eventful times demand innovative solutions -...
TRANSCRIPT
Eventful times ...
... demand innovative solutions
“Optimize productivity in manufacturing companies”
2013-01-17
Agenda
• Introduction of the company Industrie Informatik
• Solution cronetwork: overview
• Technology and interfaces
• Benefits for our customer
The company
• Founded 1991 in Linz, Austria
• Core business: system software for industrial
applications
• Sites in Austria, Germany and China
• Technology partners to SAP, ORACLE, Microsoft
• 300 installations in Europe as well as in China
• Annual growth 15 %
• Success factors :
» Satisfied customers
» Continuity
» concentration on core business
» use of standard IT
International structure
Linz
Kenzingen
China
Singapore
ItalySpain
Belgium Germany
Slovakia
Hungary
Czech Republic
Switzerland
Netherlands
Austria
Shanghai
Mexico
USA
France
national and international customers
Industrie Informatik sites in Linz (Austria), Kenzingen (Germany) and Shanghai (China)
ERP - System
scheduling board
- Parallel scheduling of machines, personnel and tools
- Transparency and on-time delivery in production through complete integration
with plant data, machine data and time & attendance
- Cost reduction via optimization of machine utilization, e.g., via setup
optimization, reduction of cycle time, ….
scheduling board
- Scheduling of order networks forward & backward
- Determining realistic delivery dates for customer orders
- APS advanced planning functionality considering stock and purchase orders
scheduling board
purchase orders
2 Bauteile2 components
end product
- Highest acceptance due to parameterizable functionality on PC
terminals
- Integration of logic for plant data, machine data and time & attendance
- Utilization as production information system via simple connection to
CAD, QM, CNC
- Basis for KPI‘s and reporting
plant data
Individually configurable layout
Display configurable
key indicators
Configurable content of
machine status and operation
Applications
- Simple overview
of current machine status
at work centers
- Key indicators
at a glance (e.g., OEE)
- Easy transition
to detailed information
(e.g., feedback list)
Foreman level (monitor)
Application
- Simple overview
of machine status
(disruption / production
over time
Machines grouped
in a tree structure
Analyze disruptions
based on color in time bar
to easily detect patterns
Color assigned to each
disruption reason
Hide/display subtrees
to focus on most relevant data
Foreman level (tachograph)
Colors indicate
current operation status
Extensive selection options
Display detailed
information
for operations
Order management
Applications
- Creation and processing of
orders
- Status overview per order
- Status per operation
- Documentation of all
feedbacks
Employee level (terminal)Function selection
via configurable
function buttons
Work center selection
Current employee
information
at terminal
MDC information
(e.g., status,
disruption reason)
Applications
- Employee identification
- Start of operation
- End of operation
- Disruption reason
- Modern, standardized connection technology lets you
connect any production machine
- Rapid ROI through early down-time information and
transparency via failure and down time reasons
- Increased utility for users through interaction with plant
data collection and scheduling board and through
visual representation
machine data
machine data driversignal processing
signal capture
OPC
project e.g. SCADA,
Engel plugin or
customer development
field bus module
Adam 6000 Series
communication via TCP/IP
manual
status collection
(html via http)
trigger
Oracle
database server
Oracle
application server
logicmonitoring of
clock ratesvalidation
plant data collection with integrated
machine data capture
cronetwork machine data
process data
Process data like pressure,
temperature... can be
linked with the work orders
- Highly automated calculation of time models and
bonuses
- Cost savings through decentralized time scheduling
and management
- Integration with scheduling board and plant data,
e.g., overtime for orders
time & attendance
personnel scheduling
100% integration in fine
scheduling of orders
Available employees
per shift
Scheduled orders /
required employees1 employee too
few scheduled
2 employees too
many scheduled
- Evaluation of entries of plant data and project time
according to time models for time & attendance
- correct data for recalculation e.g., removing breaks
from order times, generation of overhead stamps in
the gaps between order stamps
- Identification of incorrect stampings
evaluation
- Access control with time zones and room
assignments per employee
- Definition of authorization groups, terminal groups
und time profiles
- Communication with terminals
access
KPIs
Key Performance Indicators
Increase profitability with a control
instrument that meets the demands
of practice
KPIs let you measure and control
performance and economy
- Production (machine-related)
- failure frequency
- duration of failure
- scrap quantities
- scrap factor
- OEE (overall equipment effectiveness)
- Human resources (related to persons or groups)
- number of employees present
- amount of overtime
