pioneer of smart factory - industry 4.0
TRANSCRIPT
We Deliver Results In Productivity.
Pioneer of Smart Factor y
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About FORCAM Contact us @
Action
Lessons learnt
(key messages)
Action
Building the digital
transformation in
manufacturingIND 4.0 /IIoT and
smart factory
strategies meeting
customer business
challenges
Why be smarter, fiscal
performance &
opportunity
Delivering profitability in manufacturing and supply chain with digital transformation and
IND 4.0 /IIoT
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3 Who are we
We speak machineMachine communication in 1 day.
Connectivity across machines, controllers and protocols.
Template approach to connectivity.
Bridge between shop floor and ERP /back office systems.
We innovateSmart factory through FORCAM Force IIoT platform.
Leader in IND 4.0 /IIoT.
Redefining MES.
FORCAM Force (Gartner MES quadrant)Only IIoT package with out-the-box MES applications built-in.
We have the vision, capacity and capability to execute.
We deliver results in productivityWe develop concepts and solutions for digital transformation in manufacturing.
Recognized as the pioneer in Smart Factory by independent experts. We create new technologies and help define standards for the future.
We help manufacturers competitiveness with digitization (the ‘Power of 1%’).
= parts inventory reduction up to -30%
= productivity increase by up to +5%
= machinery downtime reduced by up to -40%
= time to market reduced by up to +30%
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4 Forcam FORCE & IND 4.0 /IIoT
Third Party System Connectivity via FORCE Bridge API
Machine Data Collection via Edge Computing and Plug-Ins
FORCAM FORCEMES applications built-in
ERP System Integrationvia Plug-Ins
Machine
Terminal/Worker
Administrator
Workflow Control
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INFO
Performance analysis
- Shop floor visibility / transparency to drive optimizations
ORDER
Order management
- Management of works orders and manufacturing operations
LABOUR
Labour management
- Seamless time tracking to cost centres
Production planning Schedule & dispatch
PLAN
- Optimized usage of resources by plan
Document control & DNC
DOC
- Electronics instead of paper (fast and safe)
Track & TraceProcess & productEnergy analysis
PROCESS
- Track product parameters
BRIDGE-API
PLATFORMData Driven Information
Platform & interfaces
IIoT Platform with MES apps built-in
TECH-MESA:
EDGE
Realtime shop floor information (digital, data, people, machine)
Machine data collection
One common technology framework
- Shop floor terminal + Data interfaces(compressed transfer, data to information (validated); buffer; safety)
EDGE
- Open for collaboration
- Individual to be adapted to your needs
BRIDGE API – Open collaboration with 3rd party Apps, with integration and inter-operability into your IT /OT environment
COMPLETE TEMPLATES:
PRODUCTIVITY PLAN(incl. PRODUCTIVITY)
PROCESS(incl. PRODUCTIVITY)
PREMIUM
- also can be purchased as subscription and cloud
Forcam FORCE - how its built
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Why be smarter
“Despite making up only 0.02% of the businesses in the UK, the aerospace industry contributed 0.5% of the UK’s economic activity for 2016.”
“Our review identified a £17.5 billion opportunity for the aerospace sector over the
next ten years through the adoption of currently known digital technologies.”
“Of all the sectors we examined, aerospace offers the greatest potential in terms of
both cost reduction and new business models.”
“Digital Innovation Hubs, MTC, high value manufacturing catapults, knowledge transfer
networks, provides the environment to share ideas and experiences, and common
understanding and leadership advocacy for the future of digital manufacturing.”
“The industry saw productivity growth of 19% from 2010 to 2016, compared to 3% in the general
UK economy.”
Inspire great British manufacturing, do you invest or stand back?
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Monetisation; to make money, must move the fiscal levers enough so its worthwhile, and achieving CSL’s
Pressure on returns, pressure on margins and free cash Slow and low productivity is a major inhibitor to growth
As well as improving energy efficiency of products made, manufacturers are tasked with constantly reducing amount of energy consumed making the products
Why be smarter
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OEMs will compete on multiple fronts: New affordable competitive vehicles.
Globalization: Consolidation of platforms.
Autonomous & connected: Integration and vehicles & infrastructure.
New powertrains: Electrical drives and hybrid will take 40% of the EU market.
Sustainable manufacturing: Digitization and carbon neutral smart factories.
Why be smarter - trends - Automotive
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Why be smarter - fiscal performance & opportunity - Aerospace
Shareholder Value Drivers
Turnover
Leading
Year on year
Industry Sector Average
Revenue Growth47%
Operating Margin
Return on invested capital
PPE Turns
Inventory Turns
39%
Asset Efficiency
Core operating margin 23%10.9
%
2.4%
27%
6.8%
1% Revenue Growth= £30 million margin
1% Operating Margin= £300 million margin
1 point PPE turn = £5 billion asset value
Free cash Margin
1 point inventory turn = £1 billion asset value
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4.5
1 UK Aerospace sector had a turnover of £31 billion in 2016
5
10
12%
Business programs move the needle so the investment is worthwhile
UK Aerospace potential return 1
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Why be smarter
People Machines
SystemsProcesses
Transformation; digitalizing manufacturing, this is not a technology challenge, you are asking the wrong question if you think it is…
TechnologySystems &
Networks
Business &
StrategyCollaboration
Leadership &
Advocacy
Skills & Competences Development
InnovationAdoption
Its not easy; its complex, its not about boiling the ocean, its about competency frameworks, knowledge sharing, behaviours, new ways of working and new business models.
