vehicle fleet replacement as economy recovers ndash average age of vehicle on US roads in 11frac12 years
Rising fuel efficiency standards leading to replacement of clunkers
Rising fuels costs resulting in smaller cars
Automakers likely to increase new models helping drive investment
Aerospace solid order books at the big twohellip
0
250
500
750
1000
1250
1500
1750
1994 1996 1998 2000 2002 2004 2006 2008 2010 2012 2014
Source Company reports
Airbus versus Boeing Orders
Airbus
Boeing
Number of aircraft
Note 2014 annual estimate based on annualized data through July
40
hellipwith APAC to drive long-term growth
Asia will account for almost 32 of global passenger traffic by 2017 compared to 28 in 2012
APAC to account for 40 of plane deliveries over next 20 years
US and Europe sales mainly for replacement of existing fleet
41
Need for efficiency will provide demand supporthellip
A330 revamped for 15 efficiency improvement to compete with Dreamliner 25 new orders on day of announcement
Long-haul efficiency has some ways to go to maintain airline profitability
42
Order backlogs remain high
0
500
1000
1500
2000
2500
3000
3500
1990 1993 1996 1999 2002 2005 2008 2011 2014
Deliveries
Orders
Number of aircraftAirbus amp Boeing Orders amp deliveries
Source Company reports and forecasts
43
Weaker demand for metalshellip
44
hellipand over capacity are weighing on priceshellip
45
hellipand discouraging investment
BHP Capital spending fell 32 in FY14 with another 8 fall expected next year
Rio Tinto Capital spending in FY14 cut faster than initially projected and further cut is budgeted for 2015
This is weighing on equipment makers
Caterpillar reported sales down 9 in the three months to July with sales to mining firms down 33 from the same period a year earlier
Bumper crop has brought down grain prices
47
helliphitting margins and investment
Producers are facing higher costs due to the implementation of Tier 4 engines developed to comply with emissions standards
Weaker margins are leading to farmers cutting back investment spending
John Deere has posted a 5 yy decline in revenues with an 11 decline in its agricultural division
Conclusions amp market implications
Conclusion and business implications
54
bull US economy expected to gradually accelerate through 2014 with support from a dovish Fed
bull Europe expected to recover but more ECB action could be required
bull Chinese economy is gradually rebalancing but banking crisis cannot be discounted
bull Emerging markets quiet for now but structural issue unsolved
bull Geopolitical tensions in the Middle East and Ukraine are being monitored carefully
Thank you
Gregory Daco
Chief US Economist gregorydacooxfordeconomicscom
September 2014
September 10 2014 2014 General Managersrsquo Meeting
Digital Manufacturing
World Class Shop Floor Management Release 5 The Smart Factory Revolution Mr Franz E Gruber Founder amp CEO
Dr Mohamed Abuali COO FORCAM Inc
MTConnect Evolution of a Standard and
Next Generation Interoperability Mr Courtney J Hill Chairman amp President
MTConnect Institute
QampA Session
World Class
Shop Floor Management
The Smart Factory Revolution
Franz E Gruber
Founder amp CEO
Mohamed Abuali
COO
汉语
World Class Shop Floor Management
FORCAM 2014 Page 2
FORCAMlsquos Passion
FORCAM provides proven
manufacturing solutions to
Continuously Improve Productivity
To be the global solutions provider of
the best-in-class Manufacturing
Execution Systems
FORCAM 2014 Page 3
FORCAM ndash 2014 Best Practices Award by Frost amp Sullivan
Frost amp Sullivan
ldquoFORCAM is a plant production software
solution provider that understands and
supports Industry 40 needsrdquo
FORCAM 2014 Page 4
FORCAMrsquos Testimonials and Industry Leadership
FORCAM 2014 Page 5
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
6 B Bartke S Wagner IPI-2
Shop Floor Management Audi - FORCAM FIT 2011-
Bernhard Bartke - Director Components Manufacturing
Stefan Wagner - Director Gear Manufacturing
7 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
bull Collection and recording of Operational Data via a database
(ex Machine States and State Changes)
Machine
Operator
Production Manager
Technical Assistant IT
Plant
Manager
Team Leader
8 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Interfaces
Time
Objectivity of Process Data
9 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Need for Continuous Improvement
bull Objective Information and Communication ndash across ALL levels
bull Transperancy and Visualization - Online
bull Real-time availability of operational data ndash Live Reports
bull Measurable increase in Plant Efficiency (OEE)
10 B Bartke S Wagner IPI-2
Shop Floor Management ndash Realtime bdquoANDONldquo Visualization
bull Web-based Interface Anywhere Anytime Access
bull Real-time Production Status Visualization
In Production
Overflow
Stoppage
Organizational
Stoppage
Idle (Pause)
Tool
Problem
11 B Bartke S Wagner IPI-2
Shop Floor Management Reporting ndash Hierarchical Status Diagrams
bull Reporting for Machines Groups Lines or the whole Plant
Technical
Stoppage In Production
Organizational
Stoppage Pause Overflow
Stoppage
Tool Problem In Setup
12 B Bartke S Wagner IPI-2
Audi Production System (APS)
Leadership Communication
bull Process Control
Standards
bull In Processes
bull Im Products
bull In the Organization
Learning Organization
bull Employee Development
bull Problem-Solving
bull CIP Culture
13 B Bartke S Wagner IPI-2
Shop Floor Management Process Control Panel on the shop floor
OEE Trend
(Day Week Month)
Measures
Quality
Process Control
14 B Bartke S Wagner IPI-2
OEE - Yesterday
Availability Trend
OEE ndash Last Week
OEE ndash Last Month
Naoki Nojiri IPI-25 BDE-Ist Stand 05042011
Shop Floor Management Process Control Panel on the shop floor
15 B Bartke S Wagner IPI-2
Shop Floor Management Management Cockpit
Planned vs Actual
(shift)
Top problems
(challenges)
OEE ndash Last Week
16 B Bartke S Wagner IPI-2
hellipand what have we achieved
17 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development suspension components (OEE Overall Equipment Effectiveness)
Radtraumlger
Start Shop Floor Management with
FORCAM +10
_
18 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development (20+ Increase in OEE in AUDI Stamping Facilities) (OEE Overall Equipment Effectiveness)
Radtraumlger
Start SFM +20
_
Our Beliefs
Respect
Collaboration
Excellence
Integrity
Community
Oct 30th 2013
Lean with Shop Floor Management BorgWarner Turbo Systems Rzeszow
Operator FactoryFrameworktrade Worker Client- Book On
Operator Downtime Reasons
Operator Actual versus Target Performance
TargetPlanned
Throughput
Actual
Performance
Opportunity for
Improvement
Actual
Throughput Machine
Data
ERP
Data
Supervisor Gantt Status
visualzation
Top 5
downtimes
Cip Top 5
Production
orders
Real data
history
Supervisor Cockpit machine
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
Manufacturing in focus
Manufacturing activity is boominghellip
Further indication that GDP decline is due to unique factors
28
hellipwith encouraging signs from leading indicators
29
US manufacturing has outperformed its peershellip
30
US has made substantial gains in competitiveness
35
Remarkable improvements
Due to productivity gains amp modest wage growthhellip
36
Remarkable improvements
Business sentiment in Europe remains weak while new orders have slowed
37
China amp Brazil have lost their edgehellip
38
Chinese wages have more than doubled over the past decade
Key industries
Loose credit and rising demand for autoshellip
36
hellipshould support productionhellip
20
25
30
35
40
45
50
405060708090
100110120130140150160
Jul-09 Jul-10 Jul-11 Jul-12 Jul-13 Jul-14
2010=100 US$ bn
Output (LHS)
Orders (RHS)
Source Oxford Economics Haver Analytics
US Output and orders
3 month moving average
37
hellipas will opportunities in the Emergers
38
Revamp of car stock to be key long-term driver
Ageing vehicle fleet replacement as economy recovers ndash average age of vehicle on US roads in 11frac12 years
Rising fuel efficiency standards leading to replacement of clunkers
Rising fuels costs resulting in smaller cars
Automakers likely to increase new models helping drive investment
Aerospace solid order books at the big twohellip
0
250
500
750
1000
1250
1500
1750
1994 1996 1998 2000 2002 2004 2006 2008 2010 2012 2014
Source Company reports
Airbus versus Boeing Orders
Airbus
Boeing
Number of aircraft
Note 2014 annual estimate based on annualized data through July
40
hellipwith APAC to drive long-term growth
Asia will account for almost 32 of global passenger traffic by 2017 compared to 28 in 2012
APAC to account for 40 of plane deliveries over next 20 years
US and Europe sales mainly for replacement of existing fleet
41
Need for efficiency will provide demand supporthellip
A330 revamped for 15 efficiency improvement to compete with Dreamliner 25 new orders on day of announcement
Long-haul efficiency has some ways to go to maintain airline profitability
42
Order backlogs remain high
0
500
1000
1500
2000
2500
3000
3500
1990 1993 1996 1999 2002 2005 2008 2011 2014
Deliveries
Orders
Number of aircraftAirbus amp Boeing Orders amp deliveries
Source Company reports and forecasts
43
Weaker demand for metalshellip
44
hellipand over capacity are weighing on priceshellip
45
hellipand discouraging investment
BHP Capital spending fell 32 in FY14 with another 8 fall expected next year
Rio Tinto Capital spending in FY14 cut faster than initially projected and further cut is budgeted for 2015
This is weighing on equipment makers
Caterpillar reported sales down 9 in the three months to July with sales to mining firms down 33 from the same period a year earlier
Bumper crop has brought down grain prices
47
helliphitting margins and investment
Producers are facing higher costs due to the implementation of Tier 4 engines developed to comply with emissions standards
Weaker margins are leading to farmers cutting back investment spending
John Deere has posted a 5 yy decline in revenues with an 11 decline in its agricultural division
Conclusions amp market implications
Conclusion and business implications
54
bull US economy expected to gradually accelerate through 2014 with support from a dovish Fed
bull Europe expected to recover but more ECB action could be required
bull Chinese economy is gradually rebalancing but banking crisis cannot be discounted
bull Emerging markets quiet for now but structural issue unsolved
bull Geopolitical tensions in the Middle East and Ukraine are being monitored carefully
Thank you
Gregory Daco
Chief US Economist gregorydacooxfordeconomicscom
September 2014
September 10 2014 2014 General Managersrsquo Meeting
Digital Manufacturing
World Class Shop Floor Management Release 5 The Smart Factory Revolution Mr Franz E Gruber Founder amp CEO
Dr Mohamed Abuali COO FORCAM Inc
MTConnect Evolution of a Standard and
Next Generation Interoperability Mr Courtney J Hill Chairman amp President
MTConnect Institute
QampA Session
World Class
Shop Floor Management
The Smart Factory Revolution
Franz E Gruber
Founder amp CEO
Mohamed Abuali
COO
汉语
World Class Shop Floor Management
FORCAM 2014 Page 2
FORCAMlsquos Passion
FORCAM provides proven
manufacturing solutions to
Continuously Improve Productivity
To be the global solutions provider of
the best-in-class Manufacturing
Execution Systems
FORCAM 2014 Page 3
FORCAM ndash 2014 Best Practices Award by Frost amp Sullivan
Frost amp Sullivan
ldquoFORCAM is a plant production software
solution provider that understands and
supports Industry 40 needsrdquo
FORCAM 2014 Page 4
FORCAMrsquos Testimonials and Industry Leadership
FORCAM 2014 Page 5
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
6 B Bartke S Wagner IPI-2
Shop Floor Management Audi - FORCAM FIT 2011-
Bernhard Bartke - Director Components Manufacturing
Stefan Wagner - Director Gear Manufacturing
7 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
bull Collection and recording of Operational Data via a database
(ex Machine States and State Changes)
Machine
Operator
Production Manager
Technical Assistant IT
Plant
Manager
Team Leader
8 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Interfaces
Time
Objectivity of Process Data
9 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Need for Continuous Improvement
bull Objective Information and Communication ndash across ALL levels
bull Transperancy and Visualization - Online
bull Real-time availability of operational data ndash Live Reports
bull Measurable increase in Plant Efficiency (OEE)
10 B Bartke S Wagner IPI-2
Shop Floor Management ndash Realtime bdquoANDONldquo Visualization
bull Web-based Interface Anywhere Anytime Access
bull Real-time Production Status Visualization
In Production
Overflow
Stoppage
Organizational
Stoppage
Idle (Pause)
Tool
Problem
11 B Bartke S Wagner IPI-2
Shop Floor Management Reporting ndash Hierarchical Status Diagrams
bull Reporting for Machines Groups Lines or the whole Plant
Technical
Stoppage In Production
Organizational
Stoppage Pause Overflow
Stoppage
Tool Problem In Setup
12 B Bartke S Wagner IPI-2
Audi Production System (APS)
Leadership Communication
bull Process Control
Standards
bull In Processes
bull Im Products
bull In the Organization
Learning Organization
bull Employee Development
bull Problem-Solving
bull CIP Culture
13 B Bartke S Wagner IPI-2
Shop Floor Management Process Control Panel on the shop floor
OEE Trend
(Day Week Month)
Measures
Quality
Process Control
14 B Bartke S Wagner IPI-2
OEE - Yesterday
Availability Trend
OEE ndash Last Week
OEE ndash Last Month
Naoki Nojiri IPI-25 BDE-Ist Stand 05042011
Shop Floor Management Process Control Panel on the shop floor
15 B Bartke S Wagner IPI-2
Shop Floor Management Management Cockpit
Planned vs Actual
(shift)
Top problems
(challenges)
OEE ndash Last Week
16 B Bartke S Wagner IPI-2
hellipand what have we achieved
17 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development suspension components (OEE Overall Equipment Effectiveness)
Radtraumlger
Start Shop Floor Management with
FORCAM +10
_
18 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development (20+ Increase in OEE in AUDI Stamping Facilities) (OEE Overall Equipment Effectiveness)
Radtraumlger
Start SFM +20
_
Our Beliefs
Respect
Collaboration
Excellence
Integrity
Community
Oct 30th 2013
Lean with Shop Floor Management BorgWarner Turbo Systems Rzeszow
Operator FactoryFrameworktrade Worker Client- Book On
Operator Downtime Reasons
Operator Actual versus Target Performance
TargetPlanned
Throughput
Actual
Performance
Opportunity for
Improvement
Actual
Throughput Machine
Data
ERP
Data
Supervisor Gantt Status
visualzation
Top 5
downtimes
Cip Top 5
Production
orders
Real data
history
Supervisor Cockpit machine
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
Manufacturing activity is boominghellip
Further indication that GDP decline is due to unique factors
28
hellipwith encouraging signs from leading indicators
29
US manufacturing has outperformed its peershellip
30
US has made substantial gains in competitiveness
35
Remarkable improvements
Due to productivity gains amp modest wage growthhellip
36
Remarkable improvements
Business sentiment in Europe remains weak while new orders have slowed
37
China amp Brazil have lost their edgehellip
38
Chinese wages have more than doubled over the past decade
Key industries
Loose credit and rising demand for autoshellip
36
hellipshould support productionhellip
20
25
30
35
40
45
50
405060708090
100110120130140150160
Jul-09 Jul-10 Jul-11 Jul-12 Jul-13 Jul-14
2010=100 US$ bn
Output (LHS)
Orders (RHS)
Source Oxford Economics Haver Analytics
US Output and orders
3 month moving average
37
hellipas will opportunities in the Emergers
38
Revamp of car stock to be key long-term driver
Ageing vehicle fleet replacement as economy recovers ndash average age of vehicle on US roads in 11frac12 years
Rising fuel efficiency standards leading to replacement of clunkers
Rising fuels costs resulting in smaller cars
Automakers likely to increase new models helping drive investment
Aerospace solid order books at the big twohellip
0
250
500
750
1000
1250
1500
1750
1994 1996 1998 2000 2002 2004 2006 2008 2010 2012 2014
Source Company reports
Airbus versus Boeing Orders
Airbus
Boeing
Number of aircraft
Note 2014 annual estimate based on annualized data through July
40
hellipwith APAC to drive long-term growth
Asia will account for almost 32 of global passenger traffic by 2017 compared to 28 in 2012
APAC to account for 40 of plane deliveries over next 20 years
US and Europe sales mainly for replacement of existing fleet
41
Need for efficiency will provide demand supporthellip
A330 revamped for 15 efficiency improvement to compete with Dreamliner 25 new orders on day of announcement
Long-haul efficiency has some ways to go to maintain airline profitability
42
Order backlogs remain high
0
500
1000
1500
2000
2500
3000
3500
1990 1993 1996 1999 2002 2005 2008 2011 2014
Deliveries
Orders
Number of aircraftAirbus amp Boeing Orders amp deliveries
Source Company reports and forecasts
43
Weaker demand for metalshellip
44
hellipand over capacity are weighing on priceshellip
45
hellipand discouraging investment
BHP Capital spending fell 32 in FY14 with another 8 fall expected next year
Rio Tinto Capital spending in FY14 cut faster than initially projected and further cut is budgeted for 2015
This is weighing on equipment makers
Caterpillar reported sales down 9 in the three months to July with sales to mining firms down 33 from the same period a year earlier
Bumper crop has brought down grain prices
47
helliphitting margins and investment
Producers are facing higher costs due to the implementation of Tier 4 engines developed to comply with emissions standards
Weaker margins are leading to farmers cutting back investment spending
John Deere has posted a 5 yy decline in revenues with an 11 decline in its agricultural division
Conclusions amp market implications
Conclusion and business implications
54
bull US economy expected to gradually accelerate through 2014 with support from a dovish Fed
bull Europe expected to recover but more ECB action could be required
bull Chinese economy is gradually rebalancing but banking crisis cannot be discounted
bull Emerging markets quiet for now but structural issue unsolved
bull Geopolitical tensions in the Middle East and Ukraine are being monitored carefully
Thank you
Gregory Daco
Chief US Economist gregorydacooxfordeconomicscom
September 2014
September 10 2014 2014 General Managersrsquo Meeting
Digital Manufacturing
World Class Shop Floor Management Release 5 The Smart Factory Revolution Mr Franz E Gruber Founder amp CEO
Dr Mohamed Abuali COO FORCAM Inc
MTConnect Evolution of a Standard and
Next Generation Interoperability Mr Courtney J Hill Chairman amp President
MTConnect Institute
QampA Session
World Class
Shop Floor Management
The Smart Factory Revolution
Franz E Gruber
Founder amp CEO
Mohamed Abuali
COO
汉语
World Class Shop Floor Management
FORCAM 2014 Page 2
FORCAMlsquos Passion
FORCAM provides proven
manufacturing solutions to
Continuously Improve Productivity
To be the global solutions provider of
the best-in-class Manufacturing
Execution Systems
FORCAM 2014 Page 3
FORCAM ndash 2014 Best Practices Award by Frost amp Sullivan
Frost amp Sullivan
ldquoFORCAM is a plant production software
solution provider that understands and
supports Industry 40 needsrdquo
FORCAM 2014 Page 4
FORCAMrsquos Testimonials and Industry Leadership
FORCAM 2014 Page 5
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
6 B Bartke S Wagner IPI-2
Shop Floor Management Audi - FORCAM FIT 2011-
Bernhard Bartke - Director Components Manufacturing
Stefan Wagner - Director Gear Manufacturing
7 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
bull Collection and recording of Operational Data via a database
(ex Machine States and State Changes)
Machine
Operator
Production Manager
Technical Assistant IT
Plant
Manager
Team Leader
8 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Interfaces
Time
Objectivity of Process Data
9 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Need for Continuous Improvement
bull Objective Information and Communication ndash across ALL levels
bull Transperancy and Visualization - Online
bull Real-time availability of operational data ndash Live Reports
bull Measurable increase in Plant Efficiency (OEE)
10 B Bartke S Wagner IPI-2
Shop Floor Management ndash Realtime bdquoANDONldquo Visualization
bull Web-based Interface Anywhere Anytime Access
bull Real-time Production Status Visualization
In Production
Overflow
Stoppage
Organizational
Stoppage
Idle (Pause)
Tool
Problem
11 B Bartke S Wagner IPI-2
Shop Floor Management Reporting ndash Hierarchical Status Diagrams
bull Reporting for Machines Groups Lines or the whole Plant
Technical
Stoppage In Production
Organizational
Stoppage Pause Overflow
Stoppage
Tool Problem In Setup
12 B Bartke S Wagner IPI-2
Audi Production System (APS)
Leadership Communication
bull Process Control
Standards
bull In Processes
bull Im Products
bull In the Organization
Learning Organization
bull Employee Development
bull Problem-Solving
bull CIP Culture
13 B Bartke S Wagner IPI-2
Shop Floor Management Process Control Panel on the shop floor
OEE Trend
(Day Week Month)
Measures
Quality
Process Control
14 B Bartke S Wagner IPI-2
OEE - Yesterday
Availability Trend
OEE ndash Last Week
OEE ndash Last Month
Naoki Nojiri IPI-25 BDE-Ist Stand 05042011
Shop Floor Management Process Control Panel on the shop floor
15 B Bartke S Wagner IPI-2
Shop Floor Management Management Cockpit
Planned vs Actual
(shift)
Top problems
(challenges)
OEE ndash Last Week
16 B Bartke S Wagner IPI-2
hellipand what have we achieved
17 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development suspension components (OEE Overall Equipment Effectiveness)
Radtraumlger
Start Shop Floor Management with
FORCAM +10
_
18 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development (20+ Increase in OEE in AUDI Stamping Facilities) (OEE Overall Equipment Effectiveness)
Radtraumlger
Start SFM +20
_
Our Beliefs
Respect
Collaboration
Excellence
Integrity
Community
Oct 30th 2013
Lean with Shop Floor Management BorgWarner Turbo Systems Rzeszow
Operator FactoryFrameworktrade Worker Client- Book On
Operator Downtime Reasons
Operator Actual versus Target Performance
TargetPlanned
Throughput
Actual
Performance
Opportunity for
Improvement
Actual
Throughput Machine
Data
ERP
Data
Supervisor Gantt Status
visualzation
Top 5
downtimes
Cip Top 5
Production
orders
Real data
history
Supervisor Cockpit machine
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
hellipwith encouraging signs from leading indicators
29
US manufacturing has outperformed its peershellip
30
US has made substantial gains in competitiveness
35
Remarkable improvements
Due to productivity gains amp modest wage growthhellip
36
Remarkable improvements
Business sentiment in Europe remains weak while new orders have slowed
37
China amp Brazil have lost their edgehellip
38
Chinese wages have more than doubled over the past decade
Key industries
Loose credit and rising demand for autoshellip
36
hellipshould support productionhellip
20
25
30
35
40
45
50
405060708090
100110120130140150160
Jul-09 Jul-10 Jul-11 Jul-12 Jul-13 Jul-14
2010=100 US$ bn
Output (LHS)
Orders (RHS)
Source Oxford Economics Haver Analytics
US Output and orders
3 month moving average
37
hellipas will opportunities in the Emergers
38
Revamp of car stock to be key long-term driver
Ageing vehicle fleet replacement as economy recovers ndash average age of vehicle on US roads in 11frac12 years
Rising fuel efficiency standards leading to replacement of clunkers
Rising fuels costs resulting in smaller cars
Automakers likely to increase new models helping drive investment
Aerospace solid order books at the big twohellip
0
250
500
750
1000
1250
1500
1750
1994 1996 1998 2000 2002 2004 2006 2008 2010 2012 2014
Source Company reports
Airbus versus Boeing Orders
Airbus
Boeing
Number of aircraft
Note 2014 annual estimate based on annualized data through July
40
hellipwith APAC to drive long-term growth
Asia will account for almost 32 of global passenger traffic by 2017 compared to 28 in 2012
APAC to account for 40 of plane deliveries over next 20 years
US and Europe sales mainly for replacement of existing fleet
41
Need for efficiency will provide demand supporthellip
A330 revamped for 15 efficiency improvement to compete with Dreamliner 25 new orders on day of announcement
Long-haul efficiency has some ways to go to maintain airline profitability
42
Order backlogs remain high
0
500
1000
1500
2000
2500
3000
3500
1990 1993 1996 1999 2002 2005 2008 2011 2014
Deliveries
Orders
Number of aircraftAirbus amp Boeing Orders amp deliveries
Source Company reports and forecasts
43
Weaker demand for metalshellip
44
hellipand over capacity are weighing on priceshellip
45
hellipand discouraging investment
BHP Capital spending fell 32 in FY14 with another 8 fall expected next year
Rio Tinto Capital spending in FY14 cut faster than initially projected and further cut is budgeted for 2015
This is weighing on equipment makers
Caterpillar reported sales down 9 in the three months to July with sales to mining firms down 33 from the same period a year earlier
Bumper crop has brought down grain prices
47
helliphitting margins and investment
Producers are facing higher costs due to the implementation of Tier 4 engines developed to comply with emissions standards
Weaker margins are leading to farmers cutting back investment spending
John Deere has posted a 5 yy decline in revenues with an 11 decline in its agricultural division
Conclusions amp market implications
Conclusion and business implications
54
bull US economy expected to gradually accelerate through 2014 with support from a dovish Fed
bull Europe expected to recover but more ECB action could be required
bull Chinese economy is gradually rebalancing but banking crisis cannot be discounted
bull Emerging markets quiet for now but structural issue unsolved
bull Geopolitical tensions in the Middle East and Ukraine are being monitored carefully
Thank you
Gregory Daco
Chief US Economist gregorydacooxfordeconomicscom
September 2014
September 10 2014 2014 General Managersrsquo Meeting
Digital Manufacturing
World Class Shop Floor Management Release 5 The Smart Factory Revolution Mr Franz E Gruber Founder amp CEO
Dr Mohamed Abuali COO FORCAM Inc
MTConnect Evolution of a Standard and
Next Generation Interoperability Mr Courtney J Hill Chairman amp President
MTConnect Institute
QampA Session
World Class
Shop Floor Management
The Smart Factory Revolution
Franz E Gruber
Founder amp CEO
Mohamed Abuali
COO
汉语
World Class Shop Floor Management
FORCAM 2014 Page 2
FORCAMlsquos Passion
FORCAM provides proven
manufacturing solutions to
Continuously Improve Productivity
To be the global solutions provider of
the best-in-class Manufacturing
Execution Systems
FORCAM 2014 Page 3
FORCAM ndash 2014 Best Practices Award by Frost amp Sullivan
Frost amp Sullivan
ldquoFORCAM is a plant production software
solution provider that understands and
supports Industry 40 needsrdquo
FORCAM 2014 Page 4
FORCAMrsquos Testimonials and Industry Leadership
FORCAM 2014 Page 5
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
6 B Bartke S Wagner IPI-2
Shop Floor Management Audi - FORCAM FIT 2011-
Bernhard Bartke - Director Components Manufacturing
Stefan Wagner - Director Gear Manufacturing
7 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
bull Collection and recording of Operational Data via a database
(ex Machine States and State Changes)
Machine
Operator
Production Manager
Technical Assistant IT
Plant
Manager
Team Leader
8 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Interfaces
Time
Objectivity of Process Data
9 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Need for Continuous Improvement
bull Objective Information and Communication ndash across ALL levels
bull Transperancy and Visualization - Online
bull Real-time availability of operational data ndash Live Reports
bull Measurable increase in Plant Efficiency (OEE)
10 B Bartke S Wagner IPI-2
Shop Floor Management ndash Realtime bdquoANDONldquo Visualization
bull Web-based Interface Anywhere Anytime Access
bull Real-time Production Status Visualization
In Production
Overflow
Stoppage
Organizational
Stoppage
Idle (Pause)
Tool
Problem
11 B Bartke S Wagner IPI-2
Shop Floor Management Reporting ndash Hierarchical Status Diagrams
bull Reporting for Machines Groups Lines or the whole Plant
Technical
Stoppage In Production
Organizational
Stoppage Pause Overflow
Stoppage
Tool Problem In Setup
12 B Bartke S Wagner IPI-2
Audi Production System (APS)
Leadership Communication
bull Process Control
Standards
bull In Processes
bull Im Products
bull In the Organization
Learning Organization
bull Employee Development
bull Problem-Solving
bull CIP Culture
13 B Bartke S Wagner IPI-2
Shop Floor Management Process Control Panel on the shop floor
OEE Trend
(Day Week Month)
Measures
Quality
Process Control
14 B Bartke S Wagner IPI-2
OEE - Yesterday
Availability Trend
OEE ndash Last Week
