man-088 kickstart your operations optimization with end of ......peat moss field equipment vacuum...
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WILHELM BIELERTVice-President & Chief Digital OfficerPremier Tech
Kickstart Brilliant Manufacturing with End-of-Line Equipment Projects
PHILIPPE HAMMONDBusiness Solutions DirectorPremier Tech
GE’s Predix
From jet engine to peat moss plant
GE’s Predix
Get the 20/80in 1 month
3 800 TEAM MEMBERS24 COUNTRIES
41 MANUFACTURING PLANTS14 COUNTRIES
IN +80 COUNTRIESCOMMERCIALLY ACTIVE
Our Brands
HorticultureFrom tradition to innovation
Packaging Equipment
Wastewater Treatment
Biotechnologies
3 Groups
Horticulture and Agriculture
Industrial Equipment
Environmental Technologies
The Project
Analytics project in a Peat Moss plant
The Objective
•Connecting packaging plant equipment through Predix
•To better understand operation downtime
Get the 20/80in 1 month
1Connecting operations
2Generating first glimpse of analytics
3Envisioning next steps
Our 1 Month Project
1) Connecting operations
Peat Moss Field Equipment
Vacuum peat harvesterOnly during dry seasonsVacuum up the thin dried layerNot included in the Analytics project
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
The St-Laurent Plant
Packaging Process
1- Vertical form, fill and seal baler
2- Robotic bag palletizer
3- Stretch hooder
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
Connecting the St-Laurent Plant
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
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
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
2) Generating first glimpse of analytics
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
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
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
OEE - Complex in the Details
Availability• Running doesn't
mean Producing
• Need to integrate the Equipment status
OEE - Complex in the Details
Performance• Depends on the SKU produced – big bags vs small
bags
• Need to integrate the Equipment recipe or pattern
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
Day-to-day Production Metrics
Production scoreboard• Number of bags• Today target vs current progress• Today’s total downtime
Generating First Glimpse of Analytics
Devils are in the detailsTeamwork with your domain expert
3) Envisioning next steps
Current State After 1 Month
Understand the pastHistorical & context data
See present conditionCurrent state & performance
Predict the futureEarly warnings & predictions
Visualize50% completed
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
Next Phase
Understand the pastHistorical & context data
See present conditionCurrent state & performance
Predict the futureEarly warnings & predictions
Optimize
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
Integrate Analytics with Execution
Brilliant Manufacturing=
Brilliant Execution Brilliant Analytics+
Integrate Analytics with Execution
– Better manage production orders across sites
– Optimize assets across availability, reliability, risk, and costs
– Reduce raw material and product variability
What’s Next?
Understand the pastHistorical & context data
See present conditionCurrent state & performance
Predict the futureEarly warnings & predictions
Innovate
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
Envisioning Next Steps
Many opportunities for the future
Next step - Making the Analytics more actionable
Achievement
Analytics project in a Peat Moss plant
Get the 20/80in 1 month
• 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
Conclusion
You can kickstart a complete factory on Predix in 1 month
Think bigstart small
Thank You