© Copyright 2006 Apriso Corporation 1
From the Operations Execution System to the collaborative Global Manufacturing Suite
Luca Introini Apriso Sales Manager mobile +39 335 [email protected]
La soluzione BPM e SOA per l’esecuzione dei processi di produttivi
ProcessProcess
CreateCreateImproveImprove
DeployDeploy
ExecuteExecuteMonitorMonitor
2© Copyright 2006 Apriso Corporation
Apriso Execution Platform
Plant Centric
Enterprise
Apriso Operation Execution
Com
plex
ity
MonoFunctional
Global Operations
Unified Data Model BPM SOA
MES
OES
GMS
cGMS AEPAEP
OESOESGMSGMS
3© Copyright 2006 Apriso Corporation
A BPM/SOA solution
FlexNet is:The only manufacturing suite to incorporate BPM/SOA architecture– Able to support a broad range of
industries and applications– Built on a Unified Data Model– Tightly integrates ERP with process
control – Includes hundreds of business
components and business process flows
The only BPM solution for mission-critical manufacturing processes– Support for Cluster and Fault Tolerant– Security and Administration
“BPM software allows a company to be more responsive to changes in business strategy by managing business processes without retooling, recoding, or replacing underlying enterprise software.”
- AMR Research
AEPAEP
OESOESGMSGMS
4© Copyright 2006 Apriso Corporation
What is a Business Process
A true BPM that go beyond traditional MES allowing graphic modeling any business processes including
• Material Flows and Routings• Recipes and Operating Procedures• Step by step Work Instructions• Validation workflows with Multi-users Collaborative
tasks coordination– Can coordinate activities combining Production,
Quality, Warehouse, Maintenance, LaborDesigned for robust industrial execution
– Automatically generates Users Screens without coding
– Persist information and status in database– Synchronize activity and reporting with ERP transactions
Configurable application versus development tool-kit– Over 130 Standard Business Process Flows used for quicker implementation
of business processes– Business Process Flows can be augmented to include customer business
logic and best practices without custom coding– Over 410 functions Business Components consistently exposing basic
manufacturing execution logic as services (SOA) then preserving ascending compatibility for easier upgrades
AEPAEP
OESOESGMSGMS
5© Copyright 2006 Apriso Corporation
The more standard implementation solution
98,97%121179Database Tables98,80%4338Screens
99,22%121546Business Components
97,23%1425260Procedures
Ratio of Standard to Custom
Number of Novelis specific elements
Number of elements in standard FlexNet
Element
Statistics from project in Mills
“Because BPM tools take development out of IT and place it in the hands of the business user, process automation and change become easier, faster, less expensive, and more flexible.
Source: AMR 2005
AEPAEP
OESOESGMSGMS
7© Copyright 2006 Apriso Corporation
Global Performance ManagerMonitors production Monitors production status, product attributes, status, product attributes, SPC and quality SPC and quality Benchmarks realBenchmarks real--time time results against plans, results against plans, targets and trends. targets and trends. Offers eventOffers event--based based alerts, personalized alerts, personalized threshold specificationthreshold specificationRobust drillRobust drill--down down capabilitycapability
AEPAEP
OESOESGMSGMS
8© Copyright 2006 Apriso Corporation
Visibility and KPIs
ProcessProcess
CreateCreateImproveImprove
DeployDeploy
ExecuteExecuteMonitorMonitor
AEPAEP
OESOESGMSGMS
9© Copyright 2006 Apriso Corporation
Integrated professional tools for high quality of service– Archiving– Audit trail– Service monitoring– Security (roles and access
rights)FDA 21 CFR part 11SOX compliance
Ready for industrial Administration
AEPAEP
OESOESGMSGMS
10© Copyright 2006 Apriso Corporation
Leverages Service-Oriented Architecture (SOA)
Organically grown solutions via numerous services effortsTightly coupledSynchronous InteractionsMany code modifications
Orchestrated solutions
Loosely coupledMessage orientedFew code modifications <10%
Large Modules/Code Base2-tier/Client-Server (wrappers)Function orientedMonolithically built and deployed
Component basedN-tier & Web basedService oriented Incrementally built and deployed
“For companies interested in becoming more demand driven, SOAs are mandatory. Existing monolithic enterprise applications alone are insufficient.”
