in18 - factorytalk productioncentre: what's new in r10 and industry suites
TRANSCRIPT
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. RA-TechED 2015 @RA-TechED #RA-TechED
PUBLIC INFORMATION
IN18 - FactoryTalk® ProductionCentre® MES Overview Presentation
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. RA-TechED 2015 @RA-TechED #RA-TechED
Agenda
FactoryTalk® ProductionCentre®
MES Strategy & Portfolio Overview
Industry Suites
Fit for Purpose Applications
Success Stories
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. RA-TechED 2015 @RA-TechED #RA-TechED 3
Leading Global Provider of Industrial Power, Control and Information
Solutions
Automation
Solutions for a
Broad Range
of Industries Serving Customers for 110
Years
Strong Culture of Integrity and
Corporate Responsibility
22,000 Employees in
80+ Countries
Fiscal 2014 in excess of $6 billion
US
Canada
EMEA
Asia Pacific
Latin America
Control Product &
Solutions
Architecture &
Software
Rockwell Automation® at a Glance
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. RA-TechED 2015 @RA-TechED #RA-TechED 4
Industry Suites that provide Specific Functionality for Vertical Industries
Fit for Purpose Applications that Perform Specialized Functions and Interoperate
Information Software Portfolio that unifies all Software Layers for an Enterprise
Architecture that is Proven, Scalability & Flexible
Leading Standards Based Java Technology for Scalability, Performance and Cost Effectiveness
HTML5 Client User Interfaces
Mobile & Tablet Solutions
Innovative, Cost Effective Solutions that Deploy Easily & Scale with the Organization
Configurable Business Workflows, Rules & User Experience
Multi-site Customer Deployments Globally, Centrally, Distributed & Cloud
Market Leading Manufacturing Solution
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. RA-TechED 2015 @RA-TechED #RA-TechED 5
Deliver Customer Value
Standardize Business Practices & Global Visibility
Improve Collaboration & Efficiency across Multiple Facilities
Manage Global Plants & Facilities including Suppliers, Customers and Partners
Effectively Control As-ordered, As-built and As-shipped
Brand Integrity
Reduce IT Lifecycle Costs: Installation, Configuration, Management & Maintenance
Reduce HW and SW Costs
Deliver Best in Class MES Suites and Fit for Purpose Applications
Comprehensive Suites Solutions Tailored and Configured for Specific Industries.
Fit for Purpose Applications are Interoperable and Installed Together to provide a Comprehensive
Solution for Discrete and Process Industries
Rockwell Automation MES Strategy
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. RA-TechED 2015 @RA-TechED #RA-TechED 6
Deliver Application and Data Integration Solutions
Data Integration Platform to Organize and Visualize all Factory Data
Aggregate Factory Data Globally across the Enterprise providing KPIs and Data Analysis
Message Bus Application Integration Platform for ERP and PLM
Deliver on Promise of the Connected Enterprise and Internet of Things
HTML5 Client User Interfaces
Mobile & Tablet Interfaces
Cloud Enabled Suites & Applications
Products that Address Level 0 to Level 4
Rockwell Automation MES Strategy
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. RA-TechED 2015 @RA-TechED #RA-TechED 7
Machine Line Enterprise Plant
Line Performance OEE
Enterprise Performance, OEE, Track&Trace, Quality, etc.
