manufacturingbdm - predictive maint solution · pdf file“the microsoft azure based...
TRANSCRIPT
Rene Kubu
Business Strategy Lead
Microsoft CZ&SK
MICROSOFT&INDUSTRY 4.0
Modern manufacturers are embracing customer centricity, innovating faster and becoming more agile
Marketing ServicesSalesSupply R&D Production
Production
R&D
Supply
Marketing
Sales
Services `
Physical DigitalDigital Transformation
Smart products
Service ecosystems
Production assets
Raw materials and products
Connected consumersPreventive maintenance
History of making big bets
We’ve used
technology very
successfully to
democratize both
creation of
information and the
distribution and
access of
information …
History of making big bets
… and now we need
to turn to
technology to
democratize
creation and access
to intelligence. That’s
the approach that
Microsoft is taking
with our AI efforts.
Satya Nadella, CEO Microsoft
Ignite 2016
“Cloud is a given. No longer ask whether to use cloud, but rather how.”
Connect and control intelligent,
productive, and trusted devices with
Internet of Things
Intelligent business applications that allow
customers profit from predictive services
Predict, prescribe and automate with a
fully managed big data and advanced
analytics suite
Embrace customer centricity and
empower your employees
Unify service, marketing and sales to
gather consumer and product usage
insights, improve the customer experience
and increase sales productivity.
Innovate faster and transform your
products
Act on data from the factory, global ops
and the customer to seize new revenue
streams, hasten new product and
service introduction, and innovate.
Optimize your operations and
become more agile
Utilize global visibility to improve
operational efficiency, streamline
the supply-chain and increase the ability
to scale seamlessly and quickly.
OPSPLANT
CUSTOMER
Customer Center Research and Development Operations & Supply-Chain Hub
Power technology provider testing new designs with HPC in the cloud
“The Microsoft Azure based UberCloud solution is beneficial for OpenFOAM users
who need to deliver their simulation results in a much faster time.”
— Wei Wu, Senior R&D Design/Development Engineer, ABB
Big-data solution provider adopts new cloud, gains thousands of processing cores
“Microsoft understands big-compute needs for the simulation industry and provides
great Azure support for HPC-centric applications.”
— Suri Bala, founder and chief executive officer, d3VIEW
Real time remote monitoring
Rockwell Automation
“What we’re talking about is delivering a degree of collaboration and visibility unheard
of in the oil and gas industry. With sensors, software and the cloud, these disparate assets
can become part of a connected enterprise, powered at its core by a rich flow of data.”
Doug Weber
Business Manager, Remote Application Monitoring, Rockwell Automation
Integrating predictive analytics with
real-time manufacturing
Jabil
“We’ll be able to improve our efficiencies, cut costs, and decrease our lead times,
which tie directly to our customers’ requirement to increase flexibility.”
Matt Behringer
CIO, Enterprise Operations and Quality Systems, Jabil
And their impact on the business
• Reduced manufacturing cycle time
• Higher cost of wasted materials, time and resources
• Inability to address customers’ critical requirement for speed to market
Product
quality not
acceptable
Challenges Jabil was facing…
• Continuous requirement to increase yield, reduce amount of scrap and re-work
• Traditional inspection techniques for ensuring quality quickly becoming
outdated with more one-off production runs
• Adding more equipment and people to existing manufacturing processes
would not have significant impact on increasing throughput
Inspection steps along the SMT line cannot always detect the quality issues
Source of failure can be introduced at multiple stages but cannot be detected until it ispowered-up for testing at the end
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Results
• Predicted machine processes that will slow
down or fail with an 80% accuracy
• Reduced costs of scrap and re-work by 17%
• Delivered energy savings of 10%
Variation: 11% (tolerance ≤ 11%)
Vibration frequency: Too high
Bit wear: High
Result in plant 2: Failed
PREDICTED
FAILURERecommended maintenance
in next 48 hours
PREVENTATIVE
MAINTENANCE
FOR TOMORROW
10 TuesdayOctober
7:00 AM
Tactics
Jabil was able to transform their manufacturing
production lines with advanced analytics solutions
built on Microsoft technology
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Objectives
Jabil wanted to better predict errors or failures on
the assembly floor before they occur, saving
customers’ time and money
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PREDICTED FAILURE
IN NEXT 48 HOURS
Supplier data
Customer
data
Production
data
Historical data
Azure
Services Our rate of rejection has decreased dramatically now
that we can predict these failures early in the process
Global elevator manufacturing
company develops service arm
ThyssenKrupp Elevator
“We wanted to go beyond the industry standard of preventative maintenance,
to offer predictive and even preemptive maintenance.”