AMR Research 9/8/05
From … To FlexNetAEPAEP
OESOESGMSGMS
11© Copyright 2006 Apriso Corporation
Multiplication of disparate applications….*
*Source SAP*Source SAP
12© Copyright 2006 Apriso Corporation
Collaborative Supply Chain Execution
Best Practices Life Cycle management & Support for Core Systems, but allows local specificities
• Processes can be authored centrally and dispatched• Processes can be edited locally• Processes can be authored locally• Reporting and data can be consolidated
DefinitionAutomation
RolloutKPI
benchmarkingFeedback
Continuous improvement
13© Copyright 2006 Apriso Corporation
FlexNet: sviluppo e implementazione
C.O.E.Configuration
Center Of ExcellenceValidation
Plant 1Operational Data
Pant 2Operational Data
Process DataProcess DataConnectorConnector
ProcessDeployment
ProcessProcessDeploymentDeployment
Pro
cess
esP
roc e
sses
Processes
Processes
Processes
Processes
Pant nOperational Data
14© Copyright 2006 Apriso Corporation
ERP LegacyERP PartnersCRM CustomersPLM
XML Manager
Suppliers
Material
Machine Integrator
WiFi PDAs TerminalsData I/O MachinesRFID
Reporting
Receiving
Reporting KPIDashboard
Execu
tion
Cen
ter O
f
Exce
llen
ce
Workflow Manager
Quality MaintenanceMaterial Production Labour Fulfilment
ProcessBuilder
Product Traceability & Genealogy
Ext. Appl.
15© Copyright 2006 Apriso Corporation
Schema funzionale
Sales Order Management
Demand Management
Distribution / Shipping
Capacity Planning
Master Planning
I2PI2P(non Exhaustive)(non Exhaustive)
FlexNetFlexNet
Labor Tracking
Production ExecutionQuality Management
Production Flow PlanningMaterial Management
Sales Order Management
Demand Management
MRP
Capacity Planning
Master PlanningPlanning System
Process Control
Machine Control
ProcessControl
FlexNetFlexNet
Labor Tracking
Production ExecutionQuality Management
Scheduling/Sequencing
Production Flow Planning
Maintenance ManagementMaterial Mngmnt Execution
Tools Management
Reporting_KPI_Dashboard
16© Copyright 2006 Apriso Corporation
FlexNet, cosa gestisce
Connette i livelli della pianificazione e dell’esecuzione– Una vera piattaforma SOA e BPM
Gestisce TUTTI i fattori del manufacturing:– Operatori, machinari, materiali, fornitori,
attrezzature/containers, specifiche/processiIntegra l’esecuzione tramite un unico database– Lavoro, Produzione, Logistica, Qualità, Manutenzione– Controllo Qualità integrato in tutti i moduli
Garantisce la governance centrale (sviluppo del Core System / controllo e diffusione delle best practice / manutenzione)Aggiunge valore al sistema ERP
17© Copyright 2006 Apriso Corporation
Apriso: esperienza consolidata in progetti strategici
31 / 43WWUSAAmcor
3 / 9EMEA SwitzerlandTetraPack
5 / 6ItalyUSALear
2 / 10 WWBrusselsVolvo
1 / 30FarEastChinaHaier
7 / 23EMEA + USFranceL’Oréal
3 / 8USAAustraliaAnsell
9 / 161WWFranceEssilor
3 / 5USUSALockheed Martin
35 / 45WWUSABecton Dickinson
15 / 19EuropeUSA / FranceSteelcase
45 / 50Europe+FranceSaint Gobain
80 / 92USUSAInternational Paper
77 / 82WWFranceValéo
111 / 120WWUSAMicrosoft
Number of sites installed / targeted
GeographyHQ LocationClient
18© Copyright 2006 Apriso Corporation
FlexNet : aperto a tutti gli standard operativi
LabelingLabeling
ReportingReporting
Interfaces Interfaces (ERP, APS(ERP, APS……))
PLC, DCS, PLC, DCS, SCADASCADA
XMLXML
Mobile Mobile devicesdevices
RFIDsRFIDs 802.11b/g802.11b/g
RS-232
MonitoringMonitoring
RDBMS
20© Copyright 2006 Apriso Corporation
Lear was founded in 1917 in Detroit as American Metal Products
Today the company exclusively serves the global automotive industry and supplies product for all five major interior systems: seat, instrument panel/cockpit, door and trim, overhead and flooring and acoustics. Lear is also one of the leading global automotive suppliers in electronic and electrical products. There is a Lear product in more than 300 nameplates around the world.