Machine Performance OEE
Pro
gre
ssiv
e F
un
ctio
nal
ity
Low
High
Plant Performance, OEE
Scalable Progressive Solutions Machine - Line - Plant - Enterprise
Deployment Options
Stratix/Edge
Panel
View/PC
IDC/Server
Cloud
Appliance
Mobile
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. RA-TechED 2015 @RA-TechED #RA-TechED
Integrated Control & Information Software
8
Level 2
Info
Platfo
rm (Eq
uip
men
t, Mate
rial, Oth
er Mo
dels)
Clo
ud
, Mo
bile (M
FT Too
lkit)
Partn
ers (OSI, M
uleSo
ft, IBM
, Red
Hat)
Sen
sin
g
man
ipu
lati
ng
pro
du
ctio
n
pro
cess
Bat
ch, D
iscr
ete
&
Co
nti
nu
ou
s
Co
ntr
ol
Man
ufa
ctu
rin
g O
per
atio
ns
Man
age
men
t
Bu
sin
ess
Pla
nn
ing
&
Logi
stic
s
Business Intelligence ERP/PLM
Portal parts
and content Manufacturing
derived KPIs
Production &
Process data
Level 3
Levels 0 and 1
MES Suites and Fit for Purpose Applications
InfoPlatform Services
FTBatch
eProcedure®
MaterialTrack
PhaseManager™ Sequence
Manager
Ladder Logic
Structured Text
Function Blocks
SFC Programs
InfoPlatform Services
IA / Resource / InfoPlatform Services
Operator Visualization
RAPID PlantPAx®
EnergyMetrix
AssetCentre
Historian
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. RA-TechED 2015 @RA-TechED #RA-TechED
MES Portfolio
9
Solutions
FactoryTalk® ProductionCentre®
Enterprise Integration Gateway
DataMart
Fit for Purpose Application for Process & Discrete Manufacturers
Order Management & Execution
Scheduling & Sequencing
Quality Management & Performance Management
Recipe Management & Execution
Material & Inventory Management
BOM Management
Equipment Management
Specialized Industry Suites for Vertical Markets
Automotive
Consumer Packaged Goods
Pharmaceutical
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. RA-TechED 2015 @RA-TechED #RA-TechED
Agenda
FactoryTalk® ProductionCentre®
MES Strategy & Portfolio Overview
Industry Suites
Fit for Purpose Applications
Success Stories
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. RA-TechED 2015 @RA-TechED #RA-TechED
FactoryTalk® ProductionCentre®
Platform provides environment for application
development and base capabilities
Capabilities
Foundation
Platform Capabilities extended as a library
Common clients and other foundation artifact
ensure reusability
Activities
Move
Consume Test
Scan
Reusable components that represent the
business logic for any step in a workflow
Workflows model operator actions,
automated processes and the business
processes
Applications
Application executes workflow, provides UI
based on current steps and allowed tasks
Workflow-based Applications
11
Workflow
Platform
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. RA-TechED 2015 @RA-TechED #RA-TechED
Java EE7 Technology
Industry-standard Technology
Widely adopted by well-known Applications like SAP R/3, ORACLE Applications, and
other Enterprise-class Applications
Proven Scalability for Single Plant and Multi-Plant Installations Designed to Support
Characteristics of Enterprise Applications
High Data Volumes, High Throughput
Many Users Accessing Data Concurrently
Complex Business Logic
Integration with other Enterprise Applications
Scalability
Fault-tolerance (High Availability)
(Confidential – For Internal Use Only) Copyright © 2011 Rockwell Automation®, Inc. All rights reserved.
Proven Technology for Mission-critical Enterprise Applications
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. RA-TechED 2015 @RA-TechED #RA-TechED
Key Business Values
Security and Stability
Platform Choice
Ease of Integration
Configuration versus Customization
Easy to Extend
Deployment by Rockwell Automation®, IT
Organizations & Partners
Service Oriented Architecture (SOA)
Feature-Rich Business Layer
Supports Rich and HTML5 Clients
Java EE7 – Proven Technology for Mission-critical
Enterprise Applications
Security and Stability
Scalability without Limits
Variety of Supported Platforms
IBM WebSphere & JBoss
Windows & Linux
SQL Server & ORACLE
Built-in Application Development Framework
Comprehensive, Flexible & Extensible
Multi-tier Data Model