OEE ndash Last Month
Naoki Nojiri IPI-25 BDE-Ist Stand 05042011
Shop Floor Management Process Control Panel on the shop floor
15 B Bartke S Wagner IPI-2
Shop Floor Management Management Cockpit
Planned vs Actual
(shift)
Top problems
(challenges)
OEE ndash Last Week
16 B Bartke S Wagner IPI-2
hellipand what have we achieved
17 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development suspension components (OEE Overall Equipment Effectiveness)
Radtraumlger
Start Shop Floor Management with
FORCAM +10
_
18 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development (20+ Increase in OEE in AUDI Stamping Facilities) (OEE Overall Equipment Effectiveness)
Radtraumlger
Start SFM +20
_
Our Beliefs
Respect
Collaboration
Excellence
Integrity
Community
Oct 30th 2013
Lean with Shop Floor Management BorgWarner Turbo Systems Rzeszow
Operator FactoryFrameworktrade Worker Client- Book On
Operator Downtime Reasons
Operator Actual versus Target Performance
TargetPlanned
Throughput
Actual
Performance
Opportunity for
Improvement
Actual
Throughput Machine
Data
ERP
Data
Supervisor Gantt Status
visualzation
Top 5
downtimes
Cip Top 5
Production
orders
Real data
history
Supervisor Cockpit machine
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
US manufacturing has outperformed its peershellip
30
US has made substantial gains in competitiveness
35
Remarkable improvements
Due to productivity gains amp modest wage growthhellip
36
Remarkable improvements
Business sentiment in Europe remains weak while new orders have slowed
37
China amp Brazil have lost their edgehellip
38
Chinese wages have more than doubled over the past decade
Key industries
Loose credit and rising demand for autoshellip
36
hellipshould support productionhellip
20
25
30
35
40
45
50
405060708090
100110120130140150160
Jul-09 Jul-10 Jul-11 Jul-12 Jul-13 Jul-14
2010=100 US$ bn
Output (LHS)
Orders (RHS)
Source Oxford Economics Haver Analytics
US Output and orders
3 month moving average
37
hellipas will opportunities in the Emergers
38
Revamp of car stock to be key long-term driver
Ageing vehicle fleet replacement as economy recovers ndash average age of vehicle on US roads in 11frac12 years
Rising fuel efficiency standards leading to replacement of clunkers
Rising fuels costs resulting in smaller cars
Automakers likely to increase new models helping drive investment
Aerospace solid order books at the big twohellip
0
250
500
750
1000
1250
1500
1750
1994 1996 1998 2000 2002 2004 2006 2008 2010 2012 2014
Source Company reports
Airbus versus Boeing Orders
Airbus
Boeing
Number of aircraft
Note 2014 annual estimate based on annualized data through July
40
hellipwith APAC to drive long-term growth
Asia will account for almost 32 of global passenger traffic by 2017 compared to 28 in 2012
APAC to account for 40 of plane deliveries over next 20 years
US and Europe sales mainly for replacement of existing fleet
41
Need for efficiency will provide demand supporthellip
A330 revamped for 15 efficiency improvement to compete with Dreamliner 25 new orders on day of announcement
Long-haul efficiency has some ways to go to maintain airline profitability
42
Order backlogs remain high
0
500
1000
1500
2000
2500
3000
3500
1990 1993 1996 1999 2002 2005 2008 2011 2014
Deliveries
Orders
Number of aircraftAirbus amp Boeing Orders amp deliveries
Source Company reports and forecasts
43
Weaker demand for metalshellip
44
hellipand over capacity are weighing on priceshellip
45
hellipand discouraging investment
BHP Capital spending fell 32 in FY14 with another 8 fall expected next year
Rio Tinto Capital spending in FY14 cut faster than initially projected and further cut is budgeted for 2015
This is weighing on equipment makers
Caterpillar reported sales down 9 in the three months to July with sales to mining firms down 33 from the same period a year earlier
Bumper crop has brought down grain prices
47
helliphitting margins and investment
Producers are facing higher costs due to the implementation of Tier 4 engines developed to comply with emissions standards
Weaker margins are leading to farmers cutting back investment spending
John Deere has posted a 5 yy decline in revenues with an 11 decline in its agricultural division
Conclusions amp market implications
Conclusion and business implications
54
bull US economy expected to gradually accelerate through 2014 with support from a dovish Fed
bull Europe expected to recover but more ECB action could be required
bull Chinese economy is gradually rebalancing but banking crisis cannot be discounted
bull Emerging markets quiet for now but structural issue unsolved
bull Geopolitical tensions in the Middle East and Ukraine are being monitored carefully
Thank you
Gregory Daco
Chief US Economist gregorydacooxfordeconomicscom
September 2014
September 10 2014 2014 General Managersrsquo Meeting
Digital Manufacturing
World Class Shop Floor Management Release 5 The Smart Factory Revolution Mr Franz E Gruber Founder amp CEO
Dr Mohamed Abuali COO FORCAM Inc
MTConnect Evolution of a Standard and
Next Generation Interoperability Mr Courtney J Hill Chairman amp President
MTConnect Institute
QampA Session
World Class
Shop Floor Management
The Smart Factory Revolution
Franz E Gruber
Founder amp CEO
Mohamed Abuali
COO
汉语
World Class Shop Floor Management
FORCAM 2014 Page 2
FORCAMlsquos Passion
FORCAM provides proven
manufacturing solutions to
Continuously Improve Productivity
To be the global solutions provider of
the best-in-class Manufacturing
Execution Systems
FORCAM 2014 Page 3
FORCAM ndash 2014 Best Practices Award by Frost amp Sullivan
Frost amp Sullivan
ldquoFORCAM is a plant production software
solution provider that understands and
supports Industry 40 needsrdquo
FORCAM 2014 Page 4
FORCAMrsquos Testimonials and Industry Leadership
FORCAM 2014 Page 5
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
6 B Bartke S Wagner IPI-2
Shop Floor Management Audi - FORCAM FIT 2011-
Bernhard Bartke - Director Components Manufacturing
Stefan Wagner - Director Gear Manufacturing
7 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
bull Collection and recording of Operational Data via a database
(ex Machine States and State Changes)
Machine
Operator
Production Manager
Technical Assistant IT
Plant
Manager
Team Leader
8 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Interfaces
Time
Objectivity of Process Data
9 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Need for Continuous Improvement
bull Objective Information and Communication ndash across ALL levels
bull Transperancy and Visualization - Online
bull Real-time availability of operational data ndash Live Reports
bull Measurable increase in Plant Efficiency (OEE)
10 B Bartke S Wagner IPI-2
Shop Floor Management ndash Realtime bdquoANDONldquo Visualization
bull Web-based Interface Anywhere Anytime Access
bull Real-time Production Status Visualization
In Production
Overflow
Stoppage
Organizational
Stoppage
Idle (Pause)
Tool
Problem
11 B Bartke S Wagner IPI-2
Shop Floor Management Reporting ndash Hierarchical Status Diagrams
bull Reporting for Machines Groups Lines or the whole Plant
Technical
Stoppage In Production
Organizational
Stoppage Pause Overflow
Stoppage
Tool Problem In Setup
12 B Bartke S Wagner IPI-2
Audi Production System (APS)
Leadership Communication
bull Process Control
Standards
bull In Processes
bull Im Products
bull In the Organization
Learning Organization
bull Employee Development
bull Problem-Solving
bull CIP Culture
13 B Bartke S Wagner IPI-2
Shop Floor Management Process Control Panel on the shop floor
OEE Trend
(Day Week Month)
Measures
Quality
Process Control
14 B Bartke S Wagner IPI-2
OEE - Yesterday
Availability Trend
OEE ndash Last Week
OEE ndash Last Month
Naoki Nojiri IPI-25 BDE-Ist Stand 05042011
Shop Floor Management Process Control Panel on the shop floor
15 B Bartke S Wagner IPI-2
Shop Floor Management Management Cockpit
Planned vs Actual
(shift)
Top problems
(challenges)
OEE ndash Last Week
16 B Bartke S Wagner IPI-2
hellipand what have we achieved
17 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development suspension components (OEE Overall Equipment Effectiveness)
Radtraumlger
Start Shop Floor Management with
FORCAM +10
_
18 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development (20+ Increase in OEE in AUDI Stamping Facilities) (OEE Overall Equipment Effectiveness)
Radtraumlger
Start SFM +20
_
Our Beliefs
Respect
Collaboration
Excellence
Integrity
Community
Oct 30th 2013
Lean with Shop Floor Management BorgWarner Turbo Systems Rzeszow
Operator FactoryFrameworktrade Worker Client- Book On
Operator Downtime Reasons
Operator Actual versus Target Performance
TargetPlanned
Throughput
Actual
Performance
Opportunity for
Improvement
Actual
Throughput Machine
Data
ERP
Data
Supervisor Gantt Status
visualzation
Top 5
downtimes
Cip Top 5
Production
orders
Real data
history
Supervisor Cockpit machine
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
US has made substantial gains in competitiveness
35
Remarkable improvements
Due to productivity gains amp modest wage growthhellip
36
Remarkable improvements
Business sentiment in Europe remains weak while new orders have slowed
37
China amp Brazil have lost their edgehellip
38
Chinese wages have more than doubled over the past decade
Key industries
Loose credit and rising demand for autoshellip
36
hellipshould support productionhellip
20
25
30
35
40
45
50
405060708090
100110120130140150160
Jul-09 Jul-10 Jul-11 Jul-12 Jul-13 Jul-14
2010=100 US$ bn
Output (LHS)
Orders (RHS)
Source Oxford Economics Haver Analytics
US Output and orders
3 month moving average
37
hellipas will opportunities in the Emergers
38
Revamp of car stock to be key long-term driver
Ageing vehicle fleet replacement as economy recovers ndash average age of vehicle on US roads in 11frac12 years
Rising fuel efficiency standards leading to replacement of clunkers
Rising fuels costs resulting in smaller cars
Automakers likely to increase new models helping drive investment
Aerospace solid order books at the big twohellip
0
250
500
750
1000
1250
1500
1750
1994 1996 1998 2000 2002 2004 2006 2008 2010 2012 2014
Source Company reports
Airbus versus Boeing Orders
Airbus
Boeing
Number of aircraft
Note 2014 annual estimate based on annualized data through July
40
hellipwith APAC to drive long-term growth
Asia will account for almost 32 of global passenger traffic by 2017 compared to 28 in 2012
APAC to account for 40 of plane deliveries over next 20 years
US and Europe sales mainly for replacement of existing fleet
41
Need for efficiency will provide demand supporthellip
A330 revamped for 15 efficiency improvement to compete with Dreamliner 25 new orders on day of announcement
Long-haul efficiency has some ways to go to maintain airline profitability
42
Order backlogs remain high
0
500
1000
1500
2000
2500
3000
3500
1990 1993 1996 1999 2002 2005 2008 2011 2014
Deliveries
Orders
Number of aircraftAirbus amp Boeing Orders amp deliveries
Source Company reports and forecasts
43
Weaker demand for metalshellip
44
hellipand over capacity are weighing on priceshellip
45
hellipand discouraging investment
BHP Capital spending fell 32 in FY14 with another 8 fall expected next year
Rio Tinto Capital spending in FY14 cut faster than initially projected and further cut is budgeted for 2015
This is weighing on equipment makers
Caterpillar reported sales down 9 in the three months to July with sales to mining firms down 33 from the same period a year earlier
Bumper crop has brought down grain prices
47
helliphitting margins and investment
Producers are facing higher costs due to the implementation of Tier 4 engines developed to comply with emissions standards
Weaker margins are leading to farmers cutting back investment spending
John Deere has posted a 5 yy decline in revenues with an 11 decline in its agricultural division
Conclusions amp market implications
Conclusion and business implications
54
bull US economy expected to gradually accelerate through 2014 with support from a dovish Fed
bull Europe expected to recover but more ECB action could be required
bull Chinese economy is gradually rebalancing but banking crisis cannot be discounted
bull Emerging markets quiet for now but structural issue unsolved
bull Geopolitical tensions in the Middle East and Ukraine are being monitored carefully
Thank you
Gregory Daco
Chief US Economist gregorydacooxfordeconomicscom
September 2014
September 10 2014 2014 General Managersrsquo Meeting
Digital Manufacturing
World Class Shop Floor Management Release 5 The Smart Factory Revolution Mr Franz E Gruber Founder amp CEO
Dr Mohamed Abuali COO FORCAM Inc
MTConnect Evolution of a Standard and
Next Generation Interoperability Mr Courtney J Hill Chairman amp President
MTConnect Institute
QampA Session
World Class
Shop Floor Management
The Smart Factory Revolution
Franz E Gruber
Founder amp CEO
Mohamed Abuali
COO
汉语
World Class Shop Floor Management
FORCAM 2014 Page 2
FORCAMlsquos Passion
FORCAM provides proven
manufacturing solutions to
Continuously Improve Productivity
To be the global solutions provider of
the best-in-class Manufacturing
Execution Systems
FORCAM 2014 Page 3
FORCAM ndash 2014 Best Practices Award by Frost amp Sullivan
Frost amp Sullivan
ldquoFORCAM is a plant production software
solution provider that understands and
supports Industry 40 needsrdquo
FORCAM 2014 Page 4
FORCAMrsquos Testimonials and Industry Leadership
FORCAM 2014 Page 5
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
6 B Bartke S Wagner IPI-2
Shop Floor Management Audi - FORCAM FIT 2011-
Bernhard Bartke - Director Components Manufacturing
Stefan Wagner - Director Gear Manufacturing
7 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
bull Collection and recording of Operational Data via a database
(ex Machine States and State Changes)
Machine
Operator
Production Manager
Technical Assistant IT
Plant
Manager
Team Leader
8 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Interfaces
Time
Objectivity of Process Data
9 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Need for Continuous Improvement
bull Objective Information and Communication ndash across ALL levels
bull Transperancy and Visualization - Online
bull Real-time availability of operational data ndash Live Reports
bull Measurable increase in Plant Efficiency (OEE)
10 B Bartke S Wagner IPI-2
Shop Floor Management ndash Realtime bdquoANDONldquo Visualization
bull Web-based Interface Anywhere Anytime Access
bull Real-time Production Status Visualization
In Production
Overflow
Stoppage
Organizational
Stoppage
Idle (Pause)
Tool
Problem
11 B Bartke S Wagner IPI-2
Shop Floor Management Reporting ndash Hierarchical Status Diagrams
bull Reporting for Machines Groups Lines or the whole Plant
Technical
Stoppage In Production
Organizational
Stoppage Pause Overflow
Stoppage
Tool Problem In Setup
12 B Bartke S Wagner IPI-2
Audi Production System (APS)
Leadership Communication
bull Process Control
Standards
bull In Processes
bull Im Products
bull In the Organization
Learning Organization
bull Employee Development
bull Problem-Solving
bull CIP Culture
13 B Bartke S Wagner IPI-2
Shop Floor Management Process Control Panel on the shop floor
OEE Trend
(Day Week Month)
Measures
Quality
Process Control
14 B Bartke S Wagner IPI-2
OEE - Yesterday
Availability Trend
OEE ndash Last Week
OEE ndash Last Month
Naoki Nojiri IPI-25 BDE-Ist Stand 05042011
Shop Floor Management Process Control Panel on the shop floor
15 B Bartke S Wagner IPI-2
Shop Floor Management Management Cockpit
Planned vs Actual
(shift)
Top problems
(challenges)
OEE ndash Last Week
16 B Bartke S Wagner IPI-2
hellipand what have we achieved
17 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development suspension components (OEE Overall Equipment Effectiveness)
Radtraumlger
Start Shop Floor Management with
FORCAM +10
_
18 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development (20+ Increase in OEE in AUDI Stamping Facilities) (OEE Overall Equipment Effectiveness)
Radtraumlger
Start SFM +20
_
Our Beliefs
Respect
Collaboration
Excellence
Integrity
Community
Oct 30th 2013
Lean with Shop Floor Management BorgWarner Turbo Systems Rzeszow
Operator FactoryFrameworktrade Worker Client- Book On
Operator Downtime Reasons
Operator Actual versus Target Performance
TargetPlanned
Throughput
Actual
Performance
Opportunity for
Improvement
Actual
Throughput Machine
Data
ERP
Data
Supervisor Gantt Status
visualzation
Top 5
downtimes
Cip Top 5
Production
orders
Real data
history
Supervisor Cockpit machine
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
Due to productivity gains amp modest wage growthhellip
36
Remarkable improvements
Business sentiment in Europe remains weak while new orders have slowed
37
China amp Brazil have lost their edgehellip
38
Chinese wages have more than doubled over the past decade
Key industries
Loose credit and rising demand for autoshellip
36
hellipshould support productionhellip
20
25
30
35
40
45
50
405060708090
100110120130140150160
Jul-09 Jul-10 Jul-11 Jul-12 Jul-13 Jul-14
2010=100 US$ bn
Output (LHS)
Orders (RHS)
Source Oxford Economics Haver Analytics
US Output and orders
3 month moving average
37
hellipas will opportunities in the Emergers
38
Revamp of car stock to be key long-term driver
Ageing vehicle fleet replacement as economy recovers ndash average age of vehicle on US roads in 11frac12 years
Rising fuel efficiency standards leading to replacement of clunkers
Rising fuels costs resulting in smaller cars
Automakers likely to increase new models helping drive investment
Aerospace solid order books at the big twohellip
0
250
500
750
1000
1250
1500
1750
1994 1996 1998 2000 2002 2004 2006 2008 2010 2012 2014
Source Company reports
Airbus versus Boeing Orders
Airbus
Boeing
Number of aircraft
Note 2014 annual estimate based on annualized data through July
40
hellipwith APAC to drive long-term growth
Asia will account for almost 32 of global passenger traffic by 2017 compared to 28 in 2012
APAC to account for 40 of plane deliveries over next 20 years
US and Europe sales mainly for replacement of existing fleet
41
Need for efficiency will provide demand supporthellip
A330 revamped for 15 efficiency improvement to compete with Dreamliner 25 new orders on day of announcement
Long-haul efficiency has some ways to go to maintain airline profitability
42
Order backlogs remain high
0
500
1000
1500
2000
2500
3000
3500
1990 1993 1996 1999 2002 2005 2008 2011 2014
Deliveries
Orders
Number of aircraftAirbus amp Boeing Orders amp deliveries
Source Company reports and forecasts
43
Weaker demand for metalshellip
44
hellipand over capacity are weighing on priceshellip
45
hellipand discouraging investment
BHP Capital spending fell 32 in FY14 with another 8 fall expected next year
Rio Tinto Capital spending in FY14 cut faster than initially projected and further cut is budgeted for 2015
This is weighing on equipment makers
Caterpillar reported sales down 9 in the three months to July with sales to mining firms down 33 from the same period a year earlier
Bumper crop has brought down grain prices
47
helliphitting margins and investment
Producers are facing higher costs due to the implementation of Tier 4 engines developed to comply with emissions standards
Weaker margins are leading to farmers cutting back investment spending
John Deere has posted a 5 yy decline in revenues with an 11 decline in its agricultural division
Conclusions amp market implications
Conclusion and business implications
54
bull US economy expected to gradually accelerate through 2014 with support from a dovish Fed
bull Europe expected to recover but more ECB action could be required
bull Chinese economy is gradually rebalancing but banking crisis cannot be discounted
bull Emerging markets quiet for now but structural issue unsolved
bull Geopolitical tensions in the Middle East and Ukraine are being monitored carefully
Thank you
Gregory Daco
Chief US Economist gregorydacooxfordeconomicscom
September 2014
September 10 2014 2014 General Managersrsquo Meeting
Digital Manufacturing
World Class Shop Floor Management Release 5 The Smart Factory Revolution Mr Franz E Gruber Founder amp CEO
Dr Mohamed Abuali COO FORCAM Inc
MTConnect Evolution of a Standard and
Next Generation Interoperability Mr Courtney J Hill Chairman amp President
MTConnect Institute
QampA Session
World Class
Shop Floor Management
The Smart Factory Revolution
Franz E Gruber
Founder amp CEO
Mohamed Abuali
COO
汉语
World Class Shop Floor Management
FORCAM 2014 Page 2
FORCAMlsquos Passion
FORCAM provides proven
manufacturing solutions to
Continuously Improve Productivity
To be the global solutions provider of
the best-in-class Manufacturing
Execution Systems
FORCAM 2014 Page 3
FORCAM ndash 2014 Best Practices Award by Frost amp Sullivan
Frost amp Sullivan
ldquoFORCAM is a plant production software
solution provider that understands and
supports Industry 40 needsrdquo
FORCAM 2014 Page 4
FORCAMrsquos Testimonials and Industry Leadership
FORCAM 2014 Page 5
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
6 B Bartke S Wagner IPI-2
Shop Floor Management Audi - FORCAM FIT 2011-
Bernhard Bartke - Director Components Manufacturing
Stefan Wagner - Director Gear Manufacturing
7 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
bull Collection and recording of Operational Data via a database
(ex Machine States and State Changes)
Machine
Operator
Production Manager
Technical Assistant IT
Plant
Manager
Team Leader
8 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Interfaces
Time
Objectivity of Process Data
9 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Need for Continuous Improvement
bull Objective Information and Communication ndash across ALL levels
bull Transperancy and Visualization - Online
bull Real-time availability of operational data ndash Live Reports
bull Measurable increase in Plant Efficiency (OEE)
10 B Bartke S Wagner IPI-2
Shop Floor Management ndash Realtime bdquoANDONldquo Visualization
bull Web-based Interface Anywhere Anytime Access
bull Real-time Production Status Visualization
In Production
Overflow
Stoppage
Organizational
Stoppage
Idle (Pause)
Tool
Problem
11 B Bartke S Wagner IPI-2
Shop Floor Management Reporting ndash Hierarchical Status Diagrams
bull Reporting for Machines Groups Lines or the whole Plant
Technical
Stoppage In Production
Organizational
Stoppage Pause Overflow
Stoppage
Tool Problem In Setup
12 B Bartke S Wagner IPI-2
Audi Production System (APS)
Leadership Communication
bull Process Control
Standards
bull In Processes
bull Im Products
bull In the Organization
Learning Organization
bull Employee Development
bull Problem-Solving
bull CIP Culture
13 B Bartke S Wagner IPI-2
Shop Floor Management Process Control Panel on the shop floor
OEE Trend
(Day Week Month)
Measures
Quality
Process Control
14 B Bartke S Wagner IPI-2
OEE - Yesterday
Availability Trend
OEE ndash Last Week
OEE ndash Last Month
Naoki Nojiri IPI-25 BDE-Ist Stand 05042011
Shop Floor Management Process Control Panel on the shop floor
15 B Bartke S Wagner IPI-2
Shop Floor Management Management Cockpit
Planned vs Actual
(shift)
Top problems
(challenges)
OEE ndash Last Week
16 B Bartke S Wagner IPI-2
hellipand what have we achieved
17 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development suspension components (OEE Overall Equipment Effectiveness)
Radtraumlger
Start Shop Floor Management with
FORCAM +10
_
18 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development (20+ Increase in OEE in AUDI Stamping Facilities) (OEE Overall Equipment Effectiveness)
Radtraumlger
Start SFM +20
_
Our Beliefs
Respect
Collaboration
Excellence
Integrity
Community
Oct 30th 2013
Lean with Shop Floor Management BorgWarner Turbo Systems Rzeszow
Operator FactoryFrameworktrade Worker Client- Book On
Operator Downtime Reasons
Operator Actual versus Target Performance
TargetPlanned
Throughput
Actual
Performance
Opportunity for
Improvement
Actual
Throughput Machine
Data
ERP
Data
Supervisor Gantt Status
visualzation
Top 5
downtimes
Cip Top 5
Production
orders
Real data
history
Supervisor Cockpit machine
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
Business sentiment in Europe remains weak while new orders have slowed
37
China amp Brazil have lost their edgehellip
38
Chinese wages have more than doubled over the past decade
Key industries
Loose credit and rising demand for autoshellip
36
hellipshould support productionhellip
20
25
30
35
40
45
50
405060708090
100110120130140150160
Jul-09 Jul-10 Jul-11 Jul-12 Jul-13 Jul-14
2010=100 US$ bn
Output (LHS)
Orders (RHS)
Source Oxford Economics Haver Analytics
US Output and orders
3 month moving average
37
hellipas will opportunities in the Emergers
38
Revamp of car stock to be key long-term driver
Ageing vehicle fleet replacement as economy recovers ndash average age of vehicle on US roads in 11frac12 years
Rising fuel efficiency standards leading to replacement of clunkers
Rising fuels costs resulting in smaller cars
Automakers likely to increase new models helping drive investment
Aerospace solid order books at the big twohellip
0
250
500
750
1000
1250
1500
1750
1994 1996 1998 2000 2002 2004 2006 2008 2010 2012 2014
Source Company reports
Airbus versus Boeing Orders
Airbus
Boeing
Number of aircraft
Note 2014 annual estimate based on annualized data through July
40
hellipwith APAC to drive long-term growth
Asia will account for almost 32 of global passenger traffic by 2017 compared to 28 in 2012
APAC to account for 40 of plane deliveries over next 20 years
US and Europe sales mainly for replacement of existing fleet
41
Need for efficiency will provide demand supporthellip
A330 revamped for 15 efficiency improvement to compete with Dreamliner 25 new orders on day of announcement
Long-haul efficiency has some ways to go to maintain airline profitability
42
Order backlogs remain high
0
500
1000
1500
2000
2500
3000
3500
1990 1993 1996 1999 2002 2005 2008 2011 2014
Deliveries
Orders
Number of aircraftAirbus amp Boeing Orders amp deliveries
Source Company reports and forecasts
43
Weaker demand for metalshellip
44
hellipand over capacity are weighing on priceshellip
45
hellipand discouraging investment
BHP Capital spending fell 32 in FY14 with another 8 fall expected next year
Rio Tinto Capital spending in FY14 cut faster than initially projected and further cut is budgeted for 2015
This is weighing on equipment makers
Caterpillar reported sales down 9 in the three months to July with sales to mining firms down 33 from the same period a year earlier
Bumper crop has brought down grain prices
47
helliphitting margins and investment
Producers are facing higher costs due to the implementation of Tier 4 engines developed to comply with emissions standards
Weaker margins are leading to farmers cutting back investment spending
John Deere has posted a 5 yy decline in revenues with an 11 decline in its agricultural division
Conclusions amp market implications
Conclusion and business implications
54
bull US economy expected to gradually accelerate through 2014 with support from a dovish Fed
bull Europe expected to recover but more ECB action could be required
bull Chinese economy is gradually rebalancing but banking crisis cannot be discounted
bull Emerging markets quiet for now but structural issue unsolved
bull Geopolitical tensions in the Middle East and Ukraine are being monitored carefully
Thank you
Gregory Daco
Chief US Economist gregorydacooxfordeconomicscom
September 2014
September 10 2014 2014 General Managersrsquo Meeting
Digital Manufacturing
World Class Shop Floor Management Release 5 The Smart Factory Revolution Mr Franz E Gruber Founder amp CEO
Dr Mohamed Abuali COO FORCAM Inc
MTConnect Evolution of a Standard and
Next Generation Interoperability Mr Courtney J Hill Chairman amp President
MTConnect Institute
QampA Session
World Class
Shop Floor Management
The Smart Factory Revolution
Franz E Gruber
Founder amp CEO
Mohamed Abuali
COO
汉语
World Class Shop Floor Management
FORCAM 2014 Page 2
FORCAMlsquos Passion
FORCAM provides proven
manufacturing solutions to
Continuously Improve Productivity
To be the global solutions provider of
the best-in-class Manufacturing
Execution Systems
FORCAM 2014 Page 3
FORCAM ndash 2014 Best Practices Award by Frost amp Sullivan
Frost amp Sullivan
ldquoFORCAM is a plant production software
solution provider that understands and
supports Industry 40 needsrdquo
FORCAM 2014 Page 4
FORCAMrsquos Testimonials and Industry Leadership
FORCAM 2014 Page 5
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
6 B Bartke S Wagner IPI-2
Shop Floor Management Audi - FORCAM FIT 2011-
Bernhard Bartke - Director Components Manufacturing
Stefan Wagner - Director Gear Manufacturing
7 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
bull Collection and recording of Operational Data via a database
(ex Machine States and State Changes)
Machine
Operator
Production Manager
Technical Assistant IT
Plant
Manager
Team Leader
8 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Interfaces
Time
Objectivity of Process Data
9 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Need for Continuous Improvement
