american manufacturing strategies summit

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American Manufacturing Strategies Summit

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Enabling the

Demand-Driven

Factory of the

Future

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About Your Presenter

John Maher

VP Product Strategy, Synchrono®

• 20+ years’ experience working in manufacturing

environments.

• Subject matter expertise in ERP, MRP, APS,

supply chain, manufacturing planning and

scheduling systems and constraints

management.

• APICS CPIM certification in production and

inventory management.

• Jonah certification in Theory of Constraints from

the Goldratt Institute.

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Creating the

Demand-Driven

Factory of the Future

Presentation Overview:

• Crossing the chasm from Push

to Pull

• Technology as an enabler

• What is Industry 4.0 and what

does the factory of the future

look like?

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“Watch your thoughts; they become words.

Watch your words; they become actions.

Watch your actions; they become habit.

Watch your habits; they become character.

Watch your character; it becomes your

destiny.”

- Lao Tzu

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5 Key Elements to Drive

Flow

1. Control the release (Pull)

2. Synchronize activities

3. Continuous improvement

4. Extend to supply chain

5. Align metrics

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1. Control the Release (Pull)

• Clear the traffic jams

• Turn on the lights and see for the first time

• Pace to what the system needs and can handle

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2. Synchronize Activities

• Optimize flow not local efficiencies

• Subordinate local needs to global effectiveness

(Inject your own sports analogy – they all apply)

• Labor, material, machine, method

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3. Continuous Improvement (Based

Upon Flow)

• How do you direct your CI efforts?

• Who is responsible for CI?

• How do you avoid stagnation at another level?

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4. Extend to Supply Chain

• Synchronize from the factory out

• Proactive communication

• Forecast for long-term planning; consumption for

execution

• Put an end to the emails and phone calls to

reshuffle priorities and check status (non-value)

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5. Align Metrics

• “Tell me how you will measure me and I will tell you

how I will behave”

• Metrics have to align with systemic flow, not local

optima

• Positive reinforcing loop

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Why Technology HAS to be

Part of a Demand-Driven

Strategy

• Manual is wasteful

• Technology is the only way to

take an enterprise view

• Real-time only exists in the

digital realm

• Data-driven decisions cannot

exist without data

• One version of the truth

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Model for Industry 4.0

Factory of the Future

• Visual

• Mobile

• Integrated

• Real-time

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What Does Industry 4.0

Really Look Like?

Case 1: Large A&D Manufacturer

• Integrated Platform – ERP, PLM, MES, Asset

Management, QMS, Labor Management

synchronized with:

• Planning/scheduling system

• Data collection/workflow automation system

• Alert/escalation system

• Visual factory information system

• Integrated through SyncOperations – moving

beyond just pushing data around

• Connecting the shop floor; data from RFID, EMS,

Machines, HMI contextualized and historized

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What Does Industry 4.0

Really Look Like?

Case 2: High-Temp Vacuum

Molded Parts Company

• Sales representatives enter

orders into ERP, which does

a real-time call to the PSE

system for effective CTPD

• No schedulers!

• True employee empowerment through PSE

• Main metric and bonus system driven based on

throughput

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What Does Industry 4.0

Really Look Like?

Case 3: Materials testing and

extrusion-control instrumentation

manufacturer

• eKanban solution integrated

with ERP

• Buyers converted to strategic

procurers

• Suppliers net time savings by

eliminating churn of communication

• Real-time right-sizing of inventory

Germany

USA - 2

USA - 1 USA - 3

Malaysia

SUPPLIERS

SUPPLIERS

SUPPLIERS

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“CIOs of asset-intensive companies are finding

themselves at the leading edge of industrial

analytics, the next wave of business

transformation. They surmount the existing

challenges of IT/OT data integration and

analysis by examining opportunity, business

needs and skills availability.”

- Simon Jacobson, Gartner

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Read John's blogs

Meet the Management Team

info@synchrono.com

Demand-Driven white papers

and case studies at

synchrono.com

To Learn More:

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Stay in sync

Synchrono® is a dynamic, growing

company – in the news and on the

move; innovating real-time demand-

driven manufacturing solutions.

We invite you to follow us and stay in

sync.

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