Service Oriented Architecture (SOA)
13
FactoryTalk® SOA – Reliable and Scalable Enterprise Architecture
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. RA-TechED 2015 @RA-TechED #RA-TechED 14
Differentiators:
HTML5 Clients, Mobile & Tablets
Manufacturing Models for Discrete, Process &
Hybrid Manufacturers
Multiple Device Support (Internet of Things)
Mobile, Tablet, Workstation & HMI
Flexible Installation Architectures
Centralized, Distributed & Hybrid
Reduced IT Infrastructure Cost
HTML5 Clients
Cloud Support
Sample Customers: GE Healthcare, St. Jude
Medical, Pfizer, Mahindra, Betaseed, Hexcel,
Mondelez & Kraft
Market Leading MES Product
Built on the latest JAVA EE7
Only MES with pre-built Functionality Required by
Discrete, Process & Hybrid Manufacturers
Powerful Workflow and Process Configuration
Built-in Configuration & Extension Tools
Workflow Editor & Form Builder
Configuration Management
Flexible Client Options
Rich Thick Client Supports Advanced Features
Mobile & Tablet Client
Open Platforms
IBM WebSphere, JBoss
Windows, Redhat Linux
SQL Server & ORACLE
R10 – Next Generation MES Product built on the latest JAVA EE 7 Standard
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. RA-TechED 2015 @RA-TechED #RA-TechED
Supported Platforms
Application Servers
IBM WebSphere 8.5.5.3
RedHat Jboss EAP 6.2
Operating Systems
Microsoft Windows 2008 (Enterprise & Standard Editions, 64-bit) R2 SP1
Microsoft Windows 2012 (Standard Edition, 64-bit) R2
Red Hat Enterprise Linux AS5 Update 10
Virtual Hardware Version 8 with VMWare ESX/ESX1 5.0
Operating Systems (Client)
Microsoft Windows 2008 (Enterprise & Standard Editions, 64-bit) R2 SP1
Microsoft Windows 7 (Professional Edition, 32- & 64-bit & Enterprise Edition, 64-bit) SP1
Database Servers
Microsoft SQL Server 2008 (Enterprise & Standard Edition, 64-bit): R2 SP1
Microsoft SQL Server 2012 (Enterprise Edition, 64-bit) SP1
Oracle (Enterprise Edition, 64-bit) 11g Server & 11g RAC
Oracle 12c 15
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. RA-TechED 2015 @RA-TechED #RA-TechED
Message Bus Data Integration Leverages MuleSoft MSB Certified by SAP Proven Scalability, Flexibility & High Availability Message Bus Guaranteed Event Driven Messaging
Over 120 Standard Out-of-the-box Connectors
Supports B2MML & iDoc File Types Orders, BOMs, Parts, Work Instructions Batches & Sublots, Production & Consumption ECO, Inventory, Genealogy
Drag & Drop Graphical Design
Graphical Data Mapping Configurable Workflows
Integration Productivity
Rapid Graphical Configuration for Applications Applications, Technologies & Protocols: SAP, PTC, MS SQL,
Oracle, DB2, Files, Active MQ, JDBC, etc.
16
Differentiators Message Bus Integration Standard Out-of-the-box Touch Points
Discrete & Process Industries Pharmaceutical Automotive Consumer Packaged Goods
Sample Customers: Roche, Mondelez, GE Healthcare, CJLR & Fonterra
Enterprise Integration Gateway
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. RA-TechED 2015 @RA-TechED #RA-TechED
DataMart
17
Big Data
Graphical easy to use Application Data Integration Platform
Transform, Clean & Distribute Data from & into Applications, Files,
Databases & Warehouses
Application Specific Reporting Schemas
Fit for Purpose Applications
Industry Suites
Configurable & Extensible
External Databases
VantagePoint Dashboards & Reporting
Key KPIs for Machines, Lines, Sites & Regions (Yield, Scrap, OEE,
Advance Genealogy)
Pre-defined, Extensible ETL Transformations
Powered by Talend ETL
Differentiators Enables Manufacturing Big Data
Strategy Pre-defined Specialized Reporting
Schemas Application Data Integration Platform Premier Integration to Rockwell
Software® & Devices
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. RA-TechED 2015 @RA-TechED #RA-TechED
FTPC Architecture
18
Production
Database
Operational
Data Store
Internet Browser
EJB
Business Objects
Object Relational
Mapping
JDBC
RMI Web Services
DataMart
Terminals Tablets
Multi-Tier Database Benefits High Performance Transactions
Unattended Reporting
In-Depth Analysis