bull Objective Information and Communication ndash across ALL levels
bull Transperancy and Visualization - Online
bull Real-time availability of operational data ndash Live Reports
bull Measurable increase in Plant Efficiency (OEE)
10 B Bartke S Wagner IPI-2
Shop Floor Management ndash Realtime bdquoANDONldquo Visualization
bull Web-based Interface Anywhere Anytime Access
bull Real-time Production Status Visualization
In Production
Overflow
Stoppage
Organizational
Stoppage
Idle (Pause)
Tool
Problem
11 B Bartke S Wagner IPI-2
Shop Floor Management Reporting ndash Hierarchical Status Diagrams
bull Reporting for Machines Groups Lines or the whole Plant
Technical
Stoppage In Production
Organizational
Stoppage Pause Overflow
Stoppage
Tool Problem In Setup
12 B Bartke S Wagner IPI-2
Audi Production System (APS)
Leadership Communication
bull Process Control
Standards
bull In Processes
bull Im Products
bull In the Organization
Learning Organization
bull Employee Development
bull Problem-Solving
bull CIP Culture
13 B Bartke S Wagner IPI-2
Shop Floor Management Process Control Panel on the shop floor
OEE Trend
(Day Week Month)
Measures
Quality
Process Control
14 B Bartke S Wagner IPI-2
OEE - Yesterday
Availability Trend
OEE ndash Last Week
OEE ndash Last Month
Naoki Nojiri IPI-25 BDE-Ist Stand 05042011
Shop Floor Management Process Control Panel on the shop floor
15 B Bartke S Wagner IPI-2
Shop Floor Management Management Cockpit
Planned vs Actual
(shift)
Top problems
(challenges)
OEE ndash Last Week
16 B Bartke S Wagner IPI-2
hellipand what have we achieved
17 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development suspension components (OEE Overall Equipment Effectiveness)
Radtraumlger
Start Shop Floor Management with
FORCAM +10
_
18 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development (20+ Increase in OEE in AUDI Stamping Facilities) (OEE Overall Equipment Effectiveness)
Radtraumlger
Start SFM +20
_
Our Beliefs
Respect
Collaboration
Excellence
Integrity
Community
Oct 30th 2013
Lean with Shop Floor Management BorgWarner Turbo Systems Rzeszow
Operator FactoryFrameworktrade Worker Client- Book On
Operator Downtime Reasons
Operator Actual versus Target Performance
TargetPlanned
Throughput
Actual
Performance
Opportunity for
Improvement
Actual
Throughput Machine
Data
ERP
Data
Supervisor Gantt Status
visualzation
Top 5
downtimes
Cip Top 5
Production
orders
Real data
history
Supervisor Cockpit machine
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
China amp Brazil have lost their edgehellip
38
Chinese wages have more than doubled over the past decade
Key industries
Loose credit and rising demand for autoshellip
36
hellipshould support productionhellip
20
25
30
35
40
45
50
405060708090
100110120130140150160
Jul-09 Jul-10 Jul-11 Jul-12 Jul-13 Jul-14
2010=100 US$ bn
Output (LHS)
Orders (RHS)
Source Oxford Economics Haver Analytics
US Output and orders
3 month moving average
37
hellipas will opportunities in the Emergers
38
Revamp of car stock to be key long-term driver
Ageing vehicle fleet replacement as economy recovers ndash average age of vehicle on US roads in 11frac12 years
Rising fuel efficiency standards leading to replacement of clunkers
Rising fuels costs resulting in smaller cars
Automakers likely to increase new models helping drive investment
Aerospace solid order books at the big twohellip
0
250
500
750
1000
1250
1500
1750
1994 1996 1998 2000 2002 2004 2006 2008 2010 2012 2014
Source Company reports
Airbus versus Boeing Orders
Airbus
Boeing
Number of aircraft
Note 2014 annual estimate based on annualized data through July
40
hellipwith APAC to drive long-term growth
Asia will account for almost 32 of global passenger traffic by 2017 compared to 28 in 2012
APAC to account for 40 of plane deliveries over next 20 years
US and Europe sales mainly for replacement of existing fleet
41
Need for efficiency will provide demand supporthellip
A330 revamped for 15 efficiency improvement to compete with Dreamliner 25 new orders on day of announcement
Long-haul efficiency has some ways to go to maintain airline profitability
42
Order backlogs remain high
0
500
1000
1500
2000
2500
3000
3500
1990 1993 1996 1999 2002 2005 2008 2011 2014
Deliveries
Orders
Number of aircraftAirbus amp Boeing Orders amp deliveries
Source Company reports and forecasts
43
Weaker demand for metalshellip
44
hellipand over capacity are weighing on priceshellip
45
hellipand discouraging investment
BHP Capital spending fell 32 in FY14 with another 8 fall expected next year
Rio Tinto Capital spending in FY14 cut faster than initially projected and further cut is budgeted for 2015
This is weighing on equipment makers
Caterpillar reported sales down 9 in the three months to July with sales to mining firms down 33 from the same period a year earlier
Bumper crop has brought down grain prices
47
helliphitting margins and investment
Producers are facing higher costs due to the implementation of Tier 4 engines developed to comply with emissions standards
Weaker margins are leading to farmers cutting back investment spending
John Deere has posted a 5 yy decline in revenues with an 11 decline in its agricultural division
Conclusions amp market implications
Conclusion and business implications
54
bull US economy expected to gradually accelerate through 2014 with support from a dovish Fed
bull Europe expected to recover but more ECB action could be required
bull Chinese economy is gradually rebalancing but banking crisis cannot be discounted
bull Emerging markets quiet for now but structural issue unsolved
bull Geopolitical tensions in the Middle East and Ukraine are being monitored carefully
Thank you
Gregory Daco
Chief US Economist gregorydacooxfordeconomicscom
September 2014
September 10 2014 2014 General Managersrsquo Meeting
Digital Manufacturing
World Class Shop Floor Management Release 5 The Smart Factory Revolution Mr Franz E Gruber Founder amp CEO
Dr Mohamed Abuali COO FORCAM Inc
MTConnect Evolution of a Standard and
Next Generation Interoperability Mr Courtney J Hill Chairman amp President
MTConnect Institute
QampA Session
World Class
Shop Floor Management
The Smart Factory Revolution
Franz E Gruber
Founder amp CEO
Mohamed Abuali
COO
汉语
World Class Shop Floor Management
FORCAM 2014 Page 2
FORCAMlsquos Passion
FORCAM provides proven
manufacturing solutions to
Continuously Improve Productivity
To be the global solutions provider of
the best-in-class Manufacturing
Execution Systems
FORCAM 2014 Page 3
FORCAM ndash 2014 Best Practices Award by Frost amp Sullivan
Frost amp Sullivan
ldquoFORCAM is a plant production software
solution provider that understands and
supports Industry 40 needsrdquo
FORCAM 2014 Page 4
FORCAMrsquos Testimonials and Industry Leadership
FORCAM 2014 Page 5
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
6 B Bartke S Wagner IPI-2
Shop Floor Management Audi - FORCAM FIT 2011-
Bernhard Bartke - Director Components Manufacturing
Stefan Wagner - Director Gear Manufacturing
7 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
bull Collection and recording of Operational Data via a database
(ex Machine States and State Changes)
Machine
Operator
Production Manager
Technical Assistant IT
Plant
Manager
Team Leader
8 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Interfaces
Time
Objectivity of Process Data
9 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Need for Continuous Improvement
bull Objective Information and Communication ndash across ALL levels
bull Transperancy and Visualization - Online
bull Real-time availability of operational data ndash Live Reports
bull Measurable increase in Plant Efficiency (OEE)
10 B Bartke S Wagner IPI-2
Shop Floor Management ndash Realtime bdquoANDONldquo Visualization
bull Web-based Interface Anywhere Anytime Access
bull Real-time Production Status Visualization
In Production
Overflow
Stoppage
Organizational
Stoppage
Idle (Pause)
Tool
Problem
11 B Bartke S Wagner IPI-2
Shop Floor Management Reporting ndash Hierarchical Status Diagrams
bull Reporting for Machines Groups Lines or the whole Plant
Technical
Stoppage In Production
Organizational
Stoppage Pause Overflow
Stoppage
Tool Problem In Setup
12 B Bartke S Wagner IPI-2
Audi Production System (APS)
Leadership Communication
bull Process Control
Standards
bull In Processes
bull Im Products
bull In the Organization
Learning Organization
bull Employee Development
bull Problem-Solving
bull CIP Culture
13 B Bartke S Wagner IPI-2
Shop Floor Management Process Control Panel on the shop floor
OEE Trend
(Day Week Month)
Measures
Quality
Process Control
14 B Bartke S Wagner IPI-2
OEE - Yesterday
Availability Trend
OEE ndash Last Week
OEE ndash Last Month
Naoki Nojiri IPI-25 BDE-Ist Stand 05042011
Shop Floor Management Process Control Panel on the shop floor
15 B Bartke S Wagner IPI-2
Shop Floor Management Management Cockpit
Planned vs Actual
(shift)
Top problems
(challenges)
OEE ndash Last Week
16 B Bartke S Wagner IPI-2
hellipand what have we achieved
17 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development suspension components (OEE Overall Equipment Effectiveness)
Radtraumlger
Start Shop Floor Management with
FORCAM +10
_
18 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development (20+ Increase in OEE in AUDI Stamping Facilities) (OEE Overall Equipment Effectiveness)
Radtraumlger
Start SFM +20
_
Our Beliefs
Respect
Collaboration
Excellence
Integrity
Community
Oct 30th 2013
Lean with Shop Floor Management BorgWarner Turbo Systems Rzeszow
Operator FactoryFrameworktrade Worker Client- Book On
Operator Downtime Reasons
Operator Actual versus Target Performance
TargetPlanned
Throughput
Actual
Performance
Opportunity for
Improvement
Actual
Throughput Machine
Data
ERP
Data
Supervisor Gantt Status
visualzation
Top 5
downtimes
Cip Top 5
Production
orders
Real data
history
Supervisor Cockpit machine
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
Key industries
Loose credit and rising demand for autoshellip
36
hellipshould support productionhellip
20
25
30
35
40
45
50
405060708090
100110120130140150160
Jul-09 Jul-10 Jul-11 Jul-12 Jul-13 Jul-14
2010=100 US$ bn
Output (LHS)
Orders (RHS)
Source Oxford Economics Haver Analytics
US Output and orders
3 month moving average
37
hellipas will opportunities in the Emergers
38
Revamp of car stock to be key long-term driver
Ageing vehicle fleet replacement as economy recovers ndash average age of vehicle on US roads in 11frac12 years
Rising fuel efficiency standards leading to replacement of clunkers
Rising fuels costs resulting in smaller cars
Automakers likely to increase new models helping drive investment
Aerospace solid order books at the big twohellip
0
250
500
750
1000
1250
1500
1750
1994 1996 1998 2000 2002 2004 2006 2008 2010 2012 2014
Source Company reports
Airbus versus Boeing Orders
Airbus
Boeing
Number of aircraft
Note 2014 annual estimate based on annualized data through July
40
hellipwith APAC to drive long-term growth
Asia will account for almost 32 of global passenger traffic by 2017 compared to 28 in 2012
APAC to account for 40 of plane deliveries over next 20 years
US and Europe sales mainly for replacement of existing fleet
41
Need for efficiency will provide demand supporthellip
A330 revamped for 15 efficiency improvement to compete with Dreamliner 25 new orders on day of announcement
Long-haul efficiency has some ways to go to maintain airline profitability
42
Order backlogs remain high
0
500
1000
1500
2000
2500
3000
3500
1990 1993 1996 1999 2002 2005 2008 2011 2014
Deliveries
Orders
Number of aircraftAirbus amp Boeing Orders amp deliveries
Source Company reports and forecasts
43
Weaker demand for metalshellip
44
hellipand over capacity are weighing on priceshellip
45
hellipand discouraging investment
BHP Capital spending fell 32 in FY14 with another 8 fall expected next year
Rio Tinto Capital spending in FY14 cut faster than initially projected and further cut is budgeted for 2015
This is weighing on equipment makers
Caterpillar reported sales down 9 in the three months to July with sales to mining firms down 33 from the same period a year earlier
Bumper crop has brought down grain prices
47
helliphitting margins and investment
Producers are facing higher costs due to the implementation of Tier 4 engines developed to comply with emissions standards
Weaker margins are leading to farmers cutting back investment spending
John Deere has posted a 5 yy decline in revenues with an 11 decline in its agricultural division
Conclusions amp market implications
Conclusion and business implications
54
bull US economy expected to gradually accelerate through 2014 with support from a dovish Fed
bull Europe expected to recover but more ECB action could be required
bull Chinese economy is gradually rebalancing but banking crisis cannot be discounted
bull Emerging markets quiet for now but structural issue unsolved
bull Geopolitical tensions in the Middle East and Ukraine are being monitored carefully
Thank you
Gregory Daco
Chief US Economist gregorydacooxfordeconomicscom
September 2014
September 10 2014 2014 General Managersrsquo Meeting
Digital Manufacturing
World Class Shop Floor Management Release 5 The Smart Factory Revolution Mr Franz E Gruber Founder amp CEO
Dr Mohamed Abuali COO FORCAM Inc
MTConnect Evolution of a Standard and
Next Generation Interoperability Mr Courtney J Hill Chairman amp President
MTConnect Institute
QampA Session
World Class
Shop Floor Management
The Smart Factory Revolution
Franz E Gruber
Founder amp CEO
Mohamed Abuali
COO
汉语
World Class Shop Floor Management
FORCAM 2014 Page 2
FORCAMlsquos Passion
FORCAM provides proven
manufacturing solutions to
Continuously Improve Productivity
To be the global solutions provider of
the best-in-class Manufacturing
Execution Systems
FORCAM 2014 Page 3
FORCAM ndash 2014 Best Practices Award by Frost amp Sullivan
Frost amp Sullivan
ldquoFORCAM is a plant production software
solution provider that understands and
supports Industry 40 needsrdquo
FORCAM 2014 Page 4
FORCAMrsquos Testimonials and Industry Leadership
FORCAM 2014 Page 5
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
6 B Bartke S Wagner IPI-2
Shop Floor Management Audi - FORCAM FIT 2011-
Bernhard Bartke - Director Components Manufacturing
Stefan Wagner - Director Gear Manufacturing
7 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
bull Collection and recording of Operational Data via a database
(ex Machine States and State Changes)
Machine
Operator
Production Manager
Technical Assistant IT
Plant
Manager
Team Leader
8 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Interfaces
Time
Objectivity of Process Data
9 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Need for Continuous Improvement
bull Objective Information and Communication ndash across ALL levels
bull Transperancy and Visualization - Online
bull Real-time availability of operational data ndash Live Reports
bull Measurable increase in Plant Efficiency (OEE)
10 B Bartke S Wagner IPI-2
Shop Floor Management ndash Realtime bdquoANDONldquo Visualization
bull Web-based Interface Anywhere Anytime Access
bull Real-time Production Status Visualization
In Production
Overflow
Stoppage
Organizational
Stoppage
Idle (Pause)
Tool
Problem
11 B Bartke S Wagner IPI-2
Shop Floor Management Reporting ndash Hierarchical Status Diagrams
bull Reporting for Machines Groups Lines or the whole Plant
Technical
Stoppage In Production
Organizational
Stoppage Pause Overflow
Stoppage
Tool Problem In Setup
12 B Bartke S Wagner IPI-2
Audi Production System (APS)
Leadership Communication
bull Process Control
Standards
bull In Processes
bull Im Products
bull In the Organization
Learning Organization
bull Employee Development
bull Problem-Solving
bull CIP Culture
13 B Bartke S Wagner IPI-2
Shop Floor Management Process Control Panel on the shop floor
OEE Trend
(Day Week Month)
Measures
Quality
Process Control
14 B Bartke S Wagner IPI-2
OEE - Yesterday
Availability Trend
OEE ndash Last Week
OEE ndash Last Month
Naoki Nojiri IPI-25 BDE-Ist Stand 05042011
Shop Floor Management Process Control Panel on the shop floor
15 B Bartke S Wagner IPI-2
Shop Floor Management Management Cockpit
Planned vs Actual
(shift)
Top problems
(challenges)
OEE ndash Last Week
16 B Bartke S Wagner IPI-2
hellipand what have we achieved
17 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development suspension components (OEE Overall Equipment Effectiveness)
Radtraumlger
Start Shop Floor Management with
FORCAM +10
_
18 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development (20+ Increase in OEE in AUDI Stamping Facilities) (OEE Overall Equipment Effectiveness)
Radtraumlger
Start SFM +20
_
Our Beliefs
Respect
Collaboration
Excellence
Integrity
Community
Oct 30th 2013
Lean with Shop Floor Management BorgWarner Turbo Systems Rzeszow
Operator FactoryFrameworktrade Worker Client- Book On
Operator Downtime Reasons
Operator Actual versus Target Performance
TargetPlanned
Throughput
Actual
Performance
Opportunity for
Improvement
Actual
Throughput Machine
Data
ERP
Data
Supervisor Gantt Status
visualzation
Top 5
downtimes
Cip Top 5
Production
orders
Real data
history
Supervisor Cockpit machine
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
Loose credit and rising demand for autoshellip
36
hellipshould support productionhellip
20
25
30
35
40
45
50
405060708090
100110120130140150160
Jul-09 Jul-10 Jul-11 Jul-12 Jul-13 Jul-14
2010=100 US$ bn
Output (LHS)
Orders (RHS)
Source Oxford Economics Haver Analytics
US Output and orders
3 month moving average
37
hellipas will opportunities in the Emergers
38
Revamp of car stock to be key long-term driver
Ageing vehicle fleet replacement as economy recovers ndash average age of vehicle on US roads in 11frac12 years
Rising fuel efficiency standards leading to replacement of clunkers
Rising fuels costs resulting in smaller cars
Automakers likely to increase new models helping drive investment
Aerospace solid order books at the big twohellip
0
250
500
750
1000
1250
1500
1750
1994 1996 1998 2000 2002 2004 2006 2008 2010 2012 2014
Source Company reports
Airbus versus Boeing Orders
Airbus
Boeing
Number of aircraft
Note 2014 annual estimate based on annualized data through July
40
hellipwith APAC to drive long-term growth
Asia will account for almost 32 of global passenger traffic by 2017 compared to 28 in 2012
APAC to account for 40 of plane deliveries over next 20 years
US and Europe sales mainly for replacement of existing fleet
41
Need for efficiency will provide demand supporthellip
A330 revamped for 15 efficiency improvement to compete with Dreamliner 25 new orders on day of announcement
Long-haul efficiency has some ways to go to maintain airline profitability
42
Order backlogs remain high
0
500
1000
1500
2000
2500
3000
3500
1990 1993 1996 1999 2002 2005 2008 2011 2014
Deliveries
Orders
Number of aircraftAirbus amp Boeing Orders amp deliveries
Source Company reports and forecasts
43
Weaker demand for metalshellip
44
hellipand over capacity are weighing on priceshellip
45
hellipand discouraging investment
BHP Capital spending fell 32 in FY14 with another 8 fall expected next year
Rio Tinto Capital spending in FY14 cut faster than initially projected and further cut is budgeted for 2015
This is weighing on equipment makers
Caterpillar reported sales down 9 in the three months to July with sales to mining firms down 33 from the same period a year earlier
Bumper crop has brought down grain prices
47
helliphitting margins and investment
Producers are facing higher costs due to the implementation of Tier 4 engines developed to comply with emissions standards
Weaker margins are leading to farmers cutting back investment spending
John Deere has posted a 5 yy decline in revenues with an 11 decline in its agricultural division
Conclusions amp market implications
Conclusion and business implications
54
bull US economy expected to gradually accelerate through 2014 with support from a dovish Fed
bull Europe expected to recover but more ECB action could be required
bull Chinese economy is gradually rebalancing but banking crisis cannot be discounted
bull Emerging markets quiet for now but structural issue unsolved
bull Geopolitical tensions in the Middle East and Ukraine are being monitored carefully
Thank you
Gregory Daco
Chief US Economist gregorydacooxfordeconomicscom
September 2014
September 10 2014 2014 General Managersrsquo Meeting
Digital Manufacturing
World Class Shop Floor Management Release 5 The Smart Factory Revolution Mr Franz E Gruber Founder amp CEO
Dr Mohamed Abuali COO FORCAM Inc
MTConnect Evolution of a Standard and
Next Generation Interoperability Mr Courtney J Hill Chairman amp President
MTConnect Institute
QampA Session
World Class
Shop Floor Management
The Smart Factory Revolution
Franz E Gruber
Founder amp CEO
Mohamed Abuali
COO
汉语
World Class Shop Floor Management
FORCAM 2014 Page 2
FORCAMlsquos Passion
FORCAM provides proven
manufacturing solutions to
Continuously Improve Productivity
To be the global solutions provider of
the best-in-class Manufacturing
Execution Systems
FORCAM 2014 Page 3
FORCAM ndash 2014 Best Practices Award by Frost amp Sullivan
Frost amp Sullivan
ldquoFORCAM is a plant production software
solution provider that understands and
supports Industry 40 needsrdquo
FORCAM 2014 Page 4
FORCAMrsquos Testimonials and Industry Leadership
FORCAM 2014 Page 5
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
6 B Bartke S Wagner IPI-2
Shop Floor Management Audi - FORCAM FIT 2011-
Bernhard Bartke - Director Components Manufacturing
Stefan Wagner - Director Gear Manufacturing
7 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
bull Collection and recording of Operational Data via a database
(ex Machine States and State Changes)
Machine
Operator
Production Manager
Technical Assistant IT
Plant
Manager
Team Leader
8 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Interfaces
Time
Objectivity of Process Data
9 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Need for Continuous Improvement
bull Objective Information and Communication ndash across ALL levels
bull Transperancy and Visualization - Online
bull Real-time availability of operational data ndash Live Reports
bull Measurable increase in Plant Efficiency (OEE)
10 B Bartke S Wagner IPI-2
Shop Floor Management ndash Realtime bdquoANDONldquo Visualization
bull Web-based Interface Anywhere Anytime Access
bull Real-time Production Status Visualization
In Production
Overflow
Stoppage
Organizational
Stoppage
Idle (Pause)
Tool
Problem
11 B Bartke S Wagner IPI-2
Shop Floor Management Reporting ndash Hierarchical Status Diagrams
bull Reporting for Machines Groups Lines or the whole Plant
Technical
Stoppage In Production
Organizational
Stoppage Pause Overflow
Stoppage
Tool Problem In Setup
12 B Bartke S Wagner IPI-2
Audi Production System (APS)
Leadership Communication
bull Process Control
Standards
bull In Processes
bull Im Products
bull In the Organization
Learning Organization
bull Employee Development
bull Problem-Solving
bull CIP Culture
13 B Bartke S Wagner IPI-2
Shop Floor Management Process Control Panel on the shop floor
OEE Trend
(Day Week Month)
Measures
Quality
Process Control
14 B Bartke S Wagner IPI-2
OEE - Yesterday
Availability Trend
OEE ndash Last Week
OEE ndash Last Month
Naoki Nojiri IPI-25 BDE-Ist Stand 05042011
Shop Floor Management Process Control Panel on the shop floor
15 B Bartke S Wagner IPI-2
Shop Floor Management Management Cockpit
Planned vs Actual
(shift)
Top problems
(challenges)
OEE ndash Last Week
16 B Bartke S Wagner IPI-2
hellipand what have we achieved
17 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development suspension components (OEE Overall Equipment Effectiveness)
Radtraumlger
Start Shop Floor Management with
FORCAM +10
_
18 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development (20+ Increase in OEE in AUDI Stamping Facilities) (OEE Overall Equipment Effectiveness)
Radtraumlger
Start SFM +20
_
Our Beliefs
Respect
Collaboration
Excellence
Integrity
Community
Oct 30th 2013
Lean with Shop Floor Management BorgWarner Turbo Systems Rzeszow
Operator FactoryFrameworktrade Worker Client- Book On
Operator Downtime Reasons
Operator Actual versus Target Performance
TargetPlanned
Throughput
Actual
Performance
Opportunity for
Improvement
Actual
Throughput Machine
Data
ERP
Data
Supervisor Gantt Status
visualzation
Top 5
downtimes
Cip Top 5
Production
orders
Real data
history
Supervisor Cockpit machine
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
hellipshould support productionhellip
20
25
30
35
40
45
50
405060708090
100110120130140150160
Jul-09 Jul-10 Jul-11 Jul-12 Jul-13 Jul-14
2010=100 US$ bn
Output (LHS)
Orders (RHS)
Source Oxford Economics Haver Analytics
US Output and orders
3 month moving average
37
hellipas will opportunities in the Emergers
38
Revamp of car stock to be key long-term driver
Ageing vehicle fleet replacement as economy recovers ndash average age of vehicle on US roads in 11frac12 years
Rising fuel efficiency standards leading to replacement of clunkers
Rising fuels costs resulting in smaller cars
Automakers likely to increase new models helping drive investment
Aerospace solid order books at the big twohellip
0
250
500
750
1000
1250
1500
1750
1994 1996 1998 2000 2002 2004 2006 2008 2010 2012 2014
Source Company reports
Airbus versus Boeing Orders
Airbus
Boeing
Number of aircraft
Note 2014 annual estimate based on annualized data through July
40
hellipwith APAC to drive long-term growth
Asia will account for almost 32 of global passenger traffic by 2017 compared to 28 in 2012
APAC to account for 40 of plane deliveries over next 20 years
US and Europe sales mainly for replacement of existing fleet
41
Need for efficiency will provide demand supporthellip
A330 revamped for 15 efficiency improvement to compete with Dreamliner 25 new orders on day of announcement
Long-haul efficiency has some ways to go to maintain airline profitability
42
Order backlogs remain high
0
500
1000
1500
2000
2500
3000
3500
1990 1993 1996 1999 2002 2005 2008 2011 2014
Deliveries
Orders
Number of aircraftAirbus amp Boeing Orders amp deliveries
Source Company reports and forecasts
43
Weaker demand for metalshellip
44
hellipand over capacity are weighing on priceshellip
45
hellipand discouraging investment
BHP Capital spending fell 32 in FY14 with another 8 fall expected next year
Rio Tinto Capital spending in FY14 cut faster than initially projected and further cut is budgeted for 2015
This is weighing on equipment makers
Caterpillar reported sales down 9 in the three months to July with sales to mining firms down 33 from the same period a year earlier
Bumper crop has brought down grain prices
47
helliphitting margins and investment
Producers are facing higher costs due to the implementation of Tier 4 engines developed to comply with emissions standards
Weaker margins are leading to farmers cutting back investment spending
John Deere has posted a 5 yy decline in revenues with an 11 decline in its agricultural division
Conclusions amp market implications
Conclusion and business implications
54
bull US economy expected to gradually accelerate through 2014 with support from a dovish Fed
bull Europe expected to recover but more ECB action could be required
bull Chinese economy is gradually rebalancing but banking crisis cannot be discounted
bull Emerging markets quiet for now but structural issue unsolved
bull Geopolitical tensions in the Middle East and Ukraine are being monitored carefully
Thank you
Gregory Daco
Chief US Economist gregorydacooxfordeconomicscom
September 2014
September 10 2014 2014 General Managersrsquo Meeting
Digital Manufacturing
World Class Shop Floor Management Release 5 The Smart Factory Revolution Mr Franz E Gruber Founder amp CEO
Dr Mohamed Abuali COO FORCAM Inc
MTConnect Evolution of a Standard and
Next Generation Interoperability Mr Courtney J Hill Chairman amp President
MTConnect Institute
QampA Session
World Class
Shop Floor Management
The Smart Factory Revolution
Franz E Gruber
Founder amp CEO
Mohamed Abuali
COO
汉语
World Class Shop Floor Management
FORCAM 2014 Page 2
FORCAMlsquos Passion
FORCAM provides proven
manufacturing solutions to
Continuously Improve Productivity
To be the global solutions provider of
the best-in-class Manufacturing
Execution Systems
FORCAM 2014 Page 3
FORCAM ndash 2014 Best Practices Award by Frost amp Sullivan
Frost amp Sullivan
ldquoFORCAM is a plant production software
solution provider that understands and
supports Industry 40 needsrdquo
FORCAM 2014 Page 4
FORCAMrsquos Testimonials and Industry Leadership
FORCAM 2014 Page 5
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
6 B Bartke S Wagner IPI-2
Shop Floor Management Audi - FORCAM FIT 2011-
Bernhard Bartke - Director Components Manufacturing
Stefan Wagner - Director Gear Manufacturing
7 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
bull Collection and recording of Operational Data via a database
(ex Machine States and State Changes)
Machine
Operator
Production Manager
Technical Assistant IT
Plant
Manager
Team Leader