Case study
22© Copyright 2006 Apriso Corporation
2 sedi in Italia
MILANO PESCARA
Area commerciale
Tecnologie software
implementazione curata da Synesis
Business Intelligence
Production & Logistic Applications
On Going SupportWeb Development
ERP
23© Copyright 2006 Apriso Corporation
Grugliasco: H.Q., Engineering, Seat production plant
Pozzo d’Adda: Engineering, Seat production plant
Pianfei: Engineering, Interiors production plant
Pesaro: Engineering, Interiors production plant
Cassino: 1 Seat production plant, 1 Interiors production plant
Caivano: Seat production plant
Melfi: 1 Seat production plant, 1 Interiors production plant
Termini Imerese: Seat production plant
24© Copyright 2006 Apriso Corporation
Caratteristiche degli stabilimenti
Melfi(PZ)
Grugliasco(TO)
Termini I.(PA)
Caivano(CE)
Pozzod'Adda
(MI)
5 4 3 3 115 10 10 5 103 4 1 2 5
42 sec. 120 sec. 90 sec. No takt No takt3 3 2 1 1
ca. 500 ca. 350 ca. 200 ca. 80 ca. 40
XX X X X XX XX X XX X X
- traciabilità lotto e/o SN- traciabilità dati di processo- Interfaccia utente di produzione
Funzionalità presenti:- re/sequencing tasks di lavorazione- Gestione movimentazione pezzo (reworks)
No. Centri di lavoro fuori lineaCadenza linee di assemblaggioNo. TurniNo. Prodotti finiti x turno
Requisito
No. LineePunti di controllo x linea (medi)
25© Copyright 2006 Apriso Corporation
CUSTOMER
LEAR plant
LABELS
SHIP.DOC INVOICE
ERP interfaceInterface to
shop floor sys
Customer dependent part
Sync. Msg.
FlexNET
Cartellini di produzione
S/N sedili
ODETTE
26© Copyright 2006 Apriso Corporation
Handling LineHandling LineCassioliCassioli, PSB, , PSB, TranstecnicaTranstecnica, , JofaJofa, , CooperCooper
E.R.P. E.R.P. –– MFG/ProMFG/ProH.Q. Grugliasco
Shop Shop FloorFloor ControlControl
TraceabilityTraceabilityJIT / JISJIT / JIS WarehauseWarehauseA.S.R.S.A.S.R.S.
Plant
ComponentComponent BarBar--codecodeP.C. + PrinterP.C. + Printer
27© Copyright 2006 Apriso Corporation
Shop Shop FloorFloor Control =Control =
TraceabilityTraceability = =
J.I.T. FIAT =J.I.T. FIAT = consegnare le sequenze ordinate correttamenteconsegnare le sequenze ordinate correttamente
verificare lo stato di avanzamento verificare lo stato di avanzamento della produzione della produzione
raccogliere il serial raccogliere il serial numbernumber dei componentidei componentied i dati dei controlli qualitativi svolti durante ed i dati dei controlli qualitativi svolti durante il processo produttivo ed associarli il processo produttivo ed associarli
al serial al serial numbernumber di ogni sedile di ogni sedile
28© Copyright 2006 Apriso Corporation
Avvitature
AvvitatureTest JOFA
KIT
Coppia sedili Anteriori
Kit sedili posteriori
Anteriore Dx Anteriore Sx Cuscino/i Schienale/i
Schienale Dx Cuscino Schienale Sx Fisso Scorrevole
FoderaSide-bag
Cavo
GuideRiscaldato
FoderaSide-bag
Cavo
3 P5 P
Colore
InteroSdoppiato
Guide
Distinta di produzione gestitata da FlexNet
29© Copyright 2006 Apriso Corporation
Functional Overview
Customer Message acquisition via EDI Customer Message acquisition via EDI (Datagram, (Datagram, Forecast, Setup)Forecast, Setup)
Sequence Management Sequence Management (manual management of sequence) (manual management of sequence)
Customer data correctness Customer data correctness (Sequence check, Part Number (Sequence check, Part Number check, range check, check, range check, ……))
Load Management Load Management (automatic recall of Shipping Container from (automatic recall of Shipping Container from ASRS, parametric algorithms for load definition, Shipping ContaiASRS, parametric algorithms for load definition, Shipping Container ner order by)order by)
Configuration based on customer parameter (via CDM tool)Configuration based on customer parameter (via CDM tool)
JIT featuresJIT features
30© Copyright 2006 Apriso Corporation
Functional Overview
Synchronous Launching Synchronous Launching (Each sequence is dispatched in (Each sequence is dispatched in
production at the same time itproduction at the same time it’’s received from customer) s received from customer)
