global standards presentation
TRANSCRIPT
Vision and Roadmap for Company X
Transformational Project
Meeting Objectives
• Obtain consensus on Automation/Business information standards (the Roadmap)
• Show Benefits and Cost Savings of the LSI Project methodology as applied to HB Fuller global manufacturing
Benefits of the LSI Approach
There will be the foundation in place for a world class manufacturing operation if the methodologies presented are adopted
Ability to proactively analyze and correct production delays and quality issues though standard reporting tools and KPI’s
Scalable solutions to fit both the individual plant needs and the needs of the entire enterprise
Up to 50% less time and money spent on commissioning and having new/upgraded systems in full production in 70% less time
Vision
ERP
MES
Common Data Platform and Reporting (OEE,
Trending, Batch Reports, etc.)
PLC or DCS
Field Devices, Field Busses, etc.
Automation and Business Information System Roadmap
Assessment Tool
ScalableFlexibleCost Effective
LSI Project Methodology
En
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World Class Manufacturing
Global Standards
Summary of Benefits of the LSI Approach
Up to 50% less time spent on commissioning and the plant is in full production in less time. Startup support is currently estimated at $2-4MM for HB Fuller transformational project. Roadmap adoption will result in savings of $1-2MM
Startup to full production in 70% less time 30% less hardware required for spares for individual plants 50% less control software development time and
implementation Up to a 40% reduction in MES and SCADA level software
development and deployment costs Common “language” for talking production performance and
KPI’s Foundation in place for a world class manufacturing operation
Reference slides…
Site Assessment – Page 1
Site Assessment – Page 2
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Engineering Process
Scope and Specifications clearly defined and written: Business requirements defined and agreed upon Functional and Operational requirements defined and
agreed upon Hardware and Software Design and implementation built
around the agreed upon requirements Appropriate simulation techniques used based on agreed
upon requirements Factory acceptance testing completed based on agreed upon
requirements
Benefit: Faster, smoother startups. “Eliminate the white knuckle ride of startups” – Up to 50% less time spent on commissioning and the plant is in full production in less time.
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User Requirement Specification Table of Contents
Process Control Specification
Unit Control Specification Table of Contents
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Standard PLC Hardware Platforms and Tools
Limited number of select hardware vendors and select products chosen within product vendor’s portfolios for automation projects Common hardware platform reduces spare parts requirements
across the enterprise Common software tools can be used to reduce software
development costs Appropriate vendors chosen by region based on support models
and available spare parts and product support (i.e. Siemens strong in Europe, Rockwell Automation in North America). LSI is a solution partner for both companies
Vendors will be standardized at each facility for both process and packaging
Benefit: 30% less hardware required for spares for individual plants, 50% less software control development and implementation time Back
Common SCADA/MES Software Platform
Common software and data platform to reduce development and deployments costs Object based data structures (i.e. mixers, reactors, etc.) for HMI
and for reporting MES functionality such as OEE, Process Historians,
Production reporting, etc. Ability to give plant wide and enterprise wide views via a web
interface Ability to give and “Executive” view and a “Plant view” as
required Software objects are built independent of the hardware platform
and simply “tied to” objects in the appropriate control system Worldwide acceptance and support LSI is a solution provider for Wonderware and for Intellution
Benefit: Up to a 40% reduction in SCADA and MES software development and deployment costs
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Reporting Capabilities
The common set of reporting tools will allow HB Fuller to speak a “common language” across all plants (i.e. OEE to track reporting in packaging, batch reports like the one below, etc.)
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What is OEE?
OEE (Overall Equipment Effectiveness) = Availability x Performance x Quality
Where:
1. Availability = Available Time / Scheduled Time
2. Performance = (Parts Produced * Ideal Cycle Time) / Available Time
3. Quality = Good Units / Units Started
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Common Objects for PLC and HMI
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Standard Packaging Vendors and MES/OEE Strategy
Where new packaging machines will be installed, the following will be recommended by region: Common PLC vendors Common motion control vendors Common field device vendors Common reporting interface specified by LSI through a standard set
of tags: Running/Stopped, Automatic/Manual, Package Count, Faults (where they can be automatically detected), etc.
Where packaging equipment will be retained and vendors will not be changed, the common reporting interface as detailed above will be developed
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