Andreas Schierenbeck
CEO, ThyssenKrupp Elevator
USAGE
Ensure your service techs are fully equipped
to deliver a first-time fix.
• Accelerate repair times by providing resolution guidance and connecting techs
with product experts
• Enable upsell and cross-sell opportunities by providing techs with product and
service information
4
KNOWLEDGE BASE REPAIR STATUSALERTHISTORY CASE STATUS
REAL-TIME CUSTOMER VIEW REAL-TIME CUSTOMER VIEW
Address issues faster by remotely monitoring devices and
keeping customers in the loop.
• Automatically determine if mobile technicians are needed
• View product usage, issues and repair history from a central portal
• Diagnose problems and access repair and process guides
2
ROLE REPORTING FIX RATE %
VP ENG. VP SALES Customer C. Service
96%
FIRST TIME RESOLUTION %
MODEL #SERVICE TYPE
PRODUCT RELIABILITY
REAL-TIME CUSTOMER VIEWEXECUTIVE VIEW
SERVICE ORDER STATUS SATISFACTION SURVEY
Reduce downtime with proactive alerts from
connected devices.
• Collect and catalog meaningful product data
• Predict and proactively prevent breakdowns
with advanced analysis
1
REAL-TIME CUSTOMER VIEW
Gain enhanced visibility into product, service,
company performance and customer satisfaction.
• Track employee performance by generating role-specific reports
• Improve decision making and maintenance plans by gleaning insight from internal use
and repair data and external data
• Determine product weaknesses, usage issues, or service tech knowledge gaps
• Offer visibility into parts availability, even across borders
• Improve customer loyalty with customer feedback
5
REPAIR STATUS
REPAIR STATUSREPORT A PROBLEM
Broken pump
Submit
Great work!
Reduce maintenance costs by dispatching the
right technician only when needed.
• Reduce on-site visits with remote expert assistance
• Send technicians once by verifying expertise, availability
and location
• Update technician devices with route navigation
Experienced
On duty
In the area
3
Creating a connected factory
KUKA
“We ship our customer a complete car body every 77 seconds. We don’t have time
to adjust source code, and we can’t introduce something that isn’t trusted and proven.
Our intelligent system built with Microsoft technology enables us to react very quickly.”
Jake Ladouceur
Managing Director, KUKA Systems Group Toledo facility
Local ISVs - Plantyst
Plantyst přináší světlo do výroby
Chillers now run 9x faster than
unconnected equipment,
avoiding more than $300,000
in hourly downtime costs
Gathers data from sensors and
systems to create valuable
business intelligence and
reduce downtime by 50%
Cutting fuel usage by 1 percent
could save $250,000 per plane
per year
Improves access to production
and supply chain data
worldwide, reducing downtime
costs by as much as $300,000
per day
© 2016 Microsoft Corporation. All rights reserved. Microsoft, Windows, and other product names are or may be registered trademarks and/or trademarks in the U.S. and/or other countries.
The information herein is for informational purposes only and represents the current view of Microsoft Corporation as of the date of this presentation. Because Microsoft must respond to changing market
conditions, it should not be interpreted to be a commitment on the part of Microsoft, and Microsoft cannot guarantee the accuracy of any information provided after the date of this presentation.
MICROSOFT MAKES NO WARRANTIES, EXPRESS, IMPLIED OR STATUTORY, AS TO THE INFORMATION IN THIS PRESENTATION.
Rene Kubu
+420 720 958 355