- vacation time
- number of erroneous entries
- Scheduling, logistics, project time
- throughput time
- WIP
- Systems engineering
- degree of utilization of database
Sample KPIs
for cronetwork MES
detailed
in brief
Integration into the cronetwork
product line
cronet work leistungsabrechnungcronet work leistungsabrechnung
Produktivität
Gemeinkostenanteil
Abwesenheitsanteil
Manuelle Qualitätszahl
20% 20%10%10%
Produktivität
Gemeinkostenanteil
Abwesenheitsanteil
Manuelle Qualitätszahl
20% 20%10%10%
40%
OEE Monat –DREH001
40%
OEE Monat –DREH001
X %
…
X %
…
100% 140%
20%
25%
Prämiensatz
Leistungsgrad
(=Zeitgrad)
0%120%
cronetwork production info
operative data
at event level
cronetwork employee services
cronetwork
messaging
cronetwork incentive paycronetwork kpi cockpit
Configurate a customized
dashboard with charts, pivot
tables and tachographs from a
variety of prefabricated and
self-made reports
Comfortable drill down
functionality for quick access
to detailed information
Intuitive operation enables easy
adaptation of reports to new
requirements
Management Level Dashboard
Management Level pixelperfect
reporting
define reports, using word
with plug in
define once day & time
for automatically start of
report
define receiver of report
• Integration of all cronetwork® modules
• No internal interfaces
• 100% Web capability of all cronetwork® modules
• Easy to install
• Economical operation
• Installed worldwide
• Unicode / UTF 8
• Simple possibilities to translate texts
• Release capability
• Free update annually included in maintenance agreement
• New features included in maintenance agreement
• Release capability of customer-specific extensions included in
maintenance agreement
cronetwork© Technology
SAP-Zertifikat
Industrie Informatik is the
first MES producer
to be certified as
„Powered by SAP
NetWeaverTM“
overview
Rapid prototyping • Is an efficient method for project introduction
• Enables quick acquisition of know-how
• Ensures correct documentation of customer system
Mouse click takes
you to master dataMouse click takes
you to assignments
The use of a MES (Manufacturing Execution System)
in addition to an ERP like SAP brings a lot of
benefits, e.g.:
• shorter throughput times
• increased productivity
• transparency of production processes (online)
• prompt and holistic data collection
• flexibility via paperless production control
• rapid reaction to process changes
• reduction of waiting and transport times for materials
• early detection of schedule deviations
Goal Value Note
a. Better machine
utilization
5% Improved productivity on bottleneck machines amounts to 5% of annual machine production
b. Reduction of
throughput time
> 2% of
sales
Reduced throughput time from 30 to 29 days for 200
employees yields savings of 500,000 €
c. Reduction of work
in progress
25% value
of work in
progress
Unplanned work in progress takes up space,
increases throughput times, and raises location and
transportation costs as well as financing costs
d. Improved order
handling &
delivery reliability
2% of sales Increased attractiveness and customer satisfaction;
costs of special projects, overtime, … earlier receipt
of payment
e. Support of
production and
engineering
Soft fact,
not
quantifiable
Prerequisite for the functioning of ERP and
production control systems; remedy of weak points,
support of continuous improvement process
Source: VDI seminar manual on closely coupled shop floor control
Economy computation I
Goal Value Note
f. Improvement of information flow
2–4% of sales
Avoid erroneous communication (deadline monitoring, inquiries from sales, creation & distribution of unnecessary vouchers)
g. Quality management
& process reliability
5% of
sales
Expected error rate of 15% can be reduced by one
third
h. Support of
evaluation and
certification
1% of
sales
Availability of data for controlling, certification,
documentation, audits
i. Personnel work time
documentation
20–30% of
costs of
personnel
office
Meets prerequisites for flexible work time (annual
work time models, requirement-oriented capacity);
production and evaluation of vouchers becomes
unnecessary.
Source: VDI seminar manual on closely coupled shop floor control
Economy computation II
Sinter Group
Miba Sintermetall AG
Christian Döller, Tool shop
Production scheduling and plant data / machine data 100% in cronetwork
~ 18,000 production orders per year + 450 %
~ 170,000 operations per year + 447 %
~ 240,000 feedback reports per year + 480 %
No increase in administrative personnel!
Scheduling & control at the Tool shop
situation after implementation of
Benefits for customer
Results of introducing cronetwork® MES
• Reduction of throughput times from 6 to 3 weeks
• WIP inventory cut in half
• Number of simultaneous orders from 300 to 600
• Number of simultaneousoperations from 2000 to 4800
• Double flexibility and increased quality despite cost savings
summary
- is a powerful MES
- complements and improves an ERP
- employs most modern technologies and is Web capable
- gives a high transparency “what is going on at the shop floor !”
- increases efficiency of production
- saves you money
Eventful times ...
... demand innovative solutions
2013-01-17