8 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Interfaces
Time
Objectivity of Process Data
9 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Need for Continuous Improvement
bull Objective Information and Communication ndash across ALL levels
bull Transperancy and Visualization - Online
bull Real-time availability of operational data ndash Live Reports
bull Measurable increase in Plant Efficiency (OEE)
10 B Bartke S Wagner IPI-2
Shop Floor Management ndash Realtime bdquoANDONldquo Visualization
bull Web-based Interface Anywhere Anytime Access
bull Real-time Production Status Visualization
In Production
Overflow
Stoppage
Organizational
Stoppage
Idle (Pause)
Tool
Problem
11 B Bartke S Wagner IPI-2
Shop Floor Management Reporting ndash Hierarchical Status Diagrams
bull Reporting for Machines Groups Lines or the whole Plant
Technical
Stoppage In Production
Organizational
Stoppage Pause Overflow
Stoppage
Tool Problem In Setup
12 B Bartke S Wagner IPI-2
Audi Production System (APS)
Leadership Communication
bull Process Control
Standards
bull In Processes
bull Im Products
bull In the Organization
Learning Organization
bull Employee Development
bull Problem-Solving
bull CIP Culture
13 B Bartke S Wagner IPI-2
Shop Floor Management Process Control Panel on the shop floor
OEE Trend
(Day Week Month)
Measures
Quality
Process Control
14 B Bartke S Wagner IPI-2
OEE - Yesterday
Availability Trend
OEE ndash Last Week
OEE ndash Last Month
Naoki Nojiri IPI-25 BDE-Ist Stand 05042011
Shop Floor Management Process Control Panel on the shop floor
15 B Bartke S Wagner IPI-2
Shop Floor Management Management Cockpit
Planned vs Actual
(shift)
Top problems
(challenges)
OEE ndash Last Week
16 B Bartke S Wagner IPI-2
hellipand what have we achieved
17 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development suspension components (OEE Overall Equipment Effectiveness)
Radtraumlger
Start Shop Floor Management with
FORCAM +10
_
18 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development (20+ Increase in OEE in AUDI Stamping Facilities) (OEE Overall Equipment Effectiveness)
Radtraumlger
Start SFM +20
_
Our Beliefs
Respect
Collaboration
Excellence
Integrity
Community
Oct 30th 2013
Lean with Shop Floor Management BorgWarner Turbo Systems Rzeszow
Operator FactoryFrameworktrade Worker Client- Book On
Operator Downtime Reasons
Operator Actual versus Target Performance
TargetPlanned
Throughput
Actual
Performance
Opportunity for
Improvement
Actual
Throughput Machine
Data
ERP
Data
Supervisor Gantt Status
visualzation
Top 5
downtimes
Cip Top 5
Production
orders
Real data
history
Supervisor Cockpit machine
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
hellipas will opportunities in the Emergers
38
Revamp of car stock to be key long-term driver
Ageing vehicle fleet replacement as economy recovers ndash average age of vehicle on US roads in 11frac12 years
Rising fuel efficiency standards leading to replacement of clunkers
Rising fuels costs resulting in smaller cars
Automakers likely to increase new models helping drive investment
Aerospace solid order books at the big twohellip
0
250
500
750
1000
1250
1500
1750
1994 1996 1998 2000 2002 2004 2006 2008 2010 2012 2014
Source Company reports
Airbus versus Boeing Orders
Airbus
Boeing
Number of aircraft
Note 2014 annual estimate based on annualized data through July
40
hellipwith APAC to drive long-term growth
Asia will account for almost 32 of global passenger traffic by 2017 compared to 28 in 2012
APAC to account for 40 of plane deliveries over next 20 years
US and Europe sales mainly for replacement of existing fleet
41
Need for efficiency will provide demand supporthellip
A330 revamped for 15 efficiency improvement to compete with Dreamliner 25 new orders on day of announcement
Long-haul efficiency has some ways to go to maintain airline profitability
42
Order backlogs remain high
0
500
1000
1500
2000
2500
3000
3500
1990 1993 1996 1999 2002 2005 2008 2011 2014
Deliveries
Orders
Number of aircraftAirbus amp Boeing Orders amp deliveries
Source Company reports and forecasts
43
Weaker demand for metalshellip
44
hellipand over capacity are weighing on priceshellip
45
hellipand discouraging investment
BHP Capital spending fell 32 in FY14 with another 8 fall expected next year
Rio Tinto Capital spending in FY14 cut faster than initially projected and further cut is budgeted for 2015
This is weighing on equipment makers
Caterpillar reported sales down 9 in the three months to July with sales to mining firms down 33 from the same period a year earlier
Bumper crop has brought down grain prices
47
helliphitting margins and investment
Producers are facing higher costs due to the implementation of Tier 4 engines developed to comply with emissions standards
Weaker margins are leading to farmers cutting back investment spending
John Deere has posted a 5 yy decline in revenues with an 11 decline in its agricultural division
Conclusions amp market implications
Conclusion and business implications
54
bull US economy expected to gradually accelerate through 2014 with support from a dovish Fed
bull Europe expected to recover but more ECB action could be required
bull Chinese economy is gradually rebalancing but banking crisis cannot be discounted
bull Emerging markets quiet for now but structural issue unsolved
bull Geopolitical tensions in the Middle East and Ukraine are being monitored carefully
Thank you
Gregory Daco
Chief US Economist gregorydacooxfordeconomicscom
September 2014
September 10 2014 2014 General Managersrsquo Meeting
Digital Manufacturing
World Class Shop Floor Management Release 5 The Smart Factory Revolution Mr Franz E Gruber Founder amp CEO
Dr Mohamed Abuali COO FORCAM Inc
MTConnect Evolution of a Standard and
Next Generation Interoperability Mr Courtney J Hill Chairman amp President
MTConnect Institute
QampA Session
World Class
Shop Floor Management
The Smart Factory Revolution
Franz E Gruber
Founder amp CEO
Mohamed Abuali
COO
汉语
World Class Shop Floor Management
FORCAM 2014 Page 2
FORCAMlsquos Passion
FORCAM provides proven
manufacturing solutions to
Continuously Improve Productivity
To be the global solutions provider of
the best-in-class Manufacturing
Execution Systems
FORCAM 2014 Page 3
FORCAM ndash 2014 Best Practices Award by Frost amp Sullivan
Frost amp Sullivan
ldquoFORCAM is a plant production software
solution provider that understands and
supports Industry 40 needsrdquo
FORCAM 2014 Page 4
FORCAMrsquos Testimonials and Industry Leadership
FORCAM 2014 Page 5
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
6 B Bartke S Wagner IPI-2
Shop Floor Management Audi - FORCAM FIT 2011-
Bernhard Bartke - Director Components Manufacturing
Stefan Wagner - Director Gear Manufacturing
7 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
bull Collection and recording of Operational Data via a database
(ex Machine States and State Changes)
Machine
Operator
Production Manager
Technical Assistant IT
Plant
Manager
Team Leader
8 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Interfaces
Time
Objectivity of Process Data
9 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Need for Continuous Improvement
bull Objective Information and Communication ndash across ALL levels
bull Transperancy and Visualization - Online
bull Real-time availability of operational data ndash Live Reports
bull Measurable increase in Plant Efficiency (OEE)
10 B Bartke S Wagner IPI-2
Shop Floor Management ndash Realtime bdquoANDONldquo Visualization
bull Web-based Interface Anywhere Anytime Access
bull Real-time Production Status Visualization
In Production
Overflow
Stoppage
Organizational
Stoppage
Idle (Pause)
Tool
Problem
11 B Bartke S Wagner IPI-2
Shop Floor Management Reporting ndash Hierarchical Status Diagrams
bull Reporting for Machines Groups Lines or the whole Plant
Technical
Stoppage In Production
Organizational
Stoppage Pause Overflow
Stoppage
Tool Problem In Setup
12 B Bartke S Wagner IPI-2
Audi Production System (APS)
Leadership Communication
bull Process Control
Standards
bull In Processes
bull Im Products
bull In the Organization
Learning Organization
bull Employee Development
bull Problem-Solving
bull CIP Culture
13 B Bartke S Wagner IPI-2
Shop Floor Management Process Control Panel on the shop floor
OEE Trend
(Day Week Month)
Measures
Quality
Process Control
14 B Bartke S Wagner IPI-2
OEE - Yesterday
Availability Trend
OEE ndash Last Week
OEE ndash Last Month
Naoki Nojiri IPI-25 BDE-Ist Stand 05042011
Shop Floor Management Process Control Panel on the shop floor
15 B Bartke S Wagner IPI-2
Shop Floor Management Management Cockpit
Planned vs Actual
(shift)
Top problems
(challenges)
OEE ndash Last Week
16 B Bartke S Wagner IPI-2
hellipand what have we achieved
17 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development suspension components (OEE Overall Equipment Effectiveness)
Radtraumlger
Start Shop Floor Management with
FORCAM +10
_
18 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development (20+ Increase in OEE in AUDI Stamping Facilities) (OEE Overall Equipment Effectiveness)
Radtraumlger
Start SFM +20
_
Our Beliefs
Respect
Collaboration
Excellence
Integrity
Community
Oct 30th 2013
Lean with Shop Floor Management BorgWarner Turbo Systems Rzeszow
Operator FactoryFrameworktrade Worker Client- Book On
Operator Downtime Reasons
Operator Actual versus Target Performance
TargetPlanned
Throughput
Actual
Performance
Opportunity for
Improvement
Actual
Throughput Machine
Data
ERP
Data
Supervisor Gantt Status
visualzation
Top 5
downtimes
Cip Top 5
Production
orders
Real data
history
Supervisor Cockpit machine
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
Revamp of car stock to be key long-term driver
Ageing vehicle fleet replacement as economy recovers ndash average age of vehicle on US roads in 11frac12 years
Rising fuel efficiency standards leading to replacement of clunkers
Rising fuels costs resulting in smaller cars
Automakers likely to increase new models helping drive investment
Aerospace solid order books at the big twohellip
0
250
500
750
1000
1250
1500
1750
1994 1996 1998 2000 2002 2004 2006 2008 2010 2012 2014
Source Company reports
Airbus versus Boeing Orders
Airbus
Boeing
Number of aircraft
Note 2014 annual estimate based on annualized data through July
40
hellipwith APAC to drive long-term growth
Asia will account for almost 32 of global passenger traffic by 2017 compared to 28 in 2012
APAC to account for 40 of plane deliveries over next 20 years
US and Europe sales mainly for replacement of existing fleet
41
Need for efficiency will provide demand supporthellip
A330 revamped for 15 efficiency improvement to compete with Dreamliner 25 new orders on day of announcement
Long-haul efficiency has some ways to go to maintain airline profitability
42
Order backlogs remain high
0
500
1000
1500
2000
2500
3000
3500
1990 1993 1996 1999 2002 2005 2008 2011 2014
Deliveries
Orders
Number of aircraftAirbus amp Boeing Orders amp deliveries
Source Company reports and forecasts
43
Weaker demand for metalshellip
44
hellipand over capacity are weighing on priceshellip
45
hellipand discouraging investment
BHP Capital spending fell 32 in FY14 with another 8 fall expected next year
Rio Tinto Capital spending in FY14 cut faster than initially projected and further cut is budgeted for 2015
This is weighing on equipment makers
Caterpillar reported sales down 9 in the three months to July with sales to mining firms down 33 from the same period a year earlier
Bumper crop has brought down grain prices
47
helliphitting margins and investment
Producers are facing higher costs due to the implementation of Tier 4 engines developed to comply with emissions standards
Weaker margins are leading to farmers cutting back investment spending
John Deere has posted a 5 yy decline in revenues with an 11 decline in its agricultural division
Conclusions amp market implications
Conclusion and business implications
54
bull US economy expected to gradually accelerate through 2014 with support from a dovish Fed
bull Europe expected to recover but more ECB action could be required
bull Chinese economy is gradually rebalancing but banking crisis cannot be discounted
bull Emerging markets quiet for now but structural issue unsolved
bull Geopolitical tensions in the Middle East and Ukraine are being monitored carefully
Thank you
Gregory Daco
Chief US Economist gregorydacooxfordeconomicscom
September 2014
September 10 2014 2014 General Managersrsquo Meeting
Digital Manufacturing
World Class Shop Floor Management Release 5 The Smart Factory Revolution Mr Franz E Gruber Founder amp CEO
Dr Mohamed Abuali COO FORCAM Inc
MTConnect Evolution of a Standard and
Next Generation Interoperability Mr Courtney J Hill Chairman amp President
MTConnect Institute
QampA Session
World Class
Shop Floor Management
The Smart Factory Revolution
Franz E Gruber
Founder amp CEO
Mohamed Abuali
COO
汉语
World Class Shop Floor Management
FORCAM 2014 Page 2
FORCAMlsquos Passion
FORCAM provides proven
manufacturing solutions to
Continuously Improve Productivity
To be the global solutions provider of
the best-in-class Manufacturing
Execution Systems
FORCAM 2014 Page 3
FORCAM ndash 2014 Best Practices Award by Frost amp Sullivan
Frost amp Sullivan
ldquoFORCAM is a plant production software
solution provider that understands and
supports Industry 40 needsrdquo
FORCAM 2014 Page 4
FORCAMrsquos Testimonials and Industry Leadership
FORCAM 2014 Page 5
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
6 B Bartke S Wagner IPI-2
Shop Floor Management Audi - FORCAM FIT 2011-
Bernhard Bartke - Director Components Manufacturing
Stefan Wagner - Director Gear Manufacturing
7 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
bull Collection and recording of Operational Data via a database
(ex Machine States and State Changes)
Machine
Operator
Production Manager
Technical Assistant IT
Plant
Manager
Team Leader
8 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Interfaces
Time
Objectivity of Process Data
9 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Need for Continuous Improvement
bull Objective Information and Communication ndash across ALL levels
bull Transperancy and Visualization - Online
bull Real-time availability of operational data ndash Live Reports
bull Measurable increase in Plant Efficiency (OEE)
10 B Bartke S Wagner IPI-2
Shop Floor Management ndash Realtime bdquoANDONldquo Visualization
bull Web-based Interface Anywhere Anytime Access
bull Real-time Production Status Visualization
In Production
Overflow
Stoppage
Organizational
Stoppage
Idle (Pause)
Tool
Problem
11 B Bartke S Wagner IPI-2
Shop Floor Management Reporting ndash Hierarchical Status Diagrams
bull Reporting for Machines Groups Lines or the whole Plant
Technical
Stoppage In Production
Organizational
Stoppage Pause Overflow
Stoppage
Tool Problem In Setup
12 B Bartke S Wagner IPI-2
Audi Production System (APS)
Leadership Communication
bull Process Control
Standards
bull In Processes
bull Im Products
bull In the Organization
Learning Organization
bull Employee Development
bull Problem-Solving
bull CIP Culture
13 B Bartke S Wagner IPI-2
Shop Floor Management Process Control Panel on the shop floor
OEE Trend
(Day Week Month)
Measures
Quality
Process Control
14 B Bartke S Wagner IPI-2
OEE - Yesterday
Availability Trend
OEE ndash Last Week
OEE ndash Last Month
Naoki Nojiri IPI-25 BDE-Ist Stand 05042011
Shop Floor Management Process Control Panel on the shop floor
15 B Bartke S Wagner IPI-2
Shop Floor Management Management Cockpit
Planned vs Actual
(shift)
Top problems
(challenges)
OEE ndash Last Week
16 B Bartke S Wagner IPI-2
hellipand what have we achieved
17 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development suspension components (OEE Overall Equipment Effectiveness)
Radtraumlger
Start Shop Floor Management with
FORCAM +10
_
18 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development (20+ Increase in OEE in AUDI Stamping Facilities) (OEE Overall Equipment Effectiveness)
Radtraumlger
Start SFM +20
_
Our Beliefs
Respect
Collaboration
Excellence
Integrity
Community
Oct 30th 2013
Lean with Shop Floor Management BorgWarner Turbo Systems Rzeszow
Operator FactoryFrameworktrade Worker Client- Book On
Operator Downtime Reasons
Operator Actual versus Target Performance
TargetPlanned
Throughput
Actual
Performance
Opportunity for
Improvement
Actual
Throughput Machine
Data
ERP
Data
Supervisor Gantt Status
visualzation
Top 5
downtimes
Cip Top 5
Production
orders
Real data
history
Supervisor Cockpit machine
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
Aerospace solid order books at the big twohellip
0
250
500
750
1000
1250
1500
1750
1994 1996 1998 2000 2002 2004 2006 2008 2010 2012 2014
Source Company reports
Airbus versus Boeing Orders
Airbus
Boeing
Number of aircraft
Note 2014 annual estimate based on annualized data through July
40
hellipwith APAC to drive long-term growth
Asia will account for almost 32 of global passenger traffic by 2017 compared to 28 in 2012
APAC to account for 40 of plane deliveries over next 20 years
US and Europe sales mainly for replacement of existing fleet
41
Need for efficiency will provide demand supporthellip
A330 revamped for 15 efficiency improvement to compete with Dreamliner 25 new orders on day of announcement
Long-haul efficiency has some ways to go to maintain airline profitability
42
Order backlogs remain high
0
500
1000
1500
2000
2500
3000
3500
1990 1993 1996 1999 2002 2005 2008 2011 2014
Deliveries
Orders
Number of aircraftAirbus amp Boeing Orders amp deliveries
Source Company reports and forecasts
43
Weaker demand for metalshellip
44
hellipand over capacity are weighing on priceshellip
45
hellipand discouraging investment
BHP Capital spending fell 32 in FY14 with another 8 fall expected next year
Rio Tinto Capital spending in FY14 cut faster than initially projected and further cut is budgeted for 2015
This is weighing on equipment makers
Caterpillar reported sales down 9 in the three months to July with sales to mining firms down 33 from the same period a year earlier
Bumper crop has brought down grain prices
47
helliphitting margins and investment
Producers are facing higher costs due to the implementation of Tier 4 engines developed to comply with emissions standards
Weaker margins are leading to farmers cutting back investment spending
John Deere has posted a 5 yy decline in revenues with an 11 decline in its agricultural division
Conclusions amp market implications
Conclusion and business implications
54
bull US economy expected to gradually accelerate through 2014 with support from a dovish Fed
bull Europe expected to recover but more ECB action could be required
bull Chinese economy is gradually rebalancing but banking crisis cannot be discounted
bull Emerging markets quiet for now but structural issue unsolved
bull Geopolitical tensions in the Middle East and Ukraine are being monitored carefully
Thank you
Gregory Daco
Chief US Economist gregorydacooxfordeconomicscom
September 2014
September 10 2014 2014 General Managersrsquo Meeting
Digital Manufacturing
World Class Shop Floor Management Release 5 The Smart Factory Revolution Mr Franz E Gruber Founder amp CEO
Dr Mohamed Abuali COO FORCAM Inc
MTConnect Evolution of a Standard and
Next Generation Interoperability Mr Courtney J Hill Chairman amp President
MTConnect Institute
QampA Session
World Class
Shop Floor Management
The Smart Factory Revolution
Franz E Gruber
Founder amp CEO
Mohamed Abuali
COO
汉语
World Class Shop Floor Management
FORCAM 2014 Page 2
FORCAMlsquos Passion
FORCAM provides proven
manufacturing solutions to
Continuously Improve Productivity
To be the global solutions provider of
the best-in-class Manufacturing
Execution Systems
FORCAM 2014 Page 3
FORCAM ndash 2014 Best Practices Award by Frost amp Sullivan
Frost amp Sullivan
ldquoFORCAM is a plant production software
solution provider that understands and
supports Industry 40 needsrdquo
FORCAM 2014 Page 4
FORCAMrsquos Testimonials and Industry Leadership
FORCAM 2014 Page 5
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
6 B Bartke S Wagner IPI-2
Shop Floor Management Audi - FORCAM FIT 2011-
Bernhard Bartke - Director Components Manufacturing
Stefan Wagner - Director Gear Manufacturing
7 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
bull Collection and recording of Operational Data via a database
(ex Machine States and State Changes)
Machine
Operator
Production Manager
Technical Assistant IT
Plant
Manager
Team Leader
8 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Interfaces
Time
Objectivity of Process Data
9 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Need for Continuous Improvement
bull Objective Information and Communication ndash across ALL levels
bull Transperancy and Visualization - Online
bull Real-time availability of operational data ndash Live Reports
bull Measurable increase in Plant Efficiency (OEE)
10 B Bartke S Wagner IPI-2
Shop Floor Management ndash Realtime bdquoANDONldquo Visualization
bull Web-based Interface Anywhere Anytime Access
bull Real-time Production Status Visualization
In Production
Overflow
Stoppage
Organizational
Stoppage
Idle (Pause)
Tool
Problem
11 B Bartke S Wagner IPI-2
Shop Floor Management Reporting ndash Hierarchical Status Diagrams
bull Reporting for Machines Groups Lines or the whole Plant
Technical
Stoppage In Production
Organizational
Stoppage Pause Overflow
Stoppage
Tool Problem In Setup
12 B Bartke S Wagner IPI-2
Audi Production System (APS)
Leadership Communication
bull Process Control
Standards
bull In Processes
bull Im Products
bull In the Organization
Learning Organization
bull Employee Development
bull Problem-Solving
bull CIP Culture
13 B Bartke S Wagner IPI-2
Shop Floor Management Process Control Panel on the shop floor
OEE Trend
(Day Week Month)
Measures
Quality
Process Control
14 B Bartke S Wagner IPI-2
OEE - Yesterday
Availability Trend
OEE ndash Last Week
OEE ndash Last Month
Naoki Nojiri IPI-25 BDE-Ist Stand 05042011
Shop Floor Management Process Control Panel on the shop floor
15 B Bartke S Wagner IPI-2
Shop Floor Management Management Cockpit
Planned vs Actual
(shift)
Top problems
(challenges)
OEE ndash Last Week
16 B Bartke S Wagner IPI-2
hellipand what have we achieved
17 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development suspension components (OEE Overall Equipment Effectiveness)
Radtraumlger
Start Shop Floor Management with
FORCAM +10
_
18 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development (20+ Increase in OEE in AUDI Stamping Facilities) (OEE Overall Equipment Effectiveness)
Radtraumlger
Start SFM +20
_
Our Beliefs
Respect
Collaboration
Excellence
Integrity
Community
Oct 30th 2013
Lean with Shop Floor Management BorgWarner Turbo Systems Rzeszow
Operator FactoryFrameworktrade Worker Client- Book On
Operator Downtime Reasons
Operator Actual versus Target Performance
TargetPlanned
Throughput
Actual
Performance
Opportunity for
Improvement
Actual
Throughput Machine
Data
ERP
Data
Supervisor Gantt Status
visualzation
Top 5
downtimes
Cip Top 5
Production
orders
Real data
history
Supervisor Cockpit machine
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
hellipwith APAC to drive long-term growth
Asia will account for almost 32 of global passenger traffic by 2017 compared to 28 in 2012
APAC to account for 40 of plane deliveries over next 20 years
US and Europe sales mainly for replacement of existing fleet
41
Need for efficiency will provide demand supporthellip
A330 revamped for 15 efficiency improvement to compete with Dreamliner 25 new orders on day of announcement
Long-haul efficiency has some ways to go to maintain airline profitability
42
Order backlogs remain high
0
500
1000
1500
2000
2500
3000
3500
1990 1993 1996 1999 2002 2005 2008 2011 2014
Deliveries
Orders
Number of aircraftAirbus amp Boeing Orders amp deliveries
Source Company reports and forecasts
43
Weaker demand for metalshellip
44
hellipand over capacity are weighing on priceshellip
45
hellipand discouraging investment
BHP Capital spending fell 32 in FY14 with another 8 fall expected next year
Rio Tinto Capital spending in FY14 cut faster than initially projected and further cut is budgeted for 2015
This is weighing on equipment makers
Caterpillar reported sales down 9 in the three months to July with sales to mining firms down 33 from the same period a year earlier
Bumper crop has brought down grain prices
47
helliphitting margins and investment
Producers are facing higher costs due to the implementation of Tier 4 engines developed to comply with emissions standards
Weaker margins are leading to farmers cutting back investment spending
John Deere has posted a 5 yy decline in revenues with an 11 decline in its agricultural division
Conclusions amp market implications
Conclusion and business implications
54
bull US economy expected to gradually accelerate through 2014 with support from a dovish Fed
bull Europe expected to recover but more ECB action could be required
bull Chinese economy is gradually rebalancing but banking crisis cannot be discounted
bull Emerging markets quiet for now but structural issue unsolved
bull Geopolitical tensions in the Middle East and Ukraine are being monitored carefully
Thank you
Gregory Daco
Chief US Economist gregorydacooxfordeconomicscom
September 2014
September 10 2014 2014 General Managersrsquo Meeting
Digital Manufacturing
World Class Shop Floor Management Release 5 The Smart Factory Revolution Mr Franz E Gruber Founder amp CEO
Dr Mohamed Abuali COO FORCAM Inc
MTConnect Evolution of a Standard and
Next Generation Interoperability Mr Courtney J Hill Chairman amp President
MTConnect Institute
QampA Session
World Class
Shop Floor Management
The Smart Factory Revolution
Franz E Gruber
Founder amp CEO
Mohamed Abuali
COO
汉语
World Class Shop Floor Management
FORCAM 2014 Page 2
FORCAMlsquos Passion
FORCAM provides proven
manufacturing solutions to
Continuously Improve Productivity
To be the global solutions provider of
the best-in-class Manufacturing
Execution Systems
FORCAM 2014 Page 3
FORCAM ndash 2014 Best Practices Award by Frost amp Sullivan
Frost amp Sullivan
ldquoFORCAM is a plant production software
solution provider that understands and
supports Industry 40 needsrdquo
FORCAM 2014 Page 4
FORCAMrsquos Testimonials and Industry Leadership
FORCAM 2014 Page 5
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
6 B Bartke S Wagner IPI-2
Shop Floor Management Audi - FORCAM FIT 2011-
Bernhard Bartke - Director Components Manufacturing
Stefan Wagner - Director Gear Manufacturing
7 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
bull Collection and recording of Operational Data via a database
(ex Machine States and State Changes)
Machine
Operator
Production Manager
Technical Assistant IT
Plant
Manager
Team Leader
8 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Interfaces
Time
Objectivity of Process Data
9 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Need for Continuous Improvement
bull Objective Information and Communication ndash across ALL levels
bull Transperancy and Visualization - Online
bull Real-time availability of operational data ndash Live Reports
bull Measurable increase in Plant Efficiency (OEE)
10 B Bartke S Wagner IPI-2
Shop Floor Management ndash Realtime bdquoANDONldquo Visualization
bull Web-based Interface Anywhere Anytime Access
bull Real-time Production Status Visualization
In Production
Overflow
Stoppage
Organizational
Stoppage
Idle (Pause)
Tool
Problem
11 B Bartke S Wagner IPI-2
Shop Floor Management Reporting ndash Hierarchical Status Diagrams
bull Reporting for Machines Groups Lines or the whole Plant
Technical
Stoppage In Production
Organizational
Stoppage Pause Overflow
Stoppage
Tool Problem In Setup
12 B Bartke S Wagner IPI-2
Audi Production System (APS)
Leadership Communication
bull Process Control
Standards
bull In Processes
bull Im Products
bull In the Organization
Learning Organization
bull Employee Development
bull Problem-Solving
bull CIP Culture
13 B Bartke S Wagner IPI-2
Shop Floor Management Process Control Panel on the shop floor
OEE Trend
(Day Week Month)
Measures
Quality
Process Control
14 B Bartke S Wagner IPI-2
OEE - Yesterday
Availability Trend
OEE ndash Last Week
OEE ndash Last Month
Naoki Nojiri IPI-25 BDE-Ist Stand 05042011
Shop Floor Management Process Control Panel on the shop floor
15 B Bartke S Wagner IPI-2
Shop Floor Management Management Cockpit
Planned vs Actual
(shift)
Top problems
(challenges)
OEE ndash Last Week
16 B Bartke S Wagner IPI-2
hellipand what have we achieved
17 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development suspension components (OEE Overall Equipment Effectiveness)
Radtraumlger
Start Shop Floor Management with
FORCAM +10
_
18 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development (20+ Increase in OEE in AUDI Stamping Facilities) (OEE Overall Equipment Effectiveness)
Radtraumlger
Start SFM +20
_
Our Beliefs
Respect
Collaboration
Excellence
Integrity
Community
Oct 30th 2013
Lean with Shop Floor Management BorgWarner Turbo Systems Rzeszow
Operator FactoryFrameworktrade Worker Client- Book On