Java Application
Server Benefits Industry Standard / Open System
Scalable solution with High Availability
Simplified, low impact upgrades
Near Zero $ IT support
HTML5 Client Benefits Fast, low effort deployments
Global Reach
Zero $ IT Support
Service L
ayer
HT
ML
5
Servlet
3rd Party
Applications
Java Applications
Service Layer
Mobile
Smartphones
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. RA-TechED 2015 @RA-TechED #RA-TechED
Distributed Architecture
19
N. AMERICA
Enterprise Reporting
Benefits
Plants and Facilities have Local Systems to
ensure uptime and effectiveness
Each Sites Maintains own Server & Data
Reporting at Local Site or Enterprise Level
Load Balancing & Clustering Support via the
Application Server at each Site
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. RA-TechED 2015 @RA-TechED #RA-TechED
Centralized Architecture
20
Benefits
Hosted in a Single Data Center
Private & Public Cloud
Reduced IT Costs
Global Real-time Visibility
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. RA-TechED 2015 @RA-TechED #RA-TechED
Agenda
FactoryTalk® ProductionCentre®
MES Strategy & Portfolio Overview
Industry Suites
Fit for Purpose Applications
Success Stories
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. RA-TechED 2015 @RA-TechED #RA-TechED
Business Value Lean & Continuous Improvement Progressive & Autonomous Maintenance Operational Excellence
Differentiators Capabilities
Performance Management
HTML5 Thin Clients, Mobile & Tablets
Machine Event Tracking
Downtime Data Collection
Overall Equipment Effectiveness (OEE)
Mean Time Between Failure (MTBF)
Mean Time to Repair (MTTR)
Simple Data Collection Configuration – tag browsing requires no changes to automation
Operator Console – OEE Analytics & Event Management in one simple user interface
Drives Operations Excellence – Advanced Dashboard offers 50+ Performance Reports & 20+ Performance Dashboards
HTML5 Clients
Pre-built Functionality Required by Discrete, Process & Hybrid Manufacturers
Simple User Experience & Reduced IT Infrastructure Cost
Standalone or Integrated into Production Centre MES
User Configurable Reports
Premier Integration leverages existing Rockwell Automation Investment
Operational Performance Dashboard
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. RA-TechED 2015 @RA-TechED #RA-TechED
Business Value Brand Protection Positive Release Eliminate Plant Floor Quality Paper Work Reduced Cost of Compliance Right 1st Time Manufacturing
Differentiators Capabilities
Quality Management
HTML5 Thin Clients, Mobile & Tablets
Quality Recipe Configuration
Innovative Sample Plan UI Configuration & Workflow
Flexible Sample Plan Triggering
Quality Business Process Workflow Enforcement
In-process Quality Sampling
Flexible Notification Engine – never miss a scheduled quality check
Out-of-spec Escalation – dynamically change quality testing regiment based on test results
Quality Dashboard
HTML5 Clients
Pre-built Functionality Required by Discrete, Process & Hybrid Manufacturers
Multiple Collection Sources
Simple User Experience & Reduced IT Infrastructure Cost
Configurable Out-of-spec Escalation
Configurable UI Workflow
Premier Integration leverages existing Rockwell Automation Investment
Standalone or Integrated into Production Centre MES
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. RA-TechED 2015 @RA-TechED #RA-TechED
HTML5 Thin Clients, Mobile & Tablets
Best in Class Recipe Management – advanced user interface or ERP Integration
Bill of Material Configuration
Process Parameter Management & Integration to Automation ensures that equipment is configured correctly for every order
Order Planning & Execution
Innovative UI Configuration & Workflow
Process Sequence & Route Enforcement
Complete Electronic Batch Record
Complete Electronic Production Record
HTML5 Clients
Pre-built Functionality Required by Discrete, Process & Hybrid Manufacturers
Simple User Experience & Reduced IT Infrastructure Cost
Integrated Genealogy Reporting
Premier Integration leverages existing Rockwell Automation Investment
