la soluzione bpm e soa per l’esecuzione dei processi … · aggiunge valore al sistema erp ©...

© 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


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


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


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


Define flows, from routing to screen

AEPAEP

OESOESGMSGMS


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


Visibility and KPIs

ProcessProcess

CreateCreateImproveImprove

DeployDeploy

ExecuteExecuteMonitorMonitor

AEPAEP

OESOESGMSGMS


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


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


Multiplication of disparate applications….*

*Source SAP*Source SAP


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


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


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.


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


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


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


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


Configurazione tipica


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


Seats

Headliners

Floor & Acoustic

Door Panels


2 sedi in Italia

MILANO PESCARA

Area commerciale

Tecnologie software

implementazione curata da Synesis

Business Intelligence

Production & Logistic Applications

On Going SupportWeb Development

ERP


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


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)


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


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


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


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


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


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


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


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


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


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


Technical Overview

System System ArchitectureArchitecture

ORACLE9i


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.


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]