Operator Downtime Reasons
Operator Actual versus Target Performance
TargetPlanned
Throughput
Actual
Performance
Opportunity for
Improvement
Actual
Throughput Machine
Data
ERP
Data
Supervisor Gantt Status
visualzation
Top 5
downtimes
Cip Top 5
Production
orders
Real data
history
Supervisor Cockpit machine
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
Need for efficiency will provide demand supporthellip
A330 revamped for 15 efficiency improvement to compete with Dreamliner 25 new orders on day of announcement
Long-haul efficiency has some ways to go to maintain airline profitability
42
Order backlogs remain high
0
500
1000
1500
2000
2500
3000
3500
1990 1993 1996 1999 2002 2005 2008 2011 2014
Deliveries
Orders
Number of aircraftAirbus amp Boeing Orders amp deliveries
Source Company reports and forecasts
43
Weaker demand for metalshellip
44
hellipand over capacity are weighing on priceshellip
45
hellipand discouraging investment
BHP Capital spending fell 32 in FY14 with another 8 fall expected next year
Rio Tinto Capital spending in FY14 cut faster than initially projected and further cut is budgeted for 2015
This is weighing on equipment makers
Caterpillar reported sales down 9 in the three months to July with sales to mining firms down 33 from the same period a year earlier
Bumper crop has brought down grain prices
47
helliphitting margins and investment
Producers are facing higher costs due to the implementation of Tier 4 engines developed to comply with emissions standards
Weaker margins are leading to farmers cutting back investment spending
John Deere has posted a 5 yy decline in revenues with an 11 decline in its agricultural division
Conclusions amp market implications
Conclusion and business implications
54
bull US economy expected to gradually accelerate through 2014 with support from a dovish Fed
bull Europe expected to recover but more ECB action could be required
bull Chinese economy is gradually rebalancing but banking crisis cannot be discounted
bull Emerging markets quiet for now but structural issue unsolved
bull Geopolitical tensions in the Middle East and Ukraine are being monitored carefully
Thank you
Gregory Daco
Chief US Economist gregorydacooxfordeconomicscom
September 2014
September 10 2014 2014 General Managersrsquo Meeting
Digital Manufacturing
World Class Shop Floor Management Release 5 The Smart Factory Revolution Mr Franz E Gruber Founder amp CEO
Dr Mohamed Abuali COO FORCAM Inc
MTConnect Evolution of a Standard and
Next Generation Interoperability Mr Courtney J Hill Chairman amp President
MTConnect Institute
QampA Session
World Class
Shop Floor Management
The Smart Factory Revolution
Franz E Gruber
Founder amp CEO
Mohamed Abuali
COO
汉语
World Class Shop Floor Management
FORCAM 2014 Page 2
FORCAMlsquos Passion
FORCAM provides proven
manufacturing solutions to
Continuously Improve Productivity
To be the global solutions provider of
the best-in-class Manufacturing
Execution Systems
FORCAM 2014 Page 3
FORCAM ndash 2014 Best Practices Award by Frost amp Sullivan
Frost amp Sullivan
ldquoFORCAM is a plant production software
solution provider that understands and
supports Industry 40 needsrdquo
FORCAM 2014 Page 4
FORCAMrsquos Testimonials and Industry Leadership
FORCAM 2014 Page 5
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
6 B Bartke S Wagner IPI-2
Shop Floor Management Audi - FORCAM FIT 2011-
Bernhard Bartke - Director Components Manufacturing
Stefan Wagner - Director Gear Manufacturing
7 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
bull Collection and recording of Operational Data via a database
(ex Machine States and State Changes)
Machine
Operator
Production Manager
Technical Assistant IT
Plant
Manager
Team Leader
8 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Interfaces
Time
Objectivity of Process Data
9 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Need for Continuous Improvement
bull Objective Information and Communication ndash across ALL levels
bull Transperancy and Visualization - Online
bull Real-time availability of operational data ndash Live Reports
bull Measurable increase in Plant Efficiency (OEE)
10 B Bartke S Wagner IPI-2
Shop Floor Management ndash Realtime bdquoANDONldquo Visualization
bull Web-based Interface Anywhere Anytime Access
bull Real-time Production Status Visualization
In Production
Overflow
Stoppage
Organizational
Stoppage
Idle (Pause)
Tool
Problem
11 B Bartke S Wagner IPI-2
Shop Floor Management Reporting ndash Hierarchical Status Diagrams
bull Reporting for Machines Groups Lines or the whole Plant
Technical
Stoppage In Production
Organizational
Stoppage Pause Overflow
Stoppage
Tool Problem In Setup
12 B Bartke S Wagner IPI-2
Audi Production System (APS)
Leadership Communication
bull Process Control
Standards
bull In Processes
bull Im Products
bull In the Organization
Learning Organization
bull Employee Development
bull Problem-Solving
bull CIP Culture
13 B Bartke S Wagner IPI-2
Shop Floor Management Process Control Panel on the shop floor
OEE Trend
(Day Week Month)
Measures
Quality
Process Control
14 B Bartke S Wagner IPI-2
OEE - Yesterday
Availability Trend
OEE ndash Last Week
OEE ndash Last Month
Naoki Nojiri IPI-25 BDE-Ist Stand 05042011
Shop Floor Management Process Control Panel on the shop floor
15 B Bartke S Wagner IPI-2
Shop Floor Management Management Cockpit
Planned vs Actual
(shift)
Top problems
(challenges)
OEE ndash Last Week
16 B Bartke S Wagner IPI-2
hellipand what have we achieved
17 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development suspension components (OEE Overall Equipment Effectiveness)
Radtraumlger
Start Shop Floor Management with
FORCAM +10
_
18 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development (20+ Increase in OEE in AUDI Stamping Facilities) (OEE Overall Equipment Effectiveness)
Radtraumlger
Start SFM +20
_
Our Beliefs
Respect
Collaboration
Excellence
Integrity
Community
Oct 30th 2013
Lean with Shop Floor Management BorgWarner Turbo Systems Rzeszow
Operator FactoryFrameworktrade Worker Client- Book On
Operator Downtime Reasons
Operator Actual versus Target Performance
TargetPlanned
Throughput
Actual
Performance
Opportunity for
Improvement
Actual
Throughput Machine
Data
ERP
Data
Supervisor Gantt Status
visualzation
Top 5
downtimes
Cip Top 5
Production
orders
Real data
history
Supervisor Cockpit machine
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
Order backlogs remain high
0
500
1000
1500
2000
2500
3000
3500
1990 1993 1996 1999 2002 2005 2008 2011 2014
Deliveries
Orders
Number of aircraftAirbus amp Boeing Orders amp deliveries
Source Company reports and forecasts
43
Weaker demand for metalshellip
44
hellipand over capacity are weighing on priceshellip
45
hellipand discouraging investment
BHP Capital spending fell 32 in FY14 with another 8 fall expected next year
Rio Tinto Capital spending in FY14 cut faster than initially projected and further cut is budgeted for 2015
This is weighing on equipment makers
Caterpillar reported sales down 9 in the three months to July with sales to mining firms down 33 from the same period a year earlier
Bumper crop has brought down grain prices
47
helliphitting margins and investment
Producers are facing higher costs due to the implementation of Tier 4 engines developed to comply with emissions standards
Weaker margins are leading to farmers cutting back investment spending
John Deere has posted a 5 yy decline in revenues with an 11 decline in its agricultural division
Conclusions amp market implications
Conclusion and business implications
54
bull US economy expected to gradually accelerate through 2014 with support from a dovish Fed
bull Europe expected to recover but more ECB action could be required
bull Chinese economy is gradually rebalancing but banking crisis cannot be discounted
bull Emerging markets quiet for now but structural issue unsolved
bull Geopolitical tensions in the Middle East and Ukraine are being monitored carefully
Thank you
Gregory Daco
Chief US Economist gregorydacooxfordeconomicscom
September 2014
September 10 2014 2014 General Managersrsquo Meeting
Digital Manufacturing
World Class Shop Floor Management Release 5 The Smart Factory Revolution Mr Franz E Gruber Founder amp CEO
Dr Mohamed Abuali COO FORCAM Inc
MTConnect Evolution of a Standard and
Next Generation Interoperability Mr Courtney J Hill Chairman amp President
MTConnect Institute
QampA Session
World Class
Shop Floor Management
The Smart Factory Revolution
Franz E Gruber
Founder amp CEO
Mohamed Abuali
COO
汉语
World Class Shop Floor Management
FORCAM 2014 Page 2
FORCAMlsquos Passion
FORCAM provides proven
manufacturing solutions to
Continuously Improve Productivity
To be the global solutions provider of
the best-in-class Manufacturing
Execution Systems
FORCAM 2014 Page 3
FORCAM ndash 2014 Best Practices Award by Frost amp Sullivan
Frost amp Sullivan
ldquoFORCAM is a plant production software
solution provider that understands and
supports Industry 40 needsrdquo
FORCAM 2014 Page 4
FORCAMrsquos Testimonials and Industry Leadership
FORCAM 2014 Page 5
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
6 B Bartke S Wagner IPI-2
Shop Floor Management Audi - FORCAM FIT 2011-
Bernhard Bartke - Director Components Manufacturing
Stefan Wagner - Director Gear Manufacturing
7 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
bull Collection and recording of Operational Data via a database
(ex Machine States and State Changes)
Machine
Operator
Production Manager
Technical Assistant IT
Plant
Manager
Team Leader
8 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Interfaces
Time
Objectivity of Process Data
9 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Need for Continuous Improvement
bull Objective Information and Communication ndash across ALL levels
bull Transperancy and Visualization - Online
bull Real-time availability of operational data ndash Live Reports
bull Measurable increase in Plant Efficiency (OEE)
10 B Bartke S Wagner IPI-2
Shop Floor Management ndash Realtime bdquoANDONldquo Visualization
bull Web-based Interface Anywhere Anytime Access
bull Real-time Production Status Visualization
In Production
Overflow
Stoppage
Organizational
Stoppage
Idle (Pause)
Tool
Problem
11 B Bartke S Wagner IPI-2
Shop Floor Management Reporting ndash Hierarchical Status Diagrams
bull Reporting for Machines Groups Lines or the whole Plant
Technical
Stoppage In Production
Organizational
Stoppage Pause Overflow
Stoppage
Tool Problem In Setup
12 B Bartke S Wagner IPI-2
Audi Production System (APS)
Leadership Communication
bull Process Control
Standards
bull In Processes
bull Im Products
bull In the Organization
Learning Organization
bull Employee Development
bull Problem-Solving
bull CIP Culture
13 B Bartke S Wagner IPI-2
Shop Floor Management Process Control Panel on the shop floor
OEE Trend
(Day Week Month)
Measures
Quality
Process Control
14 B Bartke S Wagner IPI-2
OEE - Yesterday
Availability Trend
OEE ndash Last Week
OEE ndash Last Month
Naoki Nojiri IPI-25 BDE-Ist Stand 05042011
Shop Floor Management Process Control Panel on the shop floor
15 B Bartke S Wagner IPI-2
Shop Floor Management Management Cockpit
Planned vs Actual
(shift)
Top problems
(challenges)
OEE ndash Last Week
16 B Bartke S Wagner IPI-2
hellipand what have we achieved
17 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development suspension components (OEE Overall Equipment Effectiveness)
Radtraumlger
Start Shop Floor Management with
FORCAM +10
_
18 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development (20+ Increase in OEE in AUDI Stamping Facilities) (OEE Overall Equipment Effectiveness)
Radtraumlger
Start SFM +20
_
Our Beliefs
Respect
Collaboration
Excellence
Integrity
Community
Oct 30th 2013
Lean with Shop Floor Management BorgWarner Turbo Systems Rzeszow
Operator FactoryFrameworktrade Worker Client- Book On
Operator Downtime Reasons
Operator Actual versus Target Performance
TargetPlanned
Throughput
Actual
Performance
Opportunity for
Improvement
Actual
Throughput Machine
Data
ERP
Data
Supervisor Gantt Status
visualzation
Top 5
downtimes
Cip Top 5
Production
orders
Real data
history
Supervisor Cockpit machine
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
Weaker demand for metalshellip
44
hellipand over capacity are weighing on priceshellip
45
hellipand discouraging investment
BHP Capital spending fell 32 in FY14 with another 8 fall expected next year
Rio Tinto Capital spending in FY14 cut faster than initially projected and further cut is budgeted for 2015
This is weighing on equipment makers
Caterpillar reported sales down 9 in the three months to July with sales to mining firms down 33 from the same period a year earlier
Bumper crop has brought down grain prices
47
helliphitting margins and investment
Producers are facing higher costs due to the implementation of Tier 4 engines developed to comply with emissions standards
Weaker margins are leading to farmers cutting back investment spending
John Deere has posted a 5 yy decline in revenues with an 11 decline in its agricultural division
Conclusions amp market implications
Conclusion and business implications
54
bull US economy expected to gradually accelerate through 2014 with support from a dovish Fed
bull Europe expected to recover but more ECB action could be required
bull Chinese economy is gradually rebalancing but banking crisis cannot be discounted
bull Emerging markets quiet for now but structural issue unsolved
bull Geopolitical tensions in the Middle East and Ukraine are being monitored carefully
Thank you
Gregory Daco
Chief US Economist gregorydacooxfordeconomicscom
September 2014
September 10 2014 2014 General Managersrsquo Meeting
Digital Manufacturing
World Class Shop Floor Management Release 5 The Smart Factory Revolution Mr Franz E Gruber Founder amp CEO
Dr Mohamed Abuali COO FORCAM Inc
MTConnect Evolution of a Standard and
Next Generation Interoperability Mr Courtney J Hill Chairman amp President
MTConnect Institute
QampA Session
World Class
Shop Floor Management
The Smart Factory Revolution
Franz E Gruber
Founder amp CEO
Mohamed Abuali
COO
汉语
World Class Shop Floor Management
FORCAM 2014 Page 2
FORCAMlsquos Passion
FORCAM provides proven
manufacturing solutions to
Continuously Improve Productivity
To be the global solutions provider of
the best-in-class Manufacturing
Execution Systems
FORCAM 2014 Page 3
FORCAM ndash 2014 Best Practices Award by Frost amp Sullivan
Frost amp Sullivan
ldquoFORCAM is a plant production software
solution provider that understands and
supports Industry 40 needsrdquo
FORCAM 2014 Page 4
FORCAMrsquos Testimonials and Industry Leadership
FORCAM 2014 Page 5
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
6 B Bartke S Wagner IPI-2
Shop Floor Management Audi - FORCAM FIT 2011-
Bernhard Bartke - Director Components Manufacturing
Stefan Wagner - Director Gear Manufacturing
7 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
bull Collection and recording of Operational Data via a database
(ex Machine States and State Changes)
Machine
Operator
Production Manager
Technical Assistant IT
Plant
Manager
Team Leader
8 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Interfaces
Time
Objectivity of Process Data
9 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Need for Continuous Improvement
bull Objective Information and Communication ndash across ALL levels
bull Transperancy and Visualization - Online
bull Real-time availability of operational data ndash Live Reports
bull Measurable increase in Plant Efficiency (OEE)
10 B Bartke S Wagner IPI-2
Shop Floor Management ndash Realtime bdquoANDONldquo Visualization
bull Web-based Interface Anywhere Anytime Access
bull Real-time Production Status Visualization
In Production
Overflow
Stoppage
Organizational
Stoppage
Idle (Pause)
Tool
Problem
11 B Bartke S Wagner IPI-2
Shop Floor Management Reporting ndash Hierarchical Status Diagrams
bull Reporting for Machines Groups Lines or the whole Plant
Technical
Stoppage In Production
Organizational
Stoppage Pause Overflow
Stoppage
Tool Problem In Setup
12 B Bartke S Wagner IPI-2
Audi Production System (APS)
Leadership Communication
bull Process Control
Standards
bull In Processes
bull Im Products
bull In the Organization
Learning Organization
bull Employee Development
bull Problem-Solving
bull CIP Culture
13 B Bartke S Wagner IPI-2
Shop Floor Management Process Control Panel on the shop floor
OEE Trend
(Day Week Month)
Measures
Quality
Process Control
14 B Bartke S Wagner IPI-2
OEE - Yesterday
Availability Trend
OEE ndash Last Week
OEE ndash Last Month
Naoki Nojiri IPI-25 BDE-Ist Stand 05042011
Shop Floor Management Process Control Panel on the shop floor
15 B Bartke S Wagner IPI-2
Shop Floor Management Management Cockpit
Planned vs Actual
(shift)
Top problems
(challenges)
OEE ndash Last Week
16 B Bartke S Wagner IPI-2
hellipand what have we achieved
17 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development suspension components (OEE Overall Equipment Effectiveness)
Radtraumlger
Start Shop Floor Management with
FORCAM +10
_
18 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development (20+ Increase in OEE in AUDI Stamping Facilities) (OEE Overall Equipment Effectiveness)
Radtraumlger
Start SFM +20
_
Our Beliefs
Respect
Collaboration
Excellence
Integrity
Community
Oct 30th 2013
Lean with Shop Floor Management BorgWarner Turbo Systems Rzeszow
Operator FactoryFrameworktrade Worker Client- Book On
Operator Downtime Reasons
Operator Actual versus Target Performance
TargetPlanned
Throughput
Actual
Performance
Opportunity for
Improvement
Actual
Throughput Machine
Data
ERP
Data
Supervisor Gantt Status
visualzation
Top 5
downtimes
Cip Top 5
Production
orders
Real data
history
Supervisor Cockpit machine
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
hellipand over capacity are weighing on priceshellip
45
hellipand discouraging investment
BHP Capital spending fell 32 in FY14 with another 8 fall expected next year
Rio Tinto Capital spending in FY14 cut faster than initially projected and further cut is budgeted for 2015
This is weighing on equipment makers
Caterpillar reported sales down 9 in the three months to July with sales to mining firms down 33 from the same period a year earlier
Bumper crop has brought down grain prices
47
helliphitting margins and investment
Producers are facing higher costs due to the implementation of Tier 4 engines developed to comply with emissions standards
Weaker margins are leading to farmers cutting back investment spending
John Deere has posted a 5 yy decline in revenues with an 11 decline in its agricultural division
Conclusions amp market implications
Conclusion and business implications
54
bull US economy expected to gradually accelerate through 2014 with support from a dovish Fed
bull Europe expected to recover but more ECB action could be required
bull Chinese economy is gradually rebalancing but banking crisis cannot be discounted
bull Emerging markets quiet for now but structural issue unsolved
bull Geopolitical tensions in the Middle East and Ukraine are being monitored carefully
Thank you
Gregory Daco
Chief US Economist gregorydacooxfordeconomicscom
September 2014
September 10 2014 2014 General Managersrsquo Meeting
Digital Manufacturing
World Class Shop Floor Management Release 5 The Smart Factory Revolution Mr Franz E Gruber Founder amp CEO
Dr Mohamed Abuali COO FORCAM Inc
MTConnect Evolution of a Standard and
Next Generation Interoperability Mr Courtney J Hill Chairman amp President
MTConnect Institute
QampA Session
World Class
Shop Floor Management
The Smart Factory Revolution
Franz E Gruber
Founder amp CEO
Mohamed Abuali
COO
汉语
World Class Shop Floor Management
FORCAM 2014 Page 2
FORCAMlsquos Passion
FORCAM provides proven
manufacturing solutions to
Continuously Improve Productivity
To be the global solutions provider of
the best-in-class Manufacturing
Execution Systems
FORCAM 2014 Page 3
FORCAM ndash 2014 Best Practices Award by Frost amp Sullivan
Frost amp Sullivan
ldquoFORCAM is a plant production software
solution provider that understands and
supports Industry 40 needsrdquo
FORCAM 2014 Page 4
FORCAMrsquos Testimonials and Industry Leadership
FORCAM 2014 Page 5
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
6 B Bartke S Wagner IPI-2
Shop Floor Management Audi - FORCAM FIT 2011-
Bernhard Bartke - Director Components Manufacturing
Stefan Wagner - Director Gear Manufacturing
7 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
bull Collection and recording of Operational Data via a database
(ex Machine States and State Changes)
Machine
Operator
Production Manager
Technical Assistant IT
Plant
Manager
Team Leader
8 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Interfaces
Time
Objectivity of Process Data
9 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Need for Continuous Improvement
bull Objective Information and Communication ndash across ALL levels
bull Transperancy and Visualization - Online
bull Real-time availability of operational data ndash Live Reports
bull Measurable increase in Plant Efficiency (OEE)
10 B Bartke S Wagner IPI-2
Shop Floor Management ndash Realtime bdquoANDONldquo Visualization
bull Web-based Interface Anywhere Anytime Access
bull Real-time Production Status Visualization
In Production
Overflow
Stoppage
Organizational
Stoppage
Idle (Pause)
Tool
Problem
11 B Bartke S Wagner IPI-2
Shop Floor Management Reporting ndash Hierarchical Status Diagrams
bull Reporting for Machines Groups Lines or the whole Plant
Technical
Stoppage In Production
Organizational
Stoppage Pause Overflow
Stoppage
Tool Problem In Setup
12 B Bartke S Wagner IPI-2
Audi Production System (APS)
Leadership Communication
bull Process Control
Standards
bull In Processes
bull Im Products
bull In the Organization
Learning Organization
bull Employee Development
bull Problem-Solving
bull CIP Culture
13 B Bartke S Wagner IPI-2
Shop Floor Management Process Control Panel on the shop floor
OEE Trend
(Day Week Month)
Measures
Quality
Process Control
14 B Bartke S Wagner IPI-2
OEE - Yesterday
Availability Trend
OEE ndash Last Week
OEE ndash Last Month
Naoki Nojiri IPI-25 BDE-Ist Stand 05042011
Shop Floor Management Process Control Panel on the shop floor
15 B Bartke S Wagner IPI-2
Shop Floor Management Management Cockpit
Planned vs Actual
(shift)
Top problems
(challenges)
OEE ndash Last Week
16 B Bartke S Wagner IPI-2
hellipand what have we achieved
17 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development suspension components (OEE Overall Equipment Effectiveness)
Radtraumlger
Start Shop Floor Management with
FORCAM +10
_
18 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development (20+ Increase in OEE in AUDI Stamping Facilities) (OEE Overall Equipment Effectiveness)
Radtraumlger
Start SFM +20
_
Our Beliefs
Respect
Collaboration
Excellence
Integrity
Community
Oct 30th 2013
Lean with Shop Floor Management BorgWarner Turbo Systems Rzeszow
Operator FactoryFrameworktrade Worker Client- Book On
Operator Downtime Reasons
Operator Actual versus Target Performance
TargetPlanned
Throughput
Actual
Performance
Opportunity for
Improvement
Actual
Throughput Machine
Data
ERP
Data
Supervisor Gantt Status
visualzation
Top 5
downtimes
Cip Top 5
Production
orders
Real data
history
Supervisor Cockpit machine
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
hellipand discouraging investment
BHP Capital spending fell 32 in FY14 with another 8 fall expected next year
Rio Tinto Capital spending in FY14 cut faster than initially projected and further cut is budgeted for 2015
This is weighing on equipment makers
Caterpillar reported sales down 9 in the three months to July with sales to mining firms down 33 from the same period a year earlier
Bumper crop has brought down grain prices
47
helliphitting margins and investment
Producers are facing higher costs due to the implementation of Tier 4 engines developed to comply with emissions standards
Weaker margins are leading to farmers cutting back investment spending
John Deere has posted a 5 yy decline in revenues with an 11 decline in its agricultural division
Conclusions amp market implications
Conclusion and business implications
54
bull US economy expected to gradually accelerate through 2014 with support from a dovish Fed
bull Europe expected to recover but more ECB action could be required
bull Chinese economy is gradually rebalancing but banking crisis cannot be discounted
bull Emerging markets quiet for now but structural issue unsolved
bull Geopolitical tensions in the Middle East and Ukraine are being monitored carefully
Thank you
Gregory Daco
Chief US Economist gregorydacooxfordeconomicscom
September 2014
September 10 2014 2014 General Managersrsquo Meeting
Digital Manufacturing
World Class Shop Floor Management Release 5 The Smart Factory Revolution Mr Franz E Gruber Founder amp CEO
Dr Mohamed Abuali COO FORCAM Inc
MTConnect Evolution of a Standard and
Next Generation Interoperability Mr Courtney J Hill Chairman amp President
MTConnect Institute
QampA Session
World Class
Shop Floor Management
The Smart Factory Revolution
Franz E Gruber
Founder amp CEO
Mohamed Abuali
COO
汉语
World Class Shop Floor Management
FORCAM 2014 Page 2
FORCAMlsquos Passion
FORCAM provides proven
manufacturing solutions to
Continuously Improve Productivity
To be the global solutions provider of
the best-in-class Manufacturing
Execution Systems
FORCAM 2014 Page 3
FORCAM ndash 2014 Best Practices Award by Frost amp Sullivan
Frost amp Sullivan
ldquoFORCAM is a plant production software
solution provider that understands and
supports Industry 40 needsrdquo
FORCAM 2014 Page 4
FORCAMrsquos Testimonials and Industry Leadership
FORCAM 2014 Page 5
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
6 B Bartke S Wagner IPI-2
Shop Floor Management Audi - FORCAM FIT 2011-
Bernhard Bartke - Director Components Manufacturing
Stefan Wagner - Director Gear Manufacturing
7 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
bull Collection and recording of Operational Data via a database
(ex Machine States and State Changes)
Machine
Operator
Production Manager
Technical Assistant IT
Plant
Manager
Team Leader
8 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Interfaces
Time
Objectivity of Process Data
9 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Need for Continuous Improvement
bull Objective Information and Communication ndash across ALL levels
bull Transperancy and Visualization - Online
bull Real-time availability of operational data ndash Live Reports
bull Measurable increase in Plant Efficiency (OEE)
10 B Bartke S Wagner IPI-2
Shop Floor Management ndash Realtime bdquoANDONldquo Visualization
bull Web-based Interface Anywhere Anytime Access
bull Real-time Production Status Visualization
In Production
Overflow
Stoppage
Organizational
Stoppage
Idle (Pause)
Tool
Problem
11 B Bartke S Wagner IPI-2
Shop Floor Management Reporting ndash Hierarchical Status Diagrams
bull Reporting for Machines Groups Lines or the whole Plant
Technical
Stoppage In Production
Organizational
Stoppage Pause Overflow
Stoppage
Tool Problem In Setup
12 B Bartke S Wagner IPI-2
Audi Production System (APS)
Leadership Communication
bull Process Control
Standards
bull In Processes
bull Im Products
bull In the Organization
Learning Organization
bull Employee Development
bull Problem-Solving
bull CIP Culture
13 B Bartke S Wagner IPI-2
Shop Floor Management Process Control Panel on the shop floor
OEE Trend
(Day Week Month)
Measures
Quality
Process Control
14 B Bartke S Wagner IPI-2
OEE - Yesterday
Availability Trend
OEE ndash Last Week
OEE ndash Last Month
Naoki Nojiri IPI-25 BDE-Ist Stand 05042011
Shop Floor Management Process Control Panel on the shop floor
15 B Bartke S Wagner IPI-2
Shop Floor Management Management Cockpit
Planned vs Actual
(shift)
Top problems
(challenges)
OEE ndash Last Week
16 B Bartke S Wagner IPI-2
hellipand what have we achieved
17 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development suspension components (OEE Overall Equipment Effectiveness)
Radtraumlger
Start Shop Floor Management with
FORCAM +10
_
18 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development (20+ Increase in OEE in AUDI Stamping Facilities) (OEE Overall Equipment Effectiveness)
Radtraumlger
Start SFM +20
_
Our Beliefs
Respect
Collaboration
Excellence
Integrity
Community
Oct 30th 2013
Lean with Shop Floor Management BorgWarner Turbo Systems Rzeszow
Operator FactoryFrameworktrade Worker Client- Book On
Operator Downtime Reasons
Operator Actual versus Target Performance
TargetPlanned
Throughput
Actual
Performance
Opportunity for
Improvement
Actual
Throughput Machine
Data
ERP
Data
Supervisor Gantt Status
visualzation
Top 5
downtimes
Cip Top 5
Production
orders
Real data
history
Supervisor Cockpit machine
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
Bumper crop has brought down grain prices
47
helliphitting margins and investment
Producers are facing higher costs due to the implementation of Tier 4 engines developed to comply with emissions standards
Weaker margins are leading to farmers cutting back investment spending