Out-of-the-box ERP Integration
Sample Customers: Beta Seed, Hexcel, Align Technologies & Beechnut
Business Value Right 1st Time Production Golden Batch Operational Excellence
Differentiators
Production Management
Capabilities
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. RA-TechED 2015 @RA-TechED #RA-TechED
Business Value Supply Chain Efficiency & Build to Order Inventory Stock Reduction Lean Manufacturing
Differentiators Capabilities
Material Management
HTML5 Thin Clients, Mobile & Tablets Bulk Material Receiving Bulk Material Inventory Management WIP & RM Inventory Management Innovative Material Path Modeling –
never start an order before validation required materials are available
Wet & Dry Inventory Consumption Rule Configuration ensures that the correct material lot is consumed & recorded
Innovative UI Configuration & Workflow Carrier Management Pre-configured Inventory Transaction
HTML5 Clients
Pre-built Functionality Required by Discrete, Process & Hybrid Manufacturers
Simple User Experience & Reduced IT Infrastructure Cost
Integrated Genealogy Reporting
Premier Integration leverages existing Rockwell Automation Investment
Out-of-the-box ERP Integration
Sample Customers: Mullins Foods, Kraft & Ford
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. RA-TechED 2015 @RA-TechED #RA-TechED
Agenda
FactoryTalk® ProductionCentre®
MES Strategy & Portfolio Overview
Industry Suites
Fit for Purpose Applications
Success Stories
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. RA-TechED 2015 @RA-TechED #RA-TechED
Business Value Operational Excellence Reduced Cost of Compliance (Trading Partner &
Regulatory) Supply Chain Effectiveness
Differentiators Capabilities
Best in Class Recipe Management
Recipe & BoM Management
Order Planning & Execution
Complete Electronic Batch Record Recording
Bulk Material Receiving
WIP & RM Inventory Management
Backwards & Forwards Genealogy
Quality Business Rule Enforcement
In-process Quality Execution
Real-time Performance Reporting via our OEE & Performance Dashboard
Industry Specific Workflows & UIs on Production Centre MES
Modular Solution – Invest in the capability needed to support today’s key business problem
Premier Integration leverages existing Rockwell Automation Investment
Out-of-the-box ERP Integration
Sample Customers: Kraft, Fonterra, Beechnut & MARS
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. RA-TechED 2015 @RA-TechED #RA-TechED
Business Value Right First Time Production On-hand Inventory & Inventory Holding Cost Reduction Supports Lean & Continuous Improvement
Differentiators Capabilities
Work Order Management
Route & Processing Sequence Enforcement
eKanban Management
Line Side Inventory Reduction leveraging eKanban & Kitting capability
Backward & Forward Genealogy
Track & Trace
“Mistake Proof Unit Assembly” – supported by integrated error proofing
In-process Quality Management & SPC
Operational Intelligence
HTML5 Clients
Industry-Specific Workflows & UIs on Production Centre MES
Modular Solution – Invest in the capability needed to support today’s key business problem
Simple User Experience & Reduced IT Infrastructure Cost
Premier Integration leverages existing Rockwell Automation Investment
Out-of-the-box ERP Integration
Sample Customers: Ford, CJLR, Tata, Mahindra & Volvo Powertrain
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. RA-TechED 2015 @RA-TechED #RA-TechED
Business Value Lowered Cost of Compliance Increased Production Efficiency Reduce Inventory
Differentiators Capabilities
Holistic Electronic Batch Recording
GMP Aligned Material, Equipment & Personnel Tracking
Weigh & Dispense
Master Recipe & Workflow Design supported by best in class Recipe Designer
Electronic Batch Record Execution with uniquie usability paradigm on the shop floor
Review by Exception in Real-time with innovative Quality Dashboard
Integration to the ERP and Automation Layer
Role-based Optimization for Each Stage of the Recipe Life Cycle – “time to results for every user”
“Open Content“ Architecture to allow content building by 3rd parties & customer IT