BUSINESS PROGRAMSOften multiple
Process & behaviours ledTechnology enabled
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IND 4.0 /IIoT and Smart Factory strategies
Its not about IND 4.0 /IIoT, its about transformation; we see 4 value initiatives emerging where our customers are already deploying specific practical IND 4.0 /IIoT projects to meet challenges.
Advanced SFMo True OEEo Real-time visualization of production facilities o Alerts and dashboardsDELIVERY, IMPROVE EFFICIENCY
Digital Manufacturingo All production relevant information from PDM,
CAQ,TDM, NC programs, DNCo Electronic work instructionso Electronic track and trace genealogyQUALITY, MANAGE CHANGE, REDUCE RISK
Advanced Process optimisationo Advanced process analyticso Combine quality, production, energy and process datao Variation Reduction, cost optimisationREDUCE COSTS, IMPROVE QUALITY
Demand Driven Supply Chain o Transparency in capacity planningo Capacity planning based on true resourceso Automated daily and weekly scheduling with real-time
simulationsCAPACITY, IMPROVE ASSET UTN AND INVENTORY TURNS
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Ambition, vision, ability to execute, creating a joined-up digitalized manufacturing transformation strategy
SW M
ain
ten
ance
BUSINESSOBJECTIVES
CHALLENGES OPERATIONAL STRATEGY DELIVERYONGOING SUPPORT
FORCAM STRATIEGIC INIATIVES
Serv
ices
Pac
kage
Need for Superior
Service andDifferentiated
Products
Need to introduce innovative technology
Need to create shareholder
value
Need for improved
traceability
Manage product
innovation
Improve asset utilisation
Ensure Compliance
Improve quality and consistency
Reduce variability
Optimise equipment performance
Optimise production planning
Reduce WIP
Target full cradle to grave
traceability
Improve production resource
utilisation
Reduce manufacturing costs
Manage high product mix and
rapid NPI
Enforce quality standards
Demand Driven Supply Chain
DDSC
Digital Manufacturing
Advanced Process Optimisation
Advanced Shop Floor Management
Digital Manufacturing
Digital Manufacturing
Reduce costs
Reduce inventory
Reduce energy costs
Advanced SFM
Reduce wasteAdvanced Process
Optimisation
Improve customer
service levels
Improve delivery to promise
Improve production planning
Demand Driven Supply Chain
Advanced SFM
#1 Meet our customer’s business and in-market challenges
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13 #2 Gathering Requirements
Building the digitalized manufacturing transformation
1. Group into business programs.
2. Assess impact on performance.
3. Develop roadmap.
Data driven digitalized performance improvement roadmap
• Tactical.
• Site level deployment.
• Limited strategic vision.
• Little alignment with processes & behaviour changes.
• Cost focused, not value created focused.
Old Approach New Approach
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14 #3 Creating the Project Roadmap
Building the digitalized manufacturing transformation
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Advanced SFMUtilise v5 standard
functionality
DDSC
Q4 2018 Q1 2019 Q2 2019 Q3 2019 Q4 2019
Automate machine actuals on Star
Review target times
Kick off weekly improvement meetings
Implement dashboards and automated reports
Implement manual defect
capture
InfrastructureUpgrade to v5.8
Implement scheduling and resource planning
Digital Manufacturing
Capture of tolerances
Analyse data in current system
Process optimisation
Predict defects
Install screens for dashboards
Capture machine data (Factory V)
1 Factory S machines 1,2,12,21,CMM Factory V – Star, Meteor Factory H - Starag
Fix Starag connection
Add production counters - Star
Start right/ end right reportingImprove process for moving
order to new machine
Add CMM machines
Add production counters – Priority Machines
Automate machines actual on priority machines
Capture of CMM dimension data
Capture of CMM status
Provide serial number visibility on shop floor
Provide tool and programme data
on shop floor
Quick wins (with upgrade) Small improvements Future phases
Capture of CMM defects
Run weekly improvement meetings
2020
Add additional production counters
Further deployment
Optimise tool life
Improve downtime capture
Business Program
#4 Project Implementation Planning Building the digitalized manufacturing transformation
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Market is continually growing but its in transformation to new automotive1. Divide the elephant into bite size chunks based upon strategic business programs.
2. Need ambition, then create the vision, don’t boil the ocean, its complex, has many stakeholders, and needs to be handled with care.
3. Maybe have a digital officer empowered by board to pull it all together (because it will go across boundaries).
4. Create business case, driven by fiscal levers, CSL’s and connecting to your customers (start from the back end).
5. Find the right partners/collaborative environment.
6. Achieve quick wins.
7. Build your community of champions.
8. Lab test, assessment tools, adopt a unified operator environment and IIoT configuration template (its in the detail of the technical architecture – its not covered in this deck, its a topic for another day).
9. Revalidate the business case.
10. Adopt the technologies.
#5 Lessons learnt (key messages)IND 4.0 /IIoT, digitalized manufacturing = transformation
Together we ARE BETTER - together we are STRONGER
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Thank You
You are very welcome to visit our team us on stand C6