SynchronousSynchronous--Kanban Launching Kanban Launching (In this case the (In this case the
system check the stock target before releasing the production orsystem check the stock target before releasing the production order) der)
Kanban Launching Kanban Launching (Automatic production order generation to (Automatic production order generation to
reach the finish good stock target defined for each FG item)reach the finish good stock target defined for each FG item)
Configuration based on product parameters (via CDM tool):Configuration based on product parameters (via CDM tool):Product Master, Bill of Materials, Routing, Product Master, Bill of Materials, Routing, ……
Production Launching featuresProduction Launching features
31© Copyright 2006 Apriso Corporation
Functional Overview
Production Order Generation Production Order Generation (based on (based on BoMBoM and Routing, and Routing, multilevel multilevel BoMBoM generation) generation)
Launching Control Launching Control (Production dispatch monitor, manual orders, (Production dispatch monitor, manual orders, label prints, label prints, ……) )
Production declaration and traceability Production declaration and traceability (based on routing (based on routing operation and operation and BoMBoM information, FGI warehouse receipt)information, FGI warehouse receipt)
Resource Management Resource Management (Work Center, Machine, Pallets)(Work Center, Machine, Pallets)
Interface with Shop Floor equipment Interface with Shop Floor equipment ((PLCsPLCs, Screwdrivers, , Screwdrivers, JOFA, RF terminals)JOFA, RF terminals)
Shop Floor Control featuresShop Floor Control features
32© Copyright 2006 Apriso Corporation
Functional Overview
FGI warehouse management FGI warehouse management (interface with ASRS for (interface with ASRS for automatic Load recalling)automatic Load recalling)
Shipping Container managementShipping Container management
Generation of Shipment Documents Generation of Shipment Documents (Odette labels, (Odette labels, packing list, delivery notes,packing list, delivery notes,……) )
Shipping ConfirmationShipping Confirmation
Shipping featuresShipping features
33© Copyright 2006 Apriso Corporation
IT Strategy
QAD
Mfg/Pro
APRISO
FlexNet
ERP
PDM
Shop Floor Control
Lear Corp.
Lear Grug. HQ
Lear Plants
UG
C
O
V
I
S
I
N
C
O
V
I
S
I
N
UG
Metaphase
34© Copyright 2006 Apriso Corporation
Master Data
Planning
Purchasing
Sales
Stocks
Accounting
Controlling
Master Data
J.I.T. module
Shop-Floor Control
PDM PLM
MFG/Pro
Business Intelligence (KPIs)
COGNOS
FLEXNET
FIAT
SEEBURGERE.D.I.
Reposrts
Printing
Sistemi Informativi LEAR Corporation Italia S.p.A.
StreamServe
Plant
H.Q. Grugliasco
Stake
Jtstake
Other
Applications
35© Copyright 2006 Apriso Corporation
Technical Overview
System System ArchitectureArchitecture
ORACLE9i
36© Copyright 2006 Apriso Corporation
Pallet tagging
Read / write system designed to interface to all poka yoke and conveyor systems.
The pallet tagging system is designed to send (Write) to poka yoke equipment product data (Options / Sequences / bar code info / data values etc.) to ensure operator option selection is eliminated and send / receive traceable real time quality data that is to be stored and / or monitored.
Can also be used to make decisions in the closed loop scenario where seat pass or fail control is required and pallet conveyor direction control is required eliminating operator dependence / choice.
37© Copyright 2006 Apriso Corporation
Benefits
The use of a pallet tagging system and tracing / logging all the Poka yoke data from Poka yoke stations eliminates the need for manual paper logging systems which have the potential for operator error.
With this system all data can be traced / logged on a data management system and used for data collation in an accurate manor.
Duplicate elementary information on TAG Rfid
© Copyright 2006 Apriso Corporation 38
Thank You!
Via Properzio 4, Via G. Pacini, 1165127 PESCARA 20131 MILANOTel. 085 454541 Tel. 02 2662631Fax 085 4545499 Fax 02 [email protected] [email protected]