Broad Capabilities to Adapt, Configure & Extend
Premier Integration leverages existing Rockwell Automation Investment
Out-of-the-box ERP Integration
Technology to Lower Deployment & Maintenance Cost
Scalable, Reliable & Upgradable
Sample Customers: Pfizer, Avon, Dr. Reddy’s, Roche Diagnostics & Sanofi-Aventis
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. RA-TechED 2015 @RA-TechED #RA-TechED
Agenda
FactoryTalk® ProductionCentre®
MES Strategy & Portfolio Overview
Industry Suites
Fit for Purpose Applications
Success Stories
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. RA-TechED 2015 @RA-TechED #RA-TechED
20 YEARS AVG PRODUCT LIFE
PRODUCT TYPES • Stock + Configure to Order
• Engineered to Order
387, 000 SKUS
200 PARTS AVG ORDER
20 PLANTS
The Connected Enterprise at Rockwell Automation® Our Journey: Discovery to Implementation
The Rockwell Automation Experience
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. RA-TechED 2015 @RA-TechED #RA-TechED
Challenges
32
ISSUES DISCOVERED Independent
ERP systems
Custom
applications
Model replication
cost prohibitive
Autonomous
P&L centers
No single
system to
run plants
Numerous
functional
experts
People + Process + Technology
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. RA-TechED 2015 @RA-TechED #RA-TechED 33
The Connected Enterprise Implementation at Rockwell Automation®
PL
AN
T
FL
OO
R
MA
NU
FA
CT
UR
ING
O
PE
RA
TIO
NS
M
AN
AG
EM
EN
T
EN
TE
RP
RIS
E
Data Collection
Secure Network
Infrastructure
Multi-discipline
Control & Information
Smart Assets
Scalable computing
Mobility
Integrated Control and Information - Logix Manufacturing Execution System -
Standard Ethernet with Common Industrial Protocol (CIP)
Rockwell Automation® Cloud platform
MACHINES & TESTERS
INDUSTRIAL “THINGS”
MATERIAL &
TRANSPORT
SHOP FLOOR PERSONNEL
PRINTERS & LABEL SERVICES
PLCS & SCANNERS
FINANCIALS HR LOGISTICS QUALITY WAREHOUSE ERP
Modular Information System –
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. RA-TechED 2015 @RA-TechED #RA-TechED 34
LOWER TOTAL COST OF
OWNERSHIP
Inventory
120 days to 82 days
CapEx
30% per year in
capital avoidance
Productivity ►4% to 5% per year
FASTER TIME TO MARKET
Delivery
Mid-80s to 96%
Lead Times
Reduced 50%
ENTERPRISE RISK
MANAGEMENT
Time to Want
82% to 98%
Quality
50% reduction in PPM
The Connected Enterprise Rockwell Automation® Transformation
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. RA-TechED 2015 @RA-TechED #RA-TechED
Results
Reduced Back Orders (80% lower for 1 plant)
Reduced Inventory, Increased Inventory Accuracy
Differentiators Capabilities
Customer Success – Building Materials
Large manufacturer of high quality residential and commercial building materials and related products improves quality and reduces
costs …
Lack of Inventory Accuracy, Supplier Visibility
High Shop Floor Inventory (stock) to Ensure Availability to Deliver is Costly
Unplanned Stock-outs Decrease Productivity and Impact Delivery Times
Build-to-stock & Build-to-order Required Flexibility in Manufacturing Execution
Paper Based Systems Introduced Variability, Cost and Complexities
Scrap & Re-work is Costly (esp. in Build-to-Order)
FactoryTalk® ProductionCentre®
Work Order Execution
KANBAN
Quality: SPC & Reporting
Supplier Integration for Material Requests &
Quality Reports
ERP Integration (BAAN)
Reduction of Scrap by Identifying Short Term Trends & Take Action
Increased Reliability in Supplier Management (integration reduces problems with wrong parts)
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. RA-TechED 2015 @RA-TechED #RA-TechED
Differentiators Capabilities
Accelerate NPI
High Overhead Costs
Lack of Visibility into Production
Lack of Predictable Quality
Efficiently Satisfy FDA & ISO
Manage Migration to Outsourcing
Supplier of small medical devices looking to improve overall quality & reduce NPI time through improved CAPA, electronic (paperless)
support for regulated industries…
FactoryTalk® ProductionCentre®
eDHR
Quality – CAPA
Supplier Management – IQA
