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Page 1: MAN-088 Kickstart Your Operations Optimization with End of ......Peat Moss Field Equipment Vacuum peat harvester Onlyduringdry seasons Vacuum up the thin dried layer Not included in
Page 2: MAN-088 Kickstart Your Operations Optimization with End of ......Peat Moss Field Equipment Vacuum peat harvester Onlyduringdry seasons Vacuum up the thin dried layer Not included in

WILHELM BIELERTVice-President & Chief Digital OfficerPremier Tech

Kickstart Brilliant Manufacturing with End-of-Line Equipment Projects

PHILIPPE HAMMONDBusiness Solutions DirectorPremier Tech

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GE’s Predix

From jet engine to peat moss plant

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GE’s Predix

Get the 20/80in 1 month

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3 800 TEAM MEMBERS24 COUNTRIES

41 MANUFACTURING PLANTS14 COUNTRIES

IN +80 COUNTRIESCOMMERCIALLY ACTIVE

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Our Brands

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HorticultureFrom tradition to innovation

Packaging Equipment

Wastewater Treatment

Biotechnologies

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3 Groups

Horticulture and Agriculture

Industrial Equipment

Environmental Technologies

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The Project

Analytics project in a Peat Moss plant

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The Objective

•Connecting packaging plant equipment through Predix

•To better understand operation downtime

Get the 20/80in 1 month

Page 11: MAN-088 Kickstart Your Operations Optimization with End of ......Peat Moss Field Equipment Vacuum peat harvester Onlyduringdry seasons Vacuum up the thin dried layer Not included in

1Connecting operations

2Generating first glimpse of analytics

3Envisioning next steps

Our 1 Month Project

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1) Connecting operations

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Peat Moss Field Equipment

Vacuum peat harvesterOnly during dry seasonsVacuum up the thin dried layerNot included in the Analytics project

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Peat Moss Bag

•3.8 cu ft / 60 lb bags–Variability of Peat Moss and bags

affect the operation efficiency • Temperature• Humidity• Bag size and plastic quality

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The St-Laurent Plant

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Packaging Process

1- Vertical form, fill and seal baler

2- Robotic bag palletizer

3- Stretch hooder

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Packaging Equipment

•Fully automated with PLCs–Allen-Bradley

• Old & New• All Ethernet enabled

–More than 500 tags

•Fanuc Robot–Palletizer

•Connected on the operation network

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Connecting the St-Laurent Plant

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Predix Field Agent

• Industrial PC running Predix Machine

• Connected to the Operation Network

• Collect data from PLCs– Already generating more than 500 tags

– Record Equipment behaviors from few tags

• No need to retrofit Equipment

• Deployed in 1 day

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Temperature & Humidity Sensor

•Raspberry PI–Temperature & Humidity

sensor• Plug and Play board

–Predix Connectivity• Field Agent installed• Prepared by GE Digital

Innovation team• Easy to install - Connect

network and power

–Simple & Low cost solution

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Connecting Operations

Data are already generated across the production line,just need to be collected

Additional data dimension, generate improvement opportunitiessimple devises like Raspberry PI are easy to deploy

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2) Generating first glimpse of analytics

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Choosing the Right Metrics

Digital Twin

Asset Performance Management

Operate

•Objective –Better understand operation downtime

•OEE - Overall Equipment Effectiveness–The standard for measuring manufacturing

productivity

–Percentage of manufacturing time that is truly productive

–Availability x Performance x Quality

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OEE - Basically Simple

OEE = Availability x Performance x Quality• Availability is a ratio of unplanned and planned stops

• Performance compare the real vs top production speed

• Quality takes into account defects vs good parts

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OEE - Basically Simple

OEE = Availability x Performance x Quality

• Requires collecting 2 data by Equipment–When a Unit is produced

–When a Unit is rejected

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OEE - Complex in the Details

Availability• Running doesn't

mean Producing

• Need to integrate the Equipment status

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OEE - Complex in the Details

Performance• Depends on the SKU produced – big bags vs small

bags

• Need to integrate the Equipment recipe or pattern

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OEE - Complex in the Details

Planned Production Time• Require to integrate the

production scheduled

• If not available from the MES

– Need to be entered manually

– Or less accurate startegy

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Day-to-day Production Metrics

Production scoreboard• Number of bags• Today target vs current progress• Today’s total downtime

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Generating First Glimpse of Analytics

Devils are in the detailsTeamwork with your domain expert

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3) Envisioning next steps

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Current State After 1 Month

Understand the pastHistorical & context data

See present conditionCurrent state & performance

Predict the futureEarly warnings & predictions

Visualize50% completed

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What is Missing?

Downtime root causes• Equipment faults• Operators reasons for stopping production• Why the equipment is waiting

Analyzing the big losses and be actionable• Generate tasks based on analytics decisions• Decrease equipment downtime• Improve yield to reduce waste• Reduce process inefficiency

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Next Phase

Understand the pastHistorical & context data

See present conditionCurrent state & performance

Predict the futureEarly warnings & predictions

Optimize

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Redefine the HMI Experience

• Equipment HMI and Cloud unified experience– Advanced metrics & trends

– Cloud HMI

– Mobile and Augmented Reality

– Integrate Work Instructions

• Reduce training time of new operators

• Empower remote users, on-demand support, and collaboration

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Integrate Analytics with Execution

Brilliant Manufacturing=

Brilliant Execution Brilliant Analytics+

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Integrate Analytics with Execution

– Better manage production orders across sites

– Optimize assets across availability, reliability, risk, and costs

– Reduce raw material and product variability

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What’s Next?

Understand the pastHistorical & context data

See present conditionCurrent state & performance

Predict the futureEarly warnings & predictions

Innovate

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Innovation Opportunities

Predictive failure of packaging equipment• Predict equipment issues before they occur• Reduce unplanned downtime by maintenance• Will require integration of new sensors on equipment

Prescribe packaging equipment setup• Reduce change over time• Adjust with operation environment changes• Adapt with raw material and product variability

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Envisioning Next Steps

Many opportunities for the future

Next step - Making the Analytics more actionable

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Achievement

Analytics project in a Peat Moss plant

Get the 20/80in 1 month

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• Most of data are already there, start to collect them

• Devils are in the details

• Opportunity is huge, if your able to integrate your business domain expertise

• Visualize your operation is a good start.

• The next step is to make it actionable to optimize.

Summary

1Connecting operations

2Generating first glimpse of analytics

3Envisioning next steps

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Conclusion

You can kickstart a complete factory on Predix in 1 month

Think bigstart small

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Thank You