John Deere has posted a 5 yy decline in revenues with an 11 decline in its agricultural division
Conclusions amp market implications
Conclusion and business implications
54
bull US economy expected to gradually accelerate through 2014 with support from a dovish Fed
bull Europe expected to recover but more ECB action could be required
bull Chinese economy is gradually rebalancing but banking crisis cannot be discounted
bull Emerging markets quiet for now but structural issue unsolved
bull Geopolitical tensions in the Middle East and Ukraine are being monitored carefully
Thank you
Gregory Daco
Chief US Economist gregorydacooxfordeconomicscom
September 2014
September 10 2014 2014 General Managersrsquo Meeting
Digital Manufacturing
World Class Shop Floor Management Release 5 The Smart Factory Revolution Mr Franz E Gruber Founder amp CEO
Dr Mohamed Abuali COO FORCAM Inc
MTConnect Evolution of a Standard and
Next Generation Interoperability Mr Courtney J Hill Chairman amp President
MTConnect Institute
QampA Session
World Class
Shop Floor Management
The Smart Factory Revolution
Franz E Gruber
Founder amp CEO
Mohamed Abuali
COO
汉语
World Class Shop Floor Management
FORCAM 2014 Page 2
FORCAMlsquos Passion
FORCAM provides proven
manufacturing solutions to
Continuously Improve Productivity
To be the global solutions provider of
the best-in-class Manufacturing
Execution Systems
FORCAM 2014 Page 3
FORCAM ndash 2014 Best Practices Award by Frost amp Sullivan
Frost amp Sullivan
ldquoFORCAM is a plant production software
solution provider that understands and
supports Industry 40 needsrdquo
FORCAM 2014 Page 4
FORCAMrsquos Testimonials and Industry Leadership
FORCAM 2014 Page 5
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
6 B Bartke S Wagner IPI-2
Shop Floor Management Audi - FORCAM FIT 2011-
Bernhard Bartke - Director Components Manufacturing
Stefan Wagner - Director Gear Manufacturing
7 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
bull Collection and recording of Operational Data via a database
(ex Machine States and State Changes)
Machine
Operator
Production Manager
Technical Assistant IT
Plant
Manager
Team Leader
8 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Interfaces
Time
Objectivity of Process Data
9 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Need for Continuous Improvement
bull Objective Information and Communication ndash across ALL levels
bull Transperancy and Visualization - Online
bull Real-time availability of operational data ndash Live Reports
bull Measurable increase in Plant Efficiency (OEE)
10 B Bartke S Wagner IPI-2
Shop Floor Management ndash Realtime bdquoANDONldquo Visualization
bull Web-based Interface Anywhere Anytime Access
bull Real-time Production Status Visualization
In Production
Overflow
Stoppage
Organizational
Stoppage
Idle (Pause)
Tool
Problem
11 B Bartke S Wagner IPI-2
Shop Floor Management Reporting ndash Hierarchical Status Diagrams
bull Reporting for Machines Groups Lines or the whole Plant
Technical
Stoppage In Production
Organizational
Stoppage Pause Overflow
Stoppage
Tool Problem In Setup
12 B Bartke S Wagner IPI-2
Audi Production System (APS)
Leadership Communication
bull Process Control
Standards
bull In Processes
bull Im Products
bull In the Organization
Learning Organization
bull Employee Development
bull Problem-Solving
bull CIP Culture
13 B Bartke S Wagner IPI-2
Shop Floor Management Process Control Panel on the shop floor
OEE Trend
(Day Week Month)
Measures
Quality
Process Control
14 B Bartke S Wagner IPI-2
OEE - Yesterday
Availability Trend
OEE ndash Last Week
OEE ndash Last Month
Naoki Nojiri IPI-25 BDE-Ist Stand 05042011
Shop Floor Management Process Control Panel on the shop floor
15 B Bartke S Wagner IPI-2
Shop Floor Management Management Cockpit
Planned vs Actual
(shift)
Top problems
(challenges)
OEE ndash Last Week
16 B Bartke S Wagner IPI-2
hellipand what have we achieved
17 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development suspension components (OEE Overall Equipment Effectiveness)
Radtraumlger
Start Shop Floor Management with
FORCAM +10
_
18 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development (20+ Increase in OEE in AUDI Stamping Facilities) (OEE Overall Equipment Effectiveness)
Radtraumlger
Start SFM +20
_
Our Beliefs
Respect
Collaboration
Excellence
Integrity
Community
Oct 30th 2013
Lean with Shop Floor Management BorgWarner Turbo Systems Rzeszow
Operator FactoryFrameworktrade Worker Client- Book On
Operator Downtime Reasons
Operator Actual versus Target Performance
TargetPlanned
Throughput
Actual
Performance
Opportunity for
Improvement
Actual
Throughput Machine
Data
ERP
Data
Supervisor Gantt Status
visualzation
Top 5
downtimes
Cip Top 5
Production
orders
Real data
history
Supervisor Cockpit machine
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
helliphitting margins and investment
Producers are facing higher costs due to the implementation of Tier 4 engines developed to comply with emissions standards
Weaker margins are leading to farmers cutting back investment spending
John Deere has posted a 5 yy decline in revenues with an 11 decline in its agricultural division
Conclusions amp market implications
Conclusion and business implications
54
bull US economy expected to gradually accelerate through 2014 with support from a dovish Fed
bull Europe expected to recover but more ECB action could be required
bull Chinese economy is gradually rebalancing but banking crisis cannot be discounted
bull Emerging markets quiet for now but structural issue unsolved
bull Geopolitical tensions in the Middle East and Ukraine are being monitored carefully
Thank you
Gregory Daco
Chief US Economist gregorydacooxfordeconomicscom
September 2014
September 10 2014 2014 General Managersrsquo Meeting
Digital Manufacturing
World Class Shop Floor Management Release 5 The Smart Factory Revolution Mr Franz E Gruber Founder amp CEO
Dr Mohamed Abuali COO FORCAM Inc
MTConnect Evolution of a Standard and
Next Generation Interoperability Mr Courtney J Hill Chairman amp President
MTConnect Institute
QampA Session
World Class
Shop Floor Management
The Smart Factory Revolution
Franz E Gruber
Founder amp CEO
Mohamed Abuali
COO
汉语
World Class Shop Floor Management
FORCAM 2014 Page 2
FORCAMlsquos Passion
FORCAM provides proven
manufacturing solutions to
Continuously Improve Productivity
To be the global solutions provider of
the best-in-class Manufacturing
Execution Systems
FORCAM 2014 Page 3
FORCAM ndash 2014 Best Practices Award by Frost amp Sullivan
Frost amp Sullivan
ldquoFORCAM is a plant production software
solution provider that understands and
supports Industry 40 needsrdquo
FORCAM 2014 Page 4
FORCAMrsquos Testimonials and Industry Leadership
FORCAM 2014 Page 5
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
6 B Bartke S Wagner IPI-2
Shop Floor Management Audi - FORCAM FIT 2011-
Bernhard Bartke - Director Components Manufacturing
Stefan Wagner - Director Gear Manufacturing
7 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
bull Collection and recording of Operational Data via a database
(ex Machine States and State Changes)
Machine
Operator
Production Manager
Technical Assistant IT
Plant
Manager
Team Leader
8 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Interfaces
Time
Objectivity of Process Data
9 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Need for Continuous Improvement
bull Objective Information and Communication ndash across ALL levels
bull Transperancy and Visualization - Online
bull Real-time availability of operational data ndash Live Reports
bull Measurable increase in Plant Efficiency (OEE)
10 B Bartke S Wagner IPI-2
Shop Floor Management ndash Realtime bdquoANDONldquo Visualization
bull Web-based Interface Anywhere Anytime Access
bull Real-time Production Status Visualization
In Production
Overflow
Stoppage
Organizational
Stoppage
Idle (Pause)
Tool
Problem
11 B Bartke S Wagner IPI-2
Shop Floor Management Reporting ndash Hierarchical Status Diagrams
bull Reporting for Machines Groups Lines or the whole Plant
Technical
Stoppage In Production
Organizational
Stoppage Pause Overflow
Stoppage
Tool Problem In Setup
12 B Bartke S Wagner IPI-2
Audi Production System (APS)
Leadership Communication
bull Process Control
Standards
bull In Processes
bull Im Products
bull In the Organization
Learning Organization
bull Employee Development
bull Problem-Solving
bull CIP Culture
13 B Bartke S Wagner IPI-2
Shop Floor Management Process Control Panel on the shop floor
OEE Trend
(Day Week Month)
Measures
Quality
Process Control
14 B Bartke S Wagner IPI-2
OEE - Yesterday
Availability Trend
OEE ndash Last Week
OEE ndash Last Month
Naoki Nojiri IPI-25 BDE-Ist Stand 05042011
Shop Floor Management Process Control Panel on the shop floor
15 B Bartke S Wagner IPI-2
Shop Floor Management Management Cockpit
Planned vs Actual
(shift)
Top problems
(challenges)
OEE ndash Last Week
16 B Bartke S Wagner IPI-2
hellipand what have we achieved
17 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development suspension components (OEE Overall Equipment Effectiveness)
Radtraumlger
Start Shop Floor Management with
FORCAM +10
_
18 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development (20+ Increase in OEE in AUDI Stamping Facilities) (OEE Overall Equipment Effectiveness)
Radtraumlger
Start SFM +20
_
Our Beliefs
Respect
Collaboration
Excellence
Integrity
Community
Oct 30th 2013
Lean with Shop Floor Management BorgWarner Turbo Systems Rzeszow
Operator FactoryFrameworktrade Worker Client- Book On
Operator Downtime Reasons
Operator Actual versus Target Performance
TargetPlanned
Throughput
Actual
Performance
Opportunity for
Improvement
Actual
Throughput Machine
Data
ERP
Data
Supervisor Gantt Status
visualzation
Top 5
downtimes
Cip Top 5
Production
orders
Real data
history
Supervisor Cockpit machine
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
Conclusions amp market implications
Conclusion and business implications
54
bull US economy expected to gradually accelerate through 2014 with support from a dovish Fed
bull Europe expected to recover but more ECB action could be required
bull Chinese economy is gradually rebalancing but banking crisis cannot be discounted
bull Emerging markets quiet for now but structural issue unsolved
bull Geopolitical tensions in the Middle East and Ukraine are being monitored carefully
Thank you
Gregory Daco
Chief US Economist gregorydacooxfordeconomicscom
September 2014
September 10 2014 2014 General Managersrsquo Meeting
Digital Manufacturing
World Class Shop Floor Management Release 5 The Smart Factory Revolution Mr Franz E Gruber Founder amp CEO
Dr Mohamed Abuali COO FORCAM Inc
MTConnect Evolution of a Standard and
Next Generation Interoperability Mr Courtney J Hill Chairman amp President
MTConnect Institute
QampA Session
World Class
Shop Floor Management
The Smart Factory Revolution
Franz E Gruber
Founder amp CEO
Mohamed Abuali
COO
汉语
World Class Shop Floor Management
FORCAM 2014 Page 2
FORCAMlsquos Passion
FORCAM provides proven
manufacturing solutions to
Continuously Improve Productivity
To be the global solutions provider of
the best-in-class Manufacturing
Execution Systems
FORCAM 2014 Page 3
FORCAM ndash 2014 Best Practices Award by Frost amp Sullivan
Frost amp Sullivan
ldquoFORCAM is a plant production software
solution provider that understands and
supports Industry 40 needsrdquo
FORCAM 2014 Page 4
FORCAMrsquos Testimonials and Industry Leadership
FORCAM 2014 Page 5
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
6 B Bartke S Wagner IPI-2
Shop Floor Management Audi - FORCAM FIT 2011-
Bernhard Bartke - Director Components Manufacturing
Stefan Wagner - Director Gear Manufacturing
7 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
bull Collection and recording of Operational Data via a database
(ex Machine States and State Changes)
Machine
Operator
Production Manager
Technical Assistant IT
Plant
Manager
Team Leader
8 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Interfaces
Time
Objectivity of Process Data
9 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Need for Continuous Improvement
bull Objective Information and Communication ndash across ALL levels
bull Transperancy and Visualization - Online
bull Real-time availability of operational data ndash Live Reports
bull Measurable increase in Plant Efficiency (OEE)
10 B Bartke S Wagner IPI-2
Shop Floor Management ndash Realtime bdquoANDONldquo Visualization
bull Web-based Interface Anywhere Anytime Access
bull Real-time Production Status Visualization
In Production
Overflow
Stoppage
Organizational
Stoppage
Idle (Pause)
Tool
Problem
11 B Bartke S Wagner IPI-2
Shop Floor Management Reporting ndash Hierarchical Status Diagrams
bull Reporting for Machines Groups Lines or the whole Plant
Technical
Stoppage In Production
Organizational
Stoppage Pause Overflow
Stoppage
Tool Problem In Setup
12 B Bartke S Wagner IPI-2
Audi Production System (APS)
Leadership Communication
bull Process Control
Standards
bull In Processes
bull Im Products
bull In the Organization
Learning Organization
bull Employee Development
bull Problem-Solving
bull CIP Culture
13 B Bartke S Wagner IPI-2
Shop Floor Management Process Control Panel on the shop floor
OEE Trend
(Day Week Month)
Measures
Quality
Process Control
14 B Bartke S Wagner IPI-2
OEE - Yesterday
Availability Trend
OEE ndash Last Week
OEE ndash Last Month
Naoki Nojiri IPI-25 BDE-Ist Stand 05042011
Shop Floor Management Process Control Panel on the shop floor
15 B Bartke S Wagner IPI-2
Shop Floor Management Management Cockpit
Planned vs Actual
(shift)
Top problems
(challenges)
OEE ndash Last Week
16 B Bartke S Wagner IPI-2
hellipand what have we achieved
17 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development suspension components (OEE Overall Equipment Effectiveness)
Radtraumlger
Start Shop Floor Management with
FORCAM +10
_
18 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development (20+ Increase in OEE in AUDI Stamping Facilities) (OEE Overall Equipment Effectiveness)
Radtraumlger
Start SFM +20
_
Our Beliefs
Respect
Collaboration
Excellence
Integrity
Community
Oct 30th 2013
Lean with Shop Floor Management BorgWarner Turbo Systems Rzeszow
Operator FactoryFrameworktrade Worker Client- Book On
Operator Downtime Reasons
Operator Actual versus Target Performance
TargetPlanned
Throughput
Actual
Performance
Opportunity for
Improvement
Actual
Throughput Machine
Data
ERP
Data
Supervisor Gantt Status
visualzation
Top 5
downtimes
Cip Top 5
Production
orders
Real data
history
Supervisor Cockpit machine
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
Conclusion and business implications
54
bull US economy expected to gradually accelerate through 2014 with support from a dovish Fed
bull Europe expected to recover but more ECB action could be required
bull Chinese economy is gradually rebalancing but banking crisis cannot be discounted
bull Emerging markets quiet for now but structural issue unsolved
bull Geopolitical tensions in the Middle East and Ukraine are being monitored carefully
Thank you
Gregory Daco
Chief US Economist gregorydacooxfordeconomicscom
September 2014
September 10 2014 2014 General Managersrsquo Meeting
Digital Manufacturing
World Class Shop Floor Management Release 5 The Smart Factory Revolution Mr Franz E Gruber Founder amp CEO
Dr Mohamed Abuali COO FORCAM Inc
MTConnect Evolution of a Standard and
Next Generation Interoperability Mr Courtney J Hill Chairman amp President
MTConnect Institute
QampA Session
World Class
Shop Floor Management
The Smart Factory Revolution
Franz E Gruber
Founder amp CEO
Mohamed Abuali
COO
汉语
World Class Shop Floor Management
FORCAM 2014 Page 2
FORCAMlsquos Passion
FORCAM provides proven
manufacturing solutions to
Continuously Improve Productivity
To be the global solutions provider of
the best-in-class Manufacturing
Execution Systems
FORCAM 2014 Page 3
FORCAM ndash 2014 Best Practices Award by Frost amp Sullivan
Frost amp Sullivan
ldquoFORCAM is a plant production software
solution provider that understands and
supports Industry 40 needsrdquo
FORCAM 2014 Page 4
FORCAMrsquos Testimonials and Industry Leadership
FORCAM 2014 Page 5
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
6 B Bartke S Wagner IPI-2
Shop Floor Management Audi - FORCAM FIT 2011-
Bernhard Bartke - Director Components Manufacturing
Stefan Wagner - Director Gear Manufacturing
7 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
bull Collection and recording of Operational Data via a database
(ex Machine States and State Changes)
Machine
Operator
Production Manager
Technical Assistant IT
Plant
Manager
Team Leader
8 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Interfaces
Time
Objectivity of Process Data
9 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Need for Continuous Improvement
bull Objective Information and Communication ndash across ALL levels
bull Transperancy and Visualization - Online
bull Real-time availability of operational data ndash Live Reports
bull Measurable increase in Plant Efficiency (OEE)
10 B Bartke S Wagner IPI-2
Shop Floor Management ndash Realtime bdquoANDONldquo Visualization
bull Web-based Interface Anywhere Anytime Access
bull Real-time Production Status Visualization
In Production
Overflow
Stoppage
Organizational
Stoppage
Idle (Pause)
Tool
Problem
11 B Bartke S Wagner IPI-2
Shop Floor Management Reporting ndash Hierarchical Status Diagrams
bull Reporting for Machines Groups Lines or the whole Plant
Technical
Stoppage In Production
Organizational
Stoppage Pause Overflow
Stoppage
Tool Problem In Setup
12 B Bartke S Wagner IPI-2
Audi Production System (APS)
Leadership Communication
bull Process Control
Standards
bull In Processes
bull Im Products
bull In the Organization
Learning Organization
bull Employee Development
bull Problem-Solving
bull CIP Culture
13 B Bartke S Wagner IPI-2
Shop Floor Management Process Control Panel on the shop floor
OEE Trend
(Day Week Month)
Measures
Quality
Process Control
14 B Bartke S Wagner IPI-2
OEE - Yesterday
Availability Trend
OEE ndash Last Week
OEE ndash Last Month
Naoki Nojiri IPI-25 BDE-Ist Stand 05042011
Shop Floor Management Process Control Panel on the shop floor
15 B Bartke S Wagner IPI-2
Shop Floor Management Management Cockpit
Planned vs Actual
(shift)
Top problems
(challenges)
OEE ndash Last Week
16 B Bartke S Wagner IPI-2
hellipand what have we achieved
17 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development suspension components (OEE Overall Equipment Effectiveness)
Radtraumlger
Start Shop Floor Management with
FORCAM +10
_
18 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development (20+ Increase in OEE in AUDI Stamping Facilities) (OEE Overall Equipment Effectiveness)
Radtraumlger
Start SFM +20
_
Our Beliefs
Respect
Collaboration
Excellence
Integrity
Community
Oct 30th 2013
Lean with Shop Floor Management BorgWarner Turbo Systems Rzeszow
Operator FactoryFrameworktrade Worker Client- Book On
Operator Downtime Reasons
Operator Actual versus Target Performance
TargetPlanned
Throughput
Actual
Performance
Opportunity for
Improvement
Actual
Throughput Machine
Data
ERP
Data
Supervisor Gantt Status
visualzation
Top 5
downtimes
Cip Top 5
Production
orders
Real data
history
Supervisor Cockpit machine
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
Thank you
Gregory Daco
Chief US Economist gregorydacooxfordeconomicscom
September 2014
September 10 2014 2014 General Managersrsquo Meeting
Digital Manufacturing
World Class Shop Floor Management Release 5 The Smart Factory Revolution Mr Franz E Gruber Founder amp CEO
Dr Mohamed Abuali COO FORCAM Inc
MTConnect Evolution of a Standard and
Next Generation Interoperability Mr Courtney J Hill Chairman amp President
MTConnect Institute
QampA Session
World Class
Shop Floor Management
The Smart Factory Revolution
Franz E Gruber
Founder amp CEO
Mohamed Abuali
COO
汉语
World Class Shop Floor Management
FORCAM 2014 Page 2
FORCAMlsquos Passion
FORCAM provides proven
manufacturing solutions to
Continuously Improve Productivity
To be the global solutions provider of
the best-in-class Manufacturing
Execution Systems
FORCAM 2014 Page 3
FORCAM ndash 2014 Best Practices Award by Frost amp Sullivan
Frost amp Sullivan
ldquoFORCAM is a plant production software
solution provider that understands and
supports Industry 40 needsrdquo
FORCAM 2014 Page 4
FORCAMrsquos Testimonials and Industry Leadership
FORCAM 2014 Page 5
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
6 B Bartke S Wagner IPI-2
Shop Floor Management Audi - FORCAM FIT 2011-
Bernhard Bartke - Director Components Manufacturing
Stefan Wagner - Director Gear Manufacturing
7 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
bull Collection and recording of Operational Data via a database
(ex Machine States and State Changes)
Machine
Operator
Production Manager
Technical Assistant IT
Plant
Manager
Team Leader
8 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Interfaces
Time
Objectivity of Process Data
9 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Need for Continuous Improvement
bull Objective Information and Communication ndash across ALL levels
bull Transperancy and Visualization - Online
bull Real-time availability of operational data ndash Live Reports
bull Measurable increase in Plant Efficiency (OEE)
10 B Bartke S Wagner IPI-2
Shop Floor Management ndash Realtime bdquoANDONldquo Visualization
bull Web-based Interface Anywhere Anytime Access
bull Real-time Production Status Visualization
In Production
Overflow
Stoppage
Organizational
Stoppage
Idle (Pause)
Tool
Problem
11 B Bartke S Wagner IPI-2
Shop Floor Management Reporting ndash Hierarchical Status Diagrams
bull Reporting for Machines Groups Lines or the whole Plant
Technical
Stoppage In Production
Organizational
Stoppage Pause Overflow
Stoppage
Tool Problem In Setup
12 B Bartke S Wagner IPI-2
Audi Production System (APS)
Leadership Communication
bull Process Control
Standards
bull In Processes
bull Im Products
bull In the Organization
Learning Organization
bull Employee Development
bull Problem-Solving
bull CIP Culture
13 B Bartke S Wagner IPI-2
Shop Floor Management Process Control Panel on the shop floor
OEE Trend
(Day Week Month)
Measures
Quality
Process Control
14 B Bartke S Wagner IPI-2
OEE - Yesterday
Availability Trend
OEE ndash Last Week
OEE ndash Last Month
Naoki Nojiri IPI-25 BDE-Ist Stand 05042011
Shop Floor Management Process Control Panel on the shop floor
15 B Bartke S Wagner IPI-2
Shop Floor Management Management Cockpit
Planned vs Actual
(shift)
Top problems
(challenges)
OEE ndash Last Week
16 B Bartke S Wagner IPI-2
hellipand what have we achieved
17 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development suspension components (OEE Overall Equipment Effectiveness)
Radtraumlger
Start Shop Floor Management with
FORCAM +10
_
18 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development (20+ Increase in OEE in AUDI Stamping Facilities) (OEE Overall Equipment Effectiveness)
Radtraumlger
Start SFM +20
_
Our Beliefs
Respect
Collaboration
Excellence
Integrity
Community
Oct 30th 2013
Lean with Shop Floor Management BorgWarner Turbo Systems Rzeszow
Operator FactoryFrameworktrade Worker Client- Book On
Operator Downtime Reasons
Operator Actual versus Target Performance
TargetPlanned
Throughput
Actual
Performance
Opportunity for
Improvement
Actual
Throughput Machine
Data
ERP
Data
Supervisor Gantt Status
visualzation
Top 5
downtimes
Cip Top 5
Production
orders
Real data
history
Supervisor Cockpit machine
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
September 10 2014 2014 General Managersrsquo Meeting
Digital Manufacturing
World Class Shop Floor Management Release 5 The Smart Factory Revolution Mr Franz E Gruber Founder amp CEO
Dr Mohamed Abuali COO FORCAM Inc
MTConnect Evolution of a Standard and
Next Generation Interoperability Mr Courtney J Hill Chairman amp President
MTConnect Institute
QampA Session
World Class
Shop Floor Management
The Smart Factory Revolution
Franz E Gruber
Founder amp CEO
Mohamed Abuali
COO
汉语
World Class Shop Floor Management
FORCAM 2014 Page 2
FORCAMlsquos Passion
FORCAM provides proven
manufacturing solutions to
Continuously Improve Productivity
To be the global solutions provider of
the best-in-class Manufacturing
Execution Systems
FORCAM 2014 Page 3
FORCAM ndash 2014 Best Practices Award by Frost amp Sullivan
Frost amp Sullivan
ldquoFORCAM is a plant production software
solution provider that understands and
supports Industry 40 needsrdquo
FORCAM 2014 Page 4
FORCAMrsquos Testimonials and Industry Leadership
FORCAM 2014 Page 5
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
6 B Bartke S Wagner IPI-2
Shop Floor Management Audi - FORCAM FIT 2011-
Bernhard Bartke - Director Components Manufacturing
Stefan Wagner - Director Gear Manufacturing
7 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
bull Collection and recording of Operational Data via a database
(ex Machine States and State Changes)
Machine
Operator
Production Manager
Technical Assistant IT
Plant
Manager
Team Leader
8 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Interfaces
Time
Objectivity of Process Data
9 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Need for Continuous Improvement
bull Objective Information and Communication ndash across ALL levels
bull Transperancy and Visualization - Online
bull Real-time availability of operational data ndash Live Reports
bull Measurable increase in Plant Efficiency (OEE)
10 B Bartke S Wagner IPI-2
Shop Floor Management ndash Realtime bdquoANDONldquo Visualization
bull Web-based Interface Anywhere Anytime Access
bull Real-time Production Status Visualization
In Production
Overflow
Stoppage
Organizational
Stoppage
Idle (Pause)
Tool
Problem
11 B Bartke S Wagner IPI-2
Shop Floor Management Reporting ndash Hierarchical Status Diagrams
bull Reporting for Machines Groups Lines or the whole Plant
Technical
Stoppage In Production
Organizational
Stoppage Pause Overflow
Stoppage
Tool Problem In Setup
12 B Bartke S Wagner IPI-2
Audi Production System (APS)
Leadership Communication
bull Process Control
Standards
bull In Processes
bull Im Products
bull In the Organization
Learning Organization
bull Employee Development
bull Problem-Solving
bull CIP Culture
13 B Bartke S Wagner IPI-2
Shop Floor Management Process Control Panel on the shop floor
OEE Trend
(Day Week Month)
Measures
Quality
Process Control
14 B Bartke S Wagner IPI-2
OEE - Yesterday
Availability Trend
OEE ndash Last Week
OEE ndash Last Month
Naoki Nojiri IPI-25 BDE-Ist Stand 05042011
Shop Floor Management Process Control Panel on the shop floor
15 B Bartke S Wagner IPI-2
Shop Floor Management Management Cockpit
Planned vs Actual
(shift)
Top problems
(challenges)
OEE ndash Last Week
16 B Bartke S Wagner IPI-2
hellipand what have we achieved
17 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development suspension components (OEE Overall Equipment Effectiveness)
Radtraumlger
Start Shop Floor Management with
FORCAM +10
_
18 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development (20+ Increase in OEE in AUDI Stamping Facilities) (OEE Overall Equipment Effectiveness)
Radtraumlger
Start SFM +20
_
Our Beliefs
Respect
Collaboration
Excellence
Integrity
Community
Oct 30th 2013
Lean with Shop Floor Management BorgWarner Turbo Systems Rzeszow
Operator FactoryFrameworktrade Worker Client- Book On
Operator Downtime Reasons
Operator Actual versus Target Performance
TargetPlanned
Throughput
Actual
Performance
Opportunity for
Improvement
Actual
Throughput Machine
Data
ERP
Data
Supervisor Gantt Status
visualzation
Top 5
downtimes
Cip Top 5
Production
orders
Real data
history
Supervisor Cockpit machine
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
World Class
Shop Floor Management
The Smart Factory Revolution
Franz E Gruber
Founder amp CEO
Mohamed Abuali
COO
汉语
World Class Shop Floor Management
FORCAM 2014 Page 2
FORCAMlsquos Passion
FORCAM provides proven
manufacturing solutions to
Continuously Improve Productivity
To be the global solutions provider of
the best-in-class Manufacturing
Execution Systems
FORCAM 2014 Page 3
FORCAM ndash 2014 Best Practices Award by Frost amp Sullivan
Frost amp Sullivan
ldquoFORCAM is a plant production software
solution provider that understands and
supports Industry 40 needsrdquo
FORCAM 2014 Page 4
FORCAMrsquos Testimonials and Industry Leadership
FORCAM 2014 Page 5
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
6 B Bartke S Wagner IPI-2
Shop Floor Management Audi - FORCAM FIT 2011-
Bernhard Bartke - Director Components Manufacturing
Stefan Wagner - Director Gear Manufacturing
7 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
bull Collection and recording of Operational Data via a database
(ex Machine States and State Changes)
Machine
Operator
Production Manager
Technical Assistant IT
Plant
Manager
Team Leader
8 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Interfaces
Time
Objectivity of Process Data
9 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Need for Continuous Improvement
bull Objective Information and Communication ndash across ALL levels