RMA
Knowledge & Dashboard
Root Cause Analysis Reporting
Customer Success – Medical Device
Results 25% CAPA Cycle Time Reduced
20% Reduced Admin Time
20% Decreased Process Defects
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. RA-TechED 2015 @RA-TechED #RA-TechED
Differentiators Capabilities
Remove Legacy Solutions & Reduce IT Spend
Support GMP Requirements
Increase Manufacturing Yield
Enhance Product Quality
Genealogy
Single System Deployment across Manufacturing Sites
Closely Aligned with SAP Deployment
Results Deployed at Over 40 Sites
Closes the Loop between Shop Floor & ERP
Complete Production Genealogy Record
Reduced Order runtime
A large dairy manufacturer with multiple sites tasked with time-to-delivery, quality (freshness) and planning challenges …
Customer Success – Dairy Manufacturer
FactoryTalk® ProductionCentre®
Recipe Management
Order Execution
ERP Integration Gateway
Integrates MES & SAP – recipe download, order download, production declaration upload
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. RA-TechED 2015 @RA-TechED #RA-TechED
Differentiators Capabilities
Supplier Quality
Problem Cycle Time Resolution
Paper Based Factory (errors)
Quality/Failure Analysis
High Field Returns
High Warranty Costs
Results
25% Quality Improvement
40% Problem Resolution Cycle Time Reduction
Replaced 7 Legacy Systems – Saved $1.2 M
Global Implementation includes Direct Access to 50 Suppliers
Customer Success – Semiconductor
FactoryTalk® ProductionCentre®
WIP Management
Quality
SPC & Yield Management
Defect & Issue Resolution
Knowledge & Dashboard
Root Cause Analysis
Proactive Alerts & Notifications
Large supplier of yield management and process control solutions for semiconductor and related microelectronics industries looking to improve overall quality through deep unit tracking, non-conformance…
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. RA-TechED 2015 @RA-TechED #RA-TechED
Differentiators Capabilities
Enabling Regulatory Compliance
Improving Quality Effectiveness
Reducing Labor & Operating Costs
Reducing Material Consumption
Improving Equipment Performance
Results High Reduction in Manual Effort to Comply with Quality & Regulatory
Requirements
Reduction in Operator Omissions & Errors
Reduction in Manual Effort in Dispensing
Reduction Operating Costs
Reduction in Wastes & Variability
Improved Availability of Accurate & Timely Information for Data Analysis
Customer Success – Life Sciences
Rockwell Software® PharmaSuiteTM
Recipe Management
Weigh & Dispense
$ 1.9 Million Savings ROI 832 %
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. RA-TechED 2015 @RA-TechED #RA-TechED
Differentiators Capabilities
Multiple Assembly, Body In White, Engine & Paint Shops Covering Distances over 5 kms
Complex Product Mix and Variants
Enterprise Real-time Visibility
Obtain Product Consistency & Quality Targets
Guide a Diversely Knowledgeable Workforce to Perform Correct Tasks & Achieve Desired Quality
Results
Leveraged Centralized Data Center & High Availability Local Plant Architectures to:
Eliminate Down Time & Production Losses Due to System Unavailability
Reduce System Support Staff for 3 Plants
Continuous Improvement in Product Quality by Error-proofing, In Line Quality
Inspection & Coordinated Prevention Measures
Inventory Cost Reduction with MES Enabling JIT / JIS Lean Manufacturing Principles
Industry Recognition: CSI 2014 Award for “Excellence in IT”
Customer Success – Automotive
Roll out of a common MES solution to leverage investment of centralized software and support
FactoryTalk® ProductionCentre®
Order Execution
Sequencing
Error proofing
Quality Management
Enterprise Integration Gateway
FactoryTalk® View & FactoryTalk Vantage Point for Real-time Displays, Reporting & Dashboards
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. RA-TechED 2015 @RA-TechED #RA-TechED
Agenda
FactoryTalk® ProductionCentre®
MES Strategy & Portfolio Overview
Industry Suites
Fit for Purpose Applications
Success Stories
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