bull Transperancy and Visualization - Online
bull Real-time availability of operational data ndash Live Reports
bull Measurable increase in Plant Efficiency (OEE)
10 B Bartke S Wagner IPI-2
Shop Floor Management ndash Realtime bdquoANDONldquo Visualization
bull Web-based Interface Anywhere Anytime Access
bull Real-time Production Status Visualization
In Production
Overflow
Stoppage
Organizational
Stoppage
Idle (Pause)
Tool
Problem
11 B Bartke S Wagner IPI-2
Shop Floor Management Reporting ndash Hierarchical Status Diagrams
bull Reporting for Machines Groups Lines or the whole Plant
Technical
Stoppage In Production
Organizational
Stoppage Pause Overflow
Stoppage
Tool Problem In Setup
12 B Bartke S Wagner IPI-2
Audi Production System (APS)
Leadership Communication
bull Process Control
Standards
bull In Processes
bull Im Products
bull In the Organization
Learning Organization
bull Employee Development
bull Problem-Solving
bull CIP Culture
13 B Bartke S Wagner IPI-2
Shop Floor Management Process Control Panel on the shop floor
OEE Trend
(Day Week Month)
Measures
Quality
Process Control
14 B Bartke S Wagner IPI-2
OEE - Yesterday
Availability Trend
OEE ndash Last Week
OEE ndash Last Month
Naoki Nojiri IPI-25 BDE-Ist Stand 05042011
Shop Floor Management Process Control Panel on the shop floor
15 B Bartke S Wagner IPI-2
Shop Floor Management Management Cockpit
Planned vs Actual
(shift)
Top problems
(challenges)
OEE ndash Last Week
16 B Bartke S Wagner IPI-2
hellipand what have we achieved
17 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development suspension components (OEE Overall Equipment Effectiveness)
Radtraumlger
Start Shop Floor Management with
FORCAM +10
_
18 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development (20+ Increase in OEE in AUDI Stamping Facilities) (OEE Overall Equipment Effectiveness)
Radtraumlger
Start SFM +20
_
Our Beliefs
Respect
Collaboration
Excellence
Integrity
Community
Oct 30th 2013
Lean with Shop Floor Management BorgWarner Turbo Systems Rzeszow
Operator FactoryFrameworktrade Worker Client- Book On
Operator Downtime Reasons
Operator Actual versus Target Performance
TargetPlanned
Throughput
Actual
Performance
Opportunity for
Improvement
Actual
Throughput Machine
Data
ERP
Data
Supervisor Gantt Status
visualzation
Top 5
downtimes
Cip Top 5
Production
orders
Real data
history
Supervisor Cockpit machine
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
FORCAM 2014 Page 2
FORCAMlsquos Passion
FORCAM provides proven
manufacturing solutions to
Continuously Improve Productivity
To be the global solutions provider of
the best-in-class Manufacturing
Execution Systems
FORCAM 2014 Page 3
FORCAM ndash 2014 Best Practices Award by Frost amp Sullivan
Frost amp Sullivan
ldquoFORCAM is a plant production software
solution provider that understands and
supports Industry 40 needsrdquo
FORCAM 2014 Page 4
FORCAMrsquos Testimonials and Industry Leadership
FORCAM 2014 Page 5
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
6 B Bartke S Wagner IPI-2
Shop Floor Management Audi - FORCAM FIT 2011-
Bernhard Bartke - Director Components Manufacturing
Stefan Wagner - Director Gear Manufacturing
7 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
bull Collection and recording of Operational Data via a database
(ex Machine States and State Changes)
Machine
Operator
Production Manager
Technical Assistant IT
Plant
Manager
Team Leader
8 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Interfaces
Time
Objectivity of Process Data
9 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Need for Continuous Improvement
bull Objective Information and Communication ndash across ALL levels
bull Transperancy and Visualization - Online
bull Real-time availability of operational data ndash Live Reports
bull Measurable increase in Plant Efficiency (OEE)
10 B Bartke S Wagner IPI-2
Shop Floor Management ndash Realtime bdquoANDONldquo Visualization
bull Web-based Interface Anywhere Anytime Access
bull Real-time Production Status Visualization
In Production
Overflow
Stoppage
Organizational
Stoppage
Idle (Pause)
Tool
Problem
11 B Bartke S Wagner IPI-2
Shop Floor Management Reporting ndash Hierarchical Status Diagrams
bull Reporting for Machines Groups Lines or the whole Plant
Technical
Stoppage In Production
Organizational
Stoppage Pause Overflow
Stoppage
Tool Problem In Setup
12 B Bartke S Wagner IPI-2
Audi Production System (APS)
Leadership Communication
bull Process Control
Standards
bull In Processes
bull Im Products
bull In the Organization
Learning Organization
bull Employee Development
bull Problem-Solving
bull CIP Culture
13 B Bartke S Wagner IPI-2
Shop Floor Management Process Control Panel on the shop floor
OEE Trend
(Day Week Month)
Measures
Quality
Process Control
14 B Bartke S Wagner IPI-2
OEE - Yesterday
Availability Trend
OEE ndash Last Week
OEE ndash Last Month
Naoki Nojiri IPI-25 BDE-Ist Stand 05042011
Shop Floor Management Process Control Panel on the shop floor
15 B Bartke S Wagner IPI-2
Shop Floor Management Management Cockpit
Planned vs Actual
(shift)
Top problems
(challenges)
OEE ndash Last Week
16 B Bartke S Wagner IPI-2
hellipand what have we achieved
17 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development suspension components (OEE Overall Equipment Effectiveness)
Radtraumlger
Start Shop Floor Management with
FORCAM +10
_
18 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development (20+ Increase in OEE in AUDI Stamping Facilities) (OEE Overall Equipment Effectiveness)
Radtraumlger
Start SFM +20
_
Our Beliefs
Respect
Collaboration
Excellence
Integrity
Community
Oct 30th 2013
Lean with Shop Floor Management BorgWarner Turbo Systems Rzeszow
Operator FactoryFrameworktrade Worker Client- Book On
Operator Downtime Reasons
Operator Actual versus Target Performance
TargetPlanned
Throughput
Actual
Performance
Opportunity for
Improvement
Actual
Throughput Machine
Data
ERP
Data
Supervisor Gantt Status
visualzation
Top 5
downtimes
Cip Top 5
Production
orders
Real data
history
Supervisor Cockpit machine
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
FORCAM 2014 Page 3
FORCAM ndash 2014 Best Practices Award by Frost amp Sullivan
Frost amp Sullivan
ldquoFORCAM is a plant production software
solution provider that understands and
supports Industry 40 needsrdquo
FORCAM 2014 Page 4
FORCAMrsquos Testimonials and Industry Leadership
FORCAM 2014 Page 5
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
6 B Bartke S Wagner IPI-2
Shop Floor Management Audi - FORCAM FIT 2011-
Bernhard Bartke - Director Components Manufacturing
Stefan Wagner - Director Gear Manufacturing
7 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
bull Collection and recording of Operational Data via a database
(ex Machine States and State Changes)
Machine
Operator
Production Manager
Technical Assistant IT
Plant
Manager
Team Leader
8 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Interfaces
Time
Objectivity of Process Data
9 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Need for Continuous Improvement
bull Objective Information and Communication ndash across ALL levels
bull Transperancy and Visualization - Online
bull Real-time availability of operational data ndash Live Reports
bull Measurable increase in Plant Efficiency (OEE)
10 B Bartke S Wagner IPI-2
Shop Floor Management ndash Realtime bdquoANDONldquo Visualization
bull Web-based Interface Anywhere Anytime Access
bull Real-time Production Status Visualization
In Production
Overflow
Stoppage
Organizational
Stoppage
Idle (Pause)
Tool
Problem
11 B Bartke S Wagner IPI-2
Shop Floor Management Reporting ndash Hierarchical Status Diagrams
bull Reporting for Machines Groups Lines or the whole Plant
Technical
Stoppage In Production
Organizational
Stoppage Pause Overflow
Stoppage
Tool Problem In Setup
12 B Bartke S Wagner IPI-2
Audi Production System (APS)
Leadership Communication
bull Process Control
Standards
bull In Processes
bull Im Products
bull In the Organization
Learning Organization
bull Employee Development
bull Problem-Solving
bull CIP Culture
13 B Bartke S Wagner IPI-2
Shop Floor Management Process Control Panel on the shop floor
OEE Trend
(Day Week Month)
Measures
Quality
Process Control
14 B Bartke S Wagner IPI-2
OEE - Yesterday
Availability Trend
OEE ndash Last Week
OEE ndash Last Month
Naoki Nojiri IPI-25 BDE-Ist Stand 05042011
Shop Floor Management Process Control Panel on the shop floor
15 B Bartke S Wagner IPI-2
Shop Floor Management Management Cockpit
Planned vs Actual
(shift)
Top problems
(challenges)
OEE ndash Last Week
16 B Bartke S Wagner IPI-2
hellipand what have we achieved
17 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development suspension components (OEE Overall Equipment Effectiveness)
Radtraumlger
Start Shop Floor Management with
FORCAM +10
_
18 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development (20+ Increase in OEE in AUDI Stamping Facilities) (OEE Overall Equipment Effectiveness)
Radtraumlger
Start SFM +20
_
Our Beliefs
Respect
Collaboration
Excellence
Integrity
Community
Oct 30th 2013
Lean with Shop Floor Management BorgWarner Turbo Systems Rzeszow
Operator FactoryFrameworktrade Worker Client- Book On
Operator Downtime Reasons
Operator Actual versus Target Performance
TargetPlanned
Throughput
Actual
Performance
Opportunity for
Improvement
Actual
Throughput Machine
Data
ERP
Data
Supervisor Gantt Status
visualzation
Top 5
downtimes
Cip Top 5
Production
orders
Real data
history
Supervisor Cockpit machine
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
FORCAM 2014 Page 4
FORCAMrsquos Testimonials and Industry Leadership
FORCAM 2014 Page 5
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
6 B Bartke S Wagner IPI-2
Shop Floor Management Audi - FORCAM FIT 2011-
Bernhard Bartke - Director Components Manufacturing
Stefan Wagner - Director Gear Manufacturing
7 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
bull Collection and recording of Operational Data via a database
(ex Machine States and State Changes)
Machine
Operator
Production Manager
Technical Assistant IT
Plant
Manager
Team Leader
8 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Interfaces
Time
Objectivity of Process Data
9 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Need for Continuous Improvement
bull Objective Information and Communication ndash across ALL levels
bull Transperancy and Visualization - Online
bull Real-time availability of operational data ndash Live Reports
bull Measurable increase in Plant Efficiency (OEE)
10 B Bartke S Wagner IPI-2
Shop Floor Management ndash Realtime bdquoANDONldquo Visualization
bull Web-based Interface Anywhere Anytime Access
bull Real-time Production Status Visualization
In Production
Overflow
Stoppage
Organizational
Stoppage
Idle (Pause)
Tool
Problem
11 B Bartke S Wagner IPI-2
Shop Floor Management Reporting ndash Hierarchical Status Diagrams
bull Reporting for Machines Groups Lines or the whole Plant
Technical
Stoppage In Production
Organizational
Stoppage Pause Overflow
Stoppage
Tool Problem In Setup
12 B Bartke S Wagner IPI-2
Audi Production System (APS)
Leadership Communication
bull Process Control
Standards
bull In Processes
bull Im Products
bull In the Organization
Learning Organization
bull Employee Development
bull Problem-Solving
bull CIP Culture
13 B Bartke S Wagner IPI-2
Shop Floor Management Process Control Panel on the shop floor
OEE Trend
(Day Week Month)
Measures
Quality
Process Control
14 B Bartke S Wagner IPI-2
OEE - Yesterday
Availability Trend
OEE ndash Last Week
OEE ndash Last Month
Naoki Nojiri IPI-25 BDE-Ist Stand 05042011
Shop Floor Management Process Control Panel on the shop floor
15 B Bartke S Wagner IPI-2
Shop Floor Management Management Cockpit
Planned vs Actual
(shift)
Top problems
(challenges)
OEE ndash Last Week
16 B Bartke S Wagner IPI-2
hellipand what have we achieved
17 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development suspension components (OEE Overall Equipment Effectiveness)
Radtraumlger
Start Shop Floor Management with
FORCAM +10
_
18 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development (20+ Increase in OEE in AUDI Stamping Facilities) (OEE Overall Equipment Effectiveness)
Radtraumlger
Start SFM +20
_
Our Beliefs
Respect
Collaboration
Excellence
Integrity
Community
Oct 30th 2013
Lean with Shop Floor Management BorgWarner Turbo Systems Rzeszow
Operator FactoryFrameworktrade Worker Client- Book On
Operator Downtime Reasons
Operator Actual versus Target Performance
TargetPlanned
Throughput
Actual
Performance
Opportunity for
Improvement
Actual
Throughput Machine
Data
ERP
Data
Supervisor Gantt Status
visualzation
Top 5
downtimes
Cip Top 5
Production
orders
Real data
history
Supervisor Cockpit machine
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
FORCAM 2014 Page 5
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
6 B Bartke S Wagner IPI-2
Shop Floor Management Audi - FORCAM FIT 2011-
Bernhard Bartke - Director Components Manufacturing
Stefan Wagner - Director Gear Manufacturing
7 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
bull Collection and recording of Operational Data via a database
(ex Machine States and State Changes)
Machine
Operator
Production Manager
Technical Assistant IT
Plant
Manager
Team Leader
8 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Interfaces
Time
Objectivity of Process Data
9 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Need for Continuous Improvement
bull Objective Information and Communication ndash across ALL levels
bull Transperancy and Visualization - Online
bull Real-time availability of operational data ndash Live Reports
bull Measurable increase in Plant Efficiency (OEE)
10 B Bartke S Wagner IPI-2
Shop Floor Management ndash Realtime bdquoANDONldquo Visualization
bull Web-based Interface Anywhere Anytime Access
bull Real-time Production Status Visualization
In Production
Overflow
Stoppage
Organizational
Stoppage
Idle (Pause)
Tool
Problem
11 B Bartke S Wagner IPI-2
Shop Floor Management Reporting ndash Hierarchical Status Diagrams
bull Reporting for Machines Groups Lines or the whole Plant
Technical
Stoppage In Production
Organizational
Stoppage Pause Overflow
Stoppage
Tool Problem In Setup
12 B Bartke S Wagner IPI-2
Audi Production System (APS)
Leadership Communication
bull Process Control
Standards
bull In Processes
bull Im Products
bull In the Organization
Learning Organization
bull Employee Development
bull Problem-Solving
bull CIP Culture
13 B Bartke S Wagner IPI-2
Shop Floor Management Process Control Panel on the shop floor
OEE Trend
(Day Week Month)
Measures
Quality
Process Control
14 B Bartke S Wagner IPI-2
OEE - Yesterday
Availability Trend
OEE ndash Last Week
OEE ndash Last Month
Naoki Nojiri IPI-25 BDE-Ist Stand 05042011
Shop Floor Management Process Control Panel on the shop floor
15 B Bartke S Wagner IPI-2
Shop Floor Management Management Cockpit
Planned vs Actual
(shift)
Top problems
(challenges)
OEE ndash Last Week
16 B Bartke S Wagner IPI-2
hellipand what have we achieved
17 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development suspension components (OEE Overall Equipment Effectiveness)
Radtraumlger
Start Shop Floor Management with
FORCAM +10
_
18 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development (20+ Increase in OEE in AUDI Stamping Facilities) (OEE Overall Equipment Effectiveness)
Radtraumlger
Start SFM +20
_
Our Beliefs
Respect
Collaboration
Excellence
Integrity
Community
Oct 30th 2013
Lean with Shop Floor Management BorgWarner Turbo Systems Rzeszow
Operator FactoryFrameworktrade Worker Client- Book On
Operator Downtime Reasons
Operator Actual versus Target Performance
TargetPlanned
Throughput
Actual
Performance
Opportunity for
Improvement
Actual
Throughput Machine
Data
ERP
Data
Supervisor Gantt Status
visualzation
Top 5
downtimes
Cip Top 5
Production
orders
Real data
history
Supervisor Cockpit machine
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
6 B Bartke S Wagner IPI-2
Shop Floor Management Audi - FORCAM FIT 2011-
Bernhard Bartke - Director Components Manufacturing
Stefan Wagner - Director Gear Manufacturing
7 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
bull Collection and recording of Operational Data via a database
(ex Machine States and State Changes)
Machine
Operator
Production Manager
Technical Assistant IT
Plant
Manager
Team Leader
8 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Interfaces
Time
Objectivity of Process Data
9 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Need for Continuous Improvement
bull Objective Information and Communication ndash across ALL levels
bull Transperancy and Visualization - Online
bull Real-time availability of operational data ndash Live Reports
bull Measurable increase in Plant Efficiency (OEE)
10 B Bartke S Wagner IPI-2
Shop Floor Management ndash Realtime bdquoANDONldquo Visualization
bull Web-based Interface Anywhere Anytime Access
bull Real-time Production Status Visualization
In Production
Overflow
Stoppage
Organizational
Stoppage
Idle (Pause)
Tool
Problem
11 B Bartke S Wagner IPI-2
Shop Floor Management Reporting ndash Hierarchical Status Diagrams
bull Reporting for Machines Groups Lines or the whole Plant
Technical
Stoppage In Production
Organizational
Stoppage Pause Overflow
Stoppage
Tool Problem In Setup
12 B Bartke S Wagner IPI-2
Audi Production System (APS)
Leadership Communication
bull Process Control
Standards
bull In Processes
bull Im Products
bull In the Organization
Learning Organization
bull Employee Development
bull Problem-Solving
bull CIP Culture
13 B Bartke S Wagner IPI-2
Shop Floor Management Process Control Panel on the shop floor
OEE Trend
(Day Week Month)
Measures
Quality
Process Control
14 B Bartke S Wagner IPI-2
OEE - Yesterday
Availability Trend
OEE ndash Last Week
OEE ndash Last Month
Naoki Nojiri IPI-25 BDE-Ist Stand 05042011
Shop Floor Management Process Control Panel on the shop floor
15 B Bartke S Wagner IPI-2
Shop Floor Management Management Cockpit
Planned vs Actual
(shift)
Top problems
(challenges)
OEE ndash Last Week
16 B Bartke S Wagner IPI-2
hellipand what have we achieved
17 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development suspension components (OEE Overall Equipment Effectiveness)
Radtraumlger
Start Shop Floor Management with
FORCAM +10
_
18 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development (20+ Increase in OEE in AUDI Stamping Facilities) (OEE Overall Equipment Effectiveness)
Radtraumlger
Start SFM +20
_
Our Beliefs
Respect
Collaboration
Excellence
Integrity
Community
Oct 30th 2013
Lean with Shop Floor Management BorgWarner Turbo Systems Rzeszow
Operator FactoryFrameworktrade Worker Client- Book On
Operator Downtime Reasons
Operator Actual versus Target Performance
TargetPlanned
Throughput
Actual
Performance
Opportunity for
Improvement
Actual
Throughput Machine
Data
ERP
Data
Supervisor Gantt Status
visualzation
Top 5
downtimes
Cip Top 5
Production
orders
Real data
history
Supervisor Cockpit machine
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
7 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
bull Collection and recording of Operational Data via a database
(ex Machine States and State Changes)
Machine
Operator
Production Manager
Technical Assistant IT
Plant
Manager
Team Leader
8 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Interfaces
Time
Objectivity of Process Data
9 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Need for Continuous Improvement
bull Objective Information and Communication ndash across ALL levels
bull Transperancy and Visualization - Online
bull Real-time availability of operational data ndash Live Reports
bull Measurable increase in Plant Efficiency (OEE)
10 B Bartke S Wagner IPI-2
Shop Floor Management ndash Realtime bdquoANDONldquo Visualization
bull Web-based Interface Anywhere Anytime Access
bull Real-time Production Status Visualization
In Production
Overflow
Stoppage
Organizational
Stoppage
Idle (Pause)
Tool
Problem
11 B Bartke S Wagner IPI-2
Shop Floor Management Reporting ndash Hierarchical Status Diagrams
bull Reporting for Machines Groups Lines or the whole Plant
Technical
Stoppage In Production
Organizational
Stoppage Pause Overflow
Stoppage
Tool Problem In Setup
12 B Bartke S Wagner IPI-2
Audi Production System (APS)
Leadership Communication
bull Process Control
Standards
bull In Processes
bull Im Products
bull In the Organization
Learning Organization
bull Employee Development
bull Problem-Solving
bull CIP Culture
13 B Bartke S Wagner IPI-2
Shop Floor Management Process Control Panel on the shop floor
OEE Trend
(Day Week Month)
Measures
Quality
Process Control
14 B Bartke S Wagner IPI-2
OEE - Yesterday
Availability Trend
OEE ndash Last Week
OEE ndash Last Month
Naoki Nojiri IPI-25 BDE-Ist Stand 05042011
Shop Floor Management Process Control Panel on the shop floor
15 B Bartke S Wagner IPI-2
Shop Floor Management Management Cockpit
Planned vs Actual
(shift)
Top problems
(challenges)
OEE ndash Last Week
16 B Bartke S Wagner IPI-2
hellipand what have we achieved
17 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development suspension components (OEE Overall Equipment Effectiveness)
Radtraumlger
Start Shop Floor Management with
FORCAM +10
_
18 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development (20+ Increase in OEE in AUDI Stamping Facilities) (OEE Overall Equipment Effectiveness)
Radtraumlger
Start SFM +20
_
Our Beliefs
Respect
Collaboration
Excellence
Integrity
Community
Oct 30th 2013
Lean with Shop Floor Management BorgWarner Turbo Systems Rzeszow
Operator FactoryFrameworktrade Worker Client- Book On
Operator Downtime Reasons
Operator Actual versus Target Performance
TargetPlanned
Throughput
Actual
Performance
Opportunity for
Improvement
Actual
Throughput Machine
Data
ERP
Data
Supervisor Gantt Status
visualzation
Top 5
downtimes
Cip Top 5
Production
orders
Real data
history
Supervisor Cockpit machine
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
8 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Interfaces
Time
Objectivity of Process Data
9 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Need for Continuous Improvement
bull Objective Information and Communication ndash across ALL levels
bull Transperancy and Visualization - Online
bull Real-time availability of operational data ndash Live Reports
bull Measurable increase in Plant Efficiency (OEE)
10 B Bartke S Wagner IPI-2
Shop Floor Management ndash Realtime bdquoANDONldquo Visualization
bull Web-based Interface Anywhere Anytime Access
bull Real-time Production Status Visualization
In Production
Overflow
Stoppage
Organizational
Stoppage
Idle (Pause)
Tool
Problem
11 B Bartke S Wagner IPI-2
Shop Floor Management Reporting ndash Hierarchical Status Diagrams
bull Reporting for Machines Groups Lines or the whole Plant
Technical
Stoppage In Production
Organizational
Stoppage Pause Overflow
Stoppage
Tool Problem In Setup
12 B Bartke S Wagner IPI-2
Audi Production System (APS)
Leadership Communication
bull Process Control
Standards
bull In Processes
bull Im Products
bull In the Organization
Learning Organization
bull Employee Development
bull Problem-Solving
bull CIP Culture
13 B Bartke S Wagner IPI-2
Shop Floor Management Process Control Panel on the shop floor
OEE Trend
(Day Week Month)
Measures
Quality
Process Control
14 B Bartke S Wagner IPI-2
OEE - Yesterday
Availability Trend
OEE ndash Last Week
OEE ndash Last Month
Naoki Nojiri IPI-25 BDE-Ist Stand 05042011
Shop Floor Management Process Control Panel on the shop floor
15 B Bartke S Wagner IPI-2
Shop Floor Management Management Cockpit
Planned vs Actual
(shift)
Top problems
(challenges)
OEE ndash Last Week
16 B Bartke S Wagner IPI-2
hellipand what have we achieved
17 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development suspension components (OEE Overall Equipment Effectiveness)
Radtraumlger
Start Shop Floor Management with
FORCAM +10
_
18 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development (20+ Increase in OEE in AUDI Stamping Facilities) (OEE Overall Equipment Effectiveness)
Radtraumlger
Start SFM +20
_
Our Beliefs
Respect
Collaboration
Excellence
Integrity
Community
Oct 30th 2013
Lean with Shop Floor Management BorgWarner Turbo Systems Rzeszow
Operator FactoryFrameworktrade Worker Client- Book On
Operator Downtime Reasons
Operator Actual versus Target Performance
TargetPlanned
Throughput
Actual
Performance
Opportunity for
Improvement
Actual
Throughput Machine
Data
ERP
Data
Supervisor Gantt Status
visualzation
Top 5
downtimes
Cip Top 5
Production
orders
Real data
history
Supervisor Cockpit machine
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
9 B Bartke S Wagner IPI-2
Current Status Baseline ndash without Shop Floor Management
Need for Continuous Improvement
bull Objective Information and Communication ndash across ALL levels
bull Transperancy and Visualization - Online
bull Real-time availability of operational data ndash Live Reports
bull Measurable increase in Plant Efficiency (OEE)
10 B Bartke S Wagner IPI-2
Shop Floor Management ndash Realtime bdquoANDONldquo Visualization
bull Web-based Interface Anywhere Anytime Access
bull Real-time Production Status Visualization
In Production
Overflow
Stoppage
Organizational
Stoppage
Idle (Pause)
Tool
Problem
11 B Bartke S Wagner IPI-2
Shop Floor Management Reporting ndash Hierarchical Status Diagrams
bull Reporting for Machines Groups Lines or the whole Plant
Technical
Stoppage In Production
Organizational
Stoppage Pause Overflow
Stoppage
Tool Problem In Setup
12 B Bartke S Wagner IPI-2
Audi Production System (APS)
Leadership Communication
bull Process Control
Standards
bull In Processes
bull Im Products
bull In the Organization
Learning Organization
bull Employee Development
bull Problem-Solving
bull CIP Culture
13 B Bartke S Wagner IPI-2
Shop Floor Management Process Control Panel on the shop floor
OEE Trend
(Day Week Month)
Measures
Quality
Process Control
14 B Bartke S Wagner IPI-2
OEE - Yesterday
Availability Trend
OEE ndash Last Week
OEE ndash Last Month
Naoki Nojiri IPI-25 BDE-Ist Stand 05042011
Shop Floor Management Process Control Panel on the shop floor
15 B Bartke S Wagner IPI-2
Shop Floor Management Management Cockpit
Planned vs Actual
(shift)
Top problems
(challenges)
OEE ndash Last Week
16 B Bartke S Wagner IPI-2
hellipand what have we achieved
17 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development suspension components (OEE Overall Equipment Effectiveness)
Radtraumlger
Start Shop Floor Management with
FORCAM +10
_
18 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development (20+ Increase in OEE in AUDI Stamping Facilities) (OEE Overall Equipment Effectiveness)
Radtraumlger
Start SFM +20
_
Our Beliefs
Respect
Collaboration
Excellence
Integrity
Community
Oct 30th 2013
Lean with Shop Floor Management BorgWarner Turbo Systems Rzeszow
Operator FactoryFrameworktrade Worker Client- Book On
Operator Downtime Reasons
Operator Actual versus Target Performance
TargetPlanned
Throughput
Actual
Performance
Opportunity for
Improvement
Actual
Throughput Machine
Data
ERP
Data
Supervisor Gantt Status
visualzation
Top 5
downtimes
Cip Top 5
Production
orders
Real data
history
Supervisor Cockpit machine
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
10 B Bartke S Wagner IPI-2
Shop Floor Management ndash Realtime bdquoANDONldquo Visualization
bull Web-based Interface Anywhere Anytime Access
bull Real-time Production Status Visualization
In Production
Overflow
Stoppage
Organizational
Stoppage
Idle (Pause)
Tool
Problem
11 B Bartke S Wagner IPI-2
Shop Floor Management Reporting ndash Hierarchical Status Diagrams
bull Reporting for Machines Groups Lines or the whole Plant
Technical
Stoppage In Production
Organizational
Stoppage Pause Overflow
Stoppage
Tool Problem In Setup
12 B Bartke S Wagner IPI-2
Audi Production System (APS)
Leadership Communication
bull Process Control
Standards
bull In Processes
bull Im Products
bull In the Organization
Learning Organization
bull Employee Development
bull Problem-Solving
bull CIP Culture
13 B Bartke S Wagner IPI-2
Shop Floor Management Process Control Panel on the shop floor
OEE Trend
(Day Week Month)
Measures
Quality
Process Control
14 B Bartke S Wagner IPI-2
OEE - Yesterday
Availability Trend
OEE ndash Last Week
OEE ndash Last Month
Naoki Nojiri IPI-25 BDE-Ist Stand 05042011
Shop Floor Management Process Control Panel on the shop floor
15 B Bartke S Wagner IPI-2
Shop Floor Management Management Cockpit
Planned vs Actual
(shift)
Top problems
(challenges)
OEE ndash Last Week
16 B Bartke S Wagner IPI-2
hellipand what have we achieved
17 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development suspension components (OEE Overall Equipment Effectiveness)
Radtraumlger
Start Shop Floor Management with
FORCAM +10
_
18 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development (20+ Increase in OEE in AUDI Stamping Facilities) (OEE Overall Equipment Effectiveness)
Radtraumlger
Start SFM +20
_
Our Beliefs
Respect
Collaboration
Excellence
Integrity
Community
Oct 30th 2013
Lean with Shop Floor Management BorgWarner Turbo Systems Rzeszow
Operator FactoryFrameworktrade Worker Client- Book On
Operator Downtime Reasons
Operator Actual versus Target Performance
TargetPlanned
Throughput
Actual
Performance
Opportunity for
Improvement
Actual
Throughput Machine
Data
ERP
Data
Supervisor Gantt Status
visualzation
Top 5
downtimes
Cip Top 5
Production
orders
Real data
history
Supervisor Cockpit machine
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
11 B Bartke S Wagner IPI-2
Shop Floor Management Reporting ndash Hierarchical Status Diagrams
bull Reporting for Machines Groups Lines or the whole Plant
Technical
Stoppage In Production
Organizational
Stoppage Pause Overflow
Stoppage
Tool Problem In Setup
12 B Bartke S Wagner IPI-2
Audi Production System (APS)
Leadership Communication
bull Process Control
Standards
bull In Processes
bull Im Products
bull In the Organization
Learning Organization
bull Employee Development
bull Problem-Solving
bull CIP Culture
13 B Bartke S Wagner IPI-2
Shop Floor Management Process Control Panel on the shop floor
OEE Trend
(Day Week Month)
Measures
Quality
Process Control
14 B Bartke S Wagner IPI-2
OEE - Yesterday
Availability Trend
OEE ndash Last Week
OEE ndash Last Month
Naoki Nojiri IPI-25 BDE-Ist Stand 05042011
Shop Floor Management Process Control Panel on the shop floor
15 B Bartke S Wagner IPI-2
Shop Floor Management Management Cockpit
Planned vs Actual
(shift)
Top problems
(challenges)
OEE ndash Last Week
16 B Bartke S Wagner IPI-2
hellipand what have we achieved
17 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development suspension components (OEE Overall Equipment Effectiveness)
Radtraumlger
Start Shop Floor Management with
FORCAM +10
_
18 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development (20+ Increase in OEE in AUDI Stamping Facilities) (OEE Overall Equipment Effectiveness)
Radtraumlger
Start SFM +20
_
Our Beliefs
Respect
Collaboration
Excellence
Integrity
Community
Oct 30th 2013
Lean with Shop Floor Management BorgWarner Turbo Systems Rzeszow
Operator FactoryFrameworktrade Worker Client- Book On
Operator Downtime Reasons
Operator Actual versus Target Performance
TargetPlanned
Throughput
Actual
Performance
Opportunity for
Improvement
Actual
Throughput Machine
Data
ERP
Data
Supervisor Gantt Status
visualzation
Top 5
downtimes
Cip Top 5
Production
orders
Real data
history
Supervisor Cockpit machine
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
12 B Bartke S Wagner IPI-2
Audi Production System (APS)
Leadership Communication
bull Process Control
Standards
bull In Processes
bull Im Products
bull In the Organization
Learning Organization
bull Employee Development
bull Problem-Solving
bull CIP Culture
13 B Bartke S Wagner IPI-2
Shop Floor Management Process Control Panel on the shop floor
OEE Trend
(Day Week Month)
Measures
Quality
Process Control
14 B Bartke S Wagner IPI-2
OEE - Yesterday
Availability Trend
OEE ndash Last Week
OEE ndash Last Month
Naoki Nojiri IPI-25 BDE-Ist Stand 05042011
Shop Floor Management Process Control Panel on the shop floor
15 B Bartke S Wagner IPI-2
Shop Floor Management Management Cockpit
Planned vs Actual
(shift)
Top problems
(challenges)
OEE ndash Last Week
16 B Bartke S Wagner IPI-2
hellipand what have we achieved
17 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development suspension components (OEE Overall Equipment Effectiveness)
Radtraumlger
Start Shop Floor Management with
FORCAM +10
_
18 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development (20+ Increase in OEE in AUDI Stamping Facilities) (OEE Overall Equipment Effectiveness)
Radtraumlger
Start SFM +20
_
Our Beliefs
Respect
Collaboration
Excellence
Integrity
Community
Oct 30th 2013
Lean with Shop Floor Management BorgWarner Turbo Systems Rzeszow
Operator FactoryFrameworktrade Worker Client- Book On
Operator Downtime Reasons
Operator Actual versus Target Performance
TargetPlanned
Throughput
Actual
Performance
Opportunity for
Improvement
Actual
Throughput Machine
Data
ERP
Data
Supervisor Gantt Status
visualzation
Top 5
downtimes
Cip Top 5
Production
orders
Real data
history
Supervisor Cockpit machine
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
13 B Bartke S Wagner IPI-2
Shop Floor Management Process Control Panel on the shop floor
OEE Trend
(Day Week Month)
Measures
Quality
Process Control
14 B Bartke S Wagner IPI-2
OEE - Yesterday
Availability Trend
OEE ndash Last Week
OEE ndash Last Month
Naoki Nojiri IPI-25 BDE-Ist Stand 05042011
Shop Floor Management Process Control Panel on the shop floor
15 B Bartke S Wagner IPI-2
Shop Floor Management Management Cockpit
Planned vs Actual
(shift)
Top problems
(challenges)
OEE ndash Last Week
16 B Bartke S Wagner IPI-2
hellipand what have we achieved
17 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development suspension components (OEE Overall Equipment Effectiveness)
Radtraumlger
Start Shop Floor Management with
FORCAM +10
_
18 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development (20+ Increase in OEE in AUDI Stamping Facilities) (OEE Overall Equipment Effectiveness)
Radtraumlger
Start SFM +20
_
Our Beliefs
Respect
Collaboration
Excellence
Integrity
Community
Oct 30th 2013
Lean with Shop Floor Management BorgWarner Turbo Systems Rzeszow
Operator FactoryFrameworktrade Worker Client- Book On
Operator Downtime Reasons
Operator Actual versus Target Performance
TargetPlanned
Throughput
Actual
Performance
Opportunity for
Improvement
Actual
Throughput Machine
Data
ERP
Data
Supervisor Gantt Status
visualzation
Top 5
downtimes
Cip Top 5
Production
orders
Real data
history
Supervisor Cockpit machine
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
14 B Bartke S Wagner IPI-2
OEE - Yesterday
Availability Trend
OEE ndash Last Week
OEE ndash Last Month
Naoki Nojiri IPI-25 BDE-Ist Stand 05042011
Shop Floor Management Process Control Panel on the shop floor
15 B Bartke S Wagner IPI-2
Shop Floor Management Management Cockpit
Planned vs Actual
(shift)
Top problems
(challenges)
OEE ndash Last Week
16 B Bartke S Wagner IPI-2
hellipand what have we achieved
17 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development suspension components (OEE Overall Equipment Effectiveness)
Radtraumlger
Start Shop Floor Management with
FORCAM +10
_
18 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development (20+ Increase in OEE in AUDI Stamping Facilities) (OEE Overall Equipment Effectiveness)
Radtraumlger
Start SFM +20
_
Our Beliefs
Respect
Collaboration
Excellence
Integrity
Community
Oct 30th 2013
Lean with Shop Floor Management BorgWarner Turbo Systems Rzeszow
Operator FactoryFrameworktrade Worker Client- Book On
Operator Downtime Reasons
Operator Actual versus Target Performance
TargetPlanned
Throughput
Actual
Performance
Opportunity for
Improvement
Actual
Throughput Machine
Data
ERP
Data
Supervisor Gantt Status
visualzation
Top 5
downtimes
Cip Top 5
Production
orders
Real data
history
Supervisor Cockpit machine
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
15 B Bartke S Wagner IPI-2
Shop Floor Management Management Cockpit
Planned vs Actual
(shift)
Top problems
(challenges)
OEE ndash Last Week
16 B Bartke S Wagner IPI-2
hellipand what have we achieved
17 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development suspension components (OEE Overall Equipment Effectiveness)
Radtraumlger
Start Shop Floor Management with
FORCAM +10
_
18 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development (20+ Increase in OEE in AUDI Stamping Facilities) (OEE Overall Equipment Effectiveness)
Radtraumlger
Start SFM +20
_
Our Beliefs
Respect
Collaboration
Excellence
Integrity
Community
Oct 30th 2013
Lean with Shop Floor Management BorgWarner Turbo Systems Rzeszow
Operator FactoryFrameworktrade Worker Client- Book On
Operator Downtime Reasons
Operator Actual versus Target Performance
TargetPlanned
Throughput
Actual
Performance
Opportunity for
Improvement
Actual
Throughput Machine
Data
ERP
Data
Supervisor Gantt Status
visualzation
Top 5
downtimes
Cip Top 5
Production
orders
Real data
history
Supervisor Cockpit machine
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
16 B Bartke S Wagner IPI-2
hellipand what have we achieved
17 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development suspension components (OEE Overall Equipment Effectiveness)
Radtraumlger
Start Shop Floor Management with
FORCAM +10
_
18 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development (20+ Increase in OEE in AUDI Stamping Facilities) (OEE Overall Equipment Effectiveness)
Radtraumlger
Start SFM +20
_
Our Beliefs
Respect
Collaboration
Excellence
Integrity
Community
Oct 30th 2013
Lean with Shop Floor Management BorgWarner Turbo Systems Rzeszow
Operator FactoryFrameworktrade Worker Client- Book On
Operator Downtime Reasons
Operator Actual versus Target Performance
TargetPlanned
Throughput
Actual
Performance
Opportunity for
Improvement
Actual
Throughput Machine
Data
ERP
Data
Supervisor Gantt Status
visualzation
Top 5
downtimes
Cip Top 5
Production
orders
Real data
history
Supervisor Cockpit machine
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
17 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development suspension components (OEE Overall Equipment Effectiveness)
Radtraumlger
Start Shop Floor Management with
FORCAM +10
_
18 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development (20+ Increase in OEE in AUDI Stamping Facilities) (OEE Overall Equipment Effectiveness)
Radtraumlger
Start SFM +20
_
Our Beliefs
Respect
Collaboration
Excellence
Integrity
Community
Oct 30th 2013
Lean with Shop Floor Management BorgWarner Turbo Systems Rzeszow
Operator FactoryFrameworktrade Worker Client- Book On
Operator Downtime Reasons
Operator Actual versus Target Performance
TargetPlanned
Throughput
Actual
Performance
Opportunity for
Improvement
Actual
Throughput Machine
Data
ERP
Data
Supervisor Gantt Status
visualzation
Top 5
downtimes
Cip Top 5
Production
orders
Real data
history
Supervisor Cockpit machine
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
18 B Bartke S Wagner IPI-2
2008 2009 2010 2011
OEE Development (20+ Increase in OEE in AUDI Stamping Facilities) (OEE Overall Equipment Effectiveness)
Radtraumlger
Start SFM +20
_
Our Beliefs
Respect
Collaboration
Excellence
Integrity
Community
Oct 30th 2013
Lean with Shop Floor Management BorgWarner Turbo Systems Rzeszow
Operator FactoryFrameworktrade Worker Client- Book On
Operator Downtime Reasons
Operator Actual versus Target Performance
TargetPlanned
Throughput
Actual
Performance
Opportunity for
Improvement
Actual
Throughput Machine
Data
ERP
Data
Supervisor Gantt Status
visualzation
Top 5
downtimes
Cip Top 5
Production
orders
Real data
history
Supervisor Cockpit machine
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
Our Beliefs
Respect
Collaboration
Excellence
Integrity
Community
Oct 30th 2013
Lean with Shop Floor Management BorgWarner Turbo Systems Rzeszow
Operator FactoryFrameworktrade Worker Client- Book On
Operator Downtime Reasons
Operator Actual versus Target Performance
TargetPlanned
Throughput
Actual
Performance
Opportunity for
Improvement
Actual
Throughput Machine
Data
ERP
Data
Supervisor Gantt Status
visualzation
Top 5
downtimes
Cip Top 5
Production
orders
Real data
history
Supervisor Cockpit machine
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
Operator FactoryFrameworktrade Worker Client- Book On
Operator Downtime Reasons
Operator Actual versus Target Performance
TargetPlanned
Throughput
Actual
Performance
Opportunity for
Improvement
Actual
Throughput Machine
Data
ERP
Data
Supervisor Gantt Status
visualzation
Top 5
downtimes
Cip Top 5
Production
orders
Real data
history
Supervisor Cockpit machine
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
Operator Downtime Reasons
Operator Actual versus Target Performance
TargetPlanned
Throughput
Actual
Performance
Opportunity for
Improvement
Actual
Throughput Machine
Data
ERP
Data
Supervisor Gantt Status
visualzation
Top 5
downtimes
Cip Top 5
Production
orders
Real data
history
Supervisor Cockpit machine
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
Operator Actual versus Target Performance
TargetPlanned
Throughput
Actual
Performance
Opportunity for
Improvement
Actual
Throughput Machine
Data
ERP
Data
Supervisor Gantt Status
visualzation
Top 5
downtimes
Cip Top 5
Production
orders
Real data
history
Supervisor Cockpit machine
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
Supervisor Gantt Status
visualzation
Top 5
downtimes
Cip Top 5
Production
orders
Real data
history
Supervisor Cockpit machine
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
visualzation
Top 5
downtimes
Cip Top 5
Production
orders
Real data
history
Supervisor Cockpit machine
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
Supervisor Shift Book
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
Supervisor Operational Status Reports
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
Supervisor Machine-Shop Visualisation
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
Shop Floor Management
Optimizing productivity by using MES at GE Jenbacher
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
29 GE Title or job number
9102014 copy by GE Jenbacher
Integration of order data with machine data (ODC + MDC)
bull Plug-Ins for heterogeneous machine data collection
bull Configuration of user interface
bull Integration of machine coordinated independently by GE
bull Real-time data
bull Seamless integration
bull Normalisation of machine signals
bull Linked with status information
Machine Connector via PlugIn
Wireless
CNC
Heidenhain
TNC
GE
Fanuc
CNC
Siemens
840D
MTConnect PLC
S5S7
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
30 GE Title or job number
9102014 copy by GE Jenbacher
Production controlling Reporting Transparency in real-time through detailed visualization of TPM methods to
uncover weaknesses and improvement potential
bull Transparency plant-wide in real-time through web technology
bull Coherent key figures (OEE NEE TEEP)
bull Large selection of predefined reports with different views workplace order material personnel
bull Creation of customized reports with the report editor
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
31 GE Title or job number
9102014 copy by GE Jenbacher
Economic Benefit
________________________
________________________
________________________
________________________
________________________ 40
50
60
80
2011 2012 2013 2014
Performance rate
in
Year
55
62 67
70
73
Example cylinder head manufacturing Performance rate
proportionally increased by 33 (from 55 to 73)
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
FORCAM 2014 Page 32
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
FORCAM 2014 Page 33
So What is Industry 40
ldquoThe virtual IT world and the real life manufacturing world are growing every closer
together Using Cyber Physical Systems and the internet to connect humans machines
and software many experts see the first step towards the fourth industrial revolutionrdquo
Prof Dr Dr Wolfgang Wahlster German Institute for Artificial Intelligence (DFKI)
Industrial Ethernet is the latest stage of industrial
development and represents the 4th Industrial Revolution
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
FORCAM 2014 Page 34
A History of Computer-Aided Manufacturing
MES
FactoryFrameworktrade
MES
CIM
LAN
Web Services
LAN
Fieldbus
Method
Connectivity
Technology
Lean
Manufacturing
Shop Floor
Management CIM
CIM (Computer Integrated Manufacturing)
bull Integrated system architecture relying on a shared database initially failed due to past state of development and
acceptance of the technology
MES (Manufacturing Execution System)
bull Integrated system architecture relying on a shared database that as opposed to CIM does not rely on an isolated
solution MES technology employs higher server performance and interlinks production facilities via the internet (W-LAN)
Interfaces and vertical integration however prove to be a difficult hurdle to overcome
SFM (Shop Floor Management)
bull Industrial internet is proving to be the way to achieve the Smart Factory SFM can support the factory of the future today
As manufacturing processes have become more and more complex SFM has to be more and more flexible Obstacles
such as heterogeneous machine connection global facility benchmarking language and time zone barriers are resolved
The system is connected globally and available at any time any where on all smart devices Web technology CEP and in-
memory computing process data in real-time and give us the basis for true excellence in production
1970 1980 1990 2000 2020 1960 2010
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
FORCAM 2014 Page 35
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industrial Internet Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
FORCAM 2014 Page 36
Shop Floor Management for the Smart Factory
Shop Floor Management (SFM) is the strategy for continuous optimization on the shop floor The goal is
improving factory productivity by eliminating errors and waste
Prerequisites
1 Leadership
Management and team leaders have to be role models in introducing a continual
improvement process (CIP) from top to bottom on the basis of the correct KPIs
2 Technology
A high-performance solution will supply real-time production data to the ERP-system
(Enterprise Resource Planning) The actual machine and production status is visualized by
the system ndash this is the first and most important step towards sustainable increases in
productivity The success of the right SFM technology depends on the seamless and
certified integration with leading ERP solutions such as SAP
If you cannot measure it you cannot improve it
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
FORCAM 2014 Page 37
37
Characteristics of the Industrial Production of Tomorrow
Strong customization of products
Highly flexible large-scale production
Integration of customers and business partners in value creation
processes
Expansion of production through high-quality after-sale services
Features of a Smart Factory
Embedded software systems communicate with each other via the
Internet
Available data and services globally
Networking across all digital channels (wireless wired local global)
Data virtually evaluated for real production optimization
Human-machine interfaces (touch screen voice gesture control)
Smart Factory
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
FORCAM 2014 Page 38
World Class Shop Floor Management
FORCAM Release-5
The Smart Factory Revolution
1
Shop Floor Management for the Smart Factory
Smart Factory Technology
2
3
Industry 40 Background and History
Our Mission
To help our clients
achieve distinctive
lasting and substantial
improvements in
shop floor
performance
Smart Factories at AUDI BorgWarner GE Power
4
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
FORCAM 2014 Page 39
39
Web Portal
Worker Client
(Touch)
Web Portal
Office Client Web Portal
Smart Devices
Real Time
Shop Floor Management
via Cloud Global Web Portal
eg China
Mazak Fanuc Siemens Heidenhain etc
FORCAMlsquos Release-5 Technology Highlights
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
FORCAM 2014 Page 40
100 Web-based Technology
100 Web-Technology
The system can be accessed from any web browser Access the software from touch
terminals PCs tablets machine controller HMI or any mobile device - the possibilities are
endless By employing state-of-the-art JAVA programming the software is both platform and
operating system independent
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
FORCAM 2014 Page 41
Time-Zone Independence ndash All Clocks Are In Sync
Release-5 is ready for global deployment ndash the key to this is time zone independent
reporting All data from different time zones is collected and adjusted to compensate for
time shifts ensuring that all clocks in all your global factories are always synchronised
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
FORCAM 2014 Page 42
BIG DATA Support with In-Memory and CEP
Live Cache means high performance In-Memory Computing offers high speed
processing of Big Data Complex Event Processing (CEP) the proven technology for
analyzing complex strings of events and circumstances provides real time data
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
FORCAM 2014 Page 43
Multi-Lingual (including Unicode)
Release-5 is ready for global deployment with any language including Unicode support
Languages can be individually configured online for each worker terminal and location
Language settings can be easily adapted for global benchmarking and reporting
汉语 English
German
Etc
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
FORCAM 2014 Page 44
44
Flexible Machine Data Collection
Real-Time Integration to CNCs and PLCs
Plug-In Concept for All Machine Interoperability (MTConnect)
Configuration via Web Interface
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
FORCAM 2014 Page 45
TECHNOLOGY Vertically-Integrated Architecture for OEE
Machine ControlsPLC Integration
Connetion of Heterogenous PLClsquos
X X
(Bit 0-7)
Formula
Operation State Mapping Engine Signal Normalization
Generation of operation states
based on configurable state engine
Visualization OEE Web-based OEE Visualisation
Performance Measurement amp Benchmarking
= NC Alarm
= Prog Run X
X
Signal Acqusition
Memory Mapping PLCs
ERP Integration Planned versus Actual Comparision
Have I reached my target today
1
2
3
4
Siemens 840D Siemens S5S7 Allen Bradley OPC OPC-UA Fanuc MAZAK MTConnect
OEE Metric ldquoUtilizationrdquo
OEE Metrics ldquoPerformance Qualityrdquo
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
FORCAM 2014 Page 46
ABOUT FORCAM - A Technology Leader in SFM
Shareholder
SAP Founder Dietmar Hopp
Web Technology
SFM Evaluations
Founding
FORCAM USA
Global Roll-Out (gt 90 Plants)
Stamping Plants
Productivity + 20 within 12 months
SAP Spin Off
Research
Partnership
Innovation
Award
15000 Monitored Assets
Release
50
+ 12 Efficiency
Increase
within 6 Months
Machine-Connector
400 Heterogeneous
Machines
Press Plants
Asset worth
US$ 25 Billion
Founding
FORCAM UK
SME Business
+ 25 increased operating
time and availability of all facilities
New Plant
Muumlnchsmuumlnster
Press Plant
Leipzig amp China
Frost amp
Sullivan
2014
Award
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
FORCAM 2014 Page 47
Download FORCAMrsquos White Papers
httpwwwforcamcomfileadminpdfDownloadFORCAM_White_Paper__June_2013_pdf
httpwwwforcamcomfileadminpdfDownloadCase_Study_Machine_Connection_engpdf
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
FORCAM 2014 Page 48
Federal Ministry of Research (Germany) httpwwwbmbfdede19955phphilite=Zukunftsprojekt
Fraunhofer Institute of Production Engineering and Automation (Stuttgart) httpwwwipafraunhoferdeEnergieeffizienz_in_der_Produktion18580html
Fraunhofer Institute IAO study Production Work for the Future ndash Industry 40 httpwwwproduktionsarbeitdecontentdamproduktionsarbeitdedocumentsFraunhofer-IAO-
Studie_Produktionsarbeit_der_Zukunft_-_Industrie_40pdf
VDA-Movie httpwwwyoutubecomwatchv=1dMSXM9PHfo
VDI-Referece MSR Technologies httpwwwforcamdeindexphpid=190
Wikipedia httpdewikipediaorgwikiIndustrie_40
REFERENCES
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
49 B Bartke S Wagner IPI-2
FORCAM Inc
250 E 5th Street
Cincinnati OH 45202
+1 (513) 878-2780
wwwforcamcom
CALL TO ACTION Join the MTConnect Initiative
Demos at FORCAMrsquos Booth This Year
Live Machine Controllers (Okuma ldquoMTConnectrdquo amp FANUC ldquoFOCASrdquo)
Mobile Apps for Multi-site Global OEE Comparisons in Real-time
Predictive Maintenance Module for the Advanced Factory
Join us
on Wed Sept 10th 130pm for ldquoSmart Factory Technologyrdquo
Presentation E-4929
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
MTConnect Evolution of a Standard and Next
Generation Interoperability
CJ Hill Chairman amp President
MTConnect Institute cjhillmtconnectorg
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
OUR PROCESSES ARE SPEAKING
Are you listening
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
1920 Factory of the Future
What will 2020 Look Like
Connecting Manufacturing
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
Connecting Manufacturing
bull Disrupting hellip ndash Process Development ndash Discrete Manufacturing ndash Supply Chain Management ndash STEM
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
Before
bull Proprietary connectivity bull Intensive non-recurring engineering cost bull Innovation headwind bull Experience driven manufacturing optimization
Data is locked up
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
Connected
bull Open connectivity bull Sustainable engineering support and
improvement bull Innovation accelerator bull Data driven manufacturing optimization
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
MTConnect History
bull October 2006 ndash The Watershed bull Interoperability and connectivity are key bull Open standard model bull Community driven innovation model
ndash Implementers and Technical Advisory Group (TAG) Members
ndash TAG Working Groups ndash User Group ndash MTConnect Board of Directors
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
MTConnect Structure
Attributes + Data hellip Applied to Machines amp Manufacturing Systems
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
Going Forward
bull Building Out the Standard ndash Refining existing body of knowledge ndash Accommodating a broader set of manufacturing
systems ndash Exercising the existing community user experience
and feedback ndash Developing the strategic roadmap
bull Building Out the Community
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
September 10 2014 2014 General Managersrsquo Meeting
International Additive Manufacturing Award
Dr Wilfried Schaumlfer Executive Director
VDW
Mr Douglas K Woods President
AMT
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
International Additive Manufacturing Award
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
Purpose
To recognize innovations in additive manufacturing for industrial applications including the design of systems processes materials new applications data generation and metrology
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
Award Judging Panel Associations bull Tim Shinbara AMT minus The Association For Manufacturing Technology bull Dr Wilfried Schaumlfer German Machine Tool Buildersrsquo Association (VDW)
Media bull Ken Fouhy VDI Verlag GmbH bull Pete Zelinski Gardner Business Media Inc
Academia bull Prof David Bourell University of Texas ndash Austin bull Prof Reinhart Poprawe Fraunhofer Institute for Laser Technology Aachen
Users bull Dr Jens Ertel BMW AG bull Greg Morris GE Aviation bull Capt Gerald Grant Walter Reed Medical Center
Legal bull John Hornick Finnegan Henderson Farabow Garret amp Dunner
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
Criteria
Specific assessment criteria are to maintain precision reproducibility and objectivity for the assessment of international submissions for the award bull Technological innovativeness bull Benefits for industry environment and
society bull Cost effectiveness bull Form of depiction presentation bull Reality test in an industrial application
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
Criteria Weighting Assessment criterion Weighting Technological innovativeness 55 Progress of knowledge with respect to the state of the art (25)
Technological quality and creativity (15)
Distinguishing characteristic compared with previous solutions (15)
Benefits for industry environment and society 20 Technological benefits in applications (10)
Environmental compatibility and properties of social relevance (10)
Cost-effectiveness 20 Economic benefits for end-consumers and end-users (10)
Demand situation sales markets (10)
Form of depiction presentation 5 Reality test in an industrial application Implementation implementability
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
Award Results
bull The 20 applications with the most points will be presented to jury
bull The panel will select the final award
winner
bull Winner will receive a $20000 cash prize plus $80000 media package to promote development
bull Award will be presented annually alternating between IMTS and METAV
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
September 10 2014 2014 General Managersrsquo Meeting
Open Forum bull Machine interoperability standards bull Additive3D printing as a developing technology amp market bull Advances in trade talks (Transatlantic Trade amp Investment Partnership Trans-Pacific Partnership etc) bull Changes in trade shows bull ldquoGlobal Forecast for Machine Toolsrdquo by Oxford Economics
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-
September 10 2014 2014 General Managersrsquo Meeting
Reception amp Luncheon
Room W470b
- IMTS2014GeneralManagersMeetingpdf
-
- Attendee List
- Agenda amp Bios13
- Economic Outlook
- World Class Shop Floor Management
- MTConnect Evolution of a Standard and Next Generation Interoperability13
- International Additive Manufacturing Award13
-