How to Start Your Journey to Data-Driven Manufacturing

How to Start Your Journey to Data-Driven Manufacturing Welcome!

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5 Steps to the Successful Realization of Smart Manufacturing

Step 2: Connect – Critical Assets | June 12th, 2020

Introduction of the Webinar SeriesJay Foran – Senior VP of Industry & Innovation at Team NEO

• Overview of Smart Manufacturing Cluster

• Overview of webinar series;o Each webinar builds on the first one;

o Each webinar includes content from and is presented by a partnering pair of Manufacturer and Solution Provider;

o The progressive webinars are presented at the end of each week for starting on June 5;

o Emphasis will be on the operational excellence, improved efficiency and profitability of SME Manufacturers;

o Concepts that help the SME Manufacturer address the influences of Covid-19 will be highlighted at each step of the Journey.

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“Connect” Webinar OverviewRick Earles – Senior Director of Industry & Innovation at Team NEO

Establish a high level understanding of data-driven manufacturing (DDM) and identify applications where it can improve your type of business

Ensure production-critical machines (old and new) are sharing their data on the corporate network

Evaluate metrics and determine key performance indicators (KPIs) that require optimization

Receive Real-Time data on all levels of the operations and enable sharing of insights

Make business decisions based on data analytics to continuously improve productivity, profitability, and efficiency

Presented on June 5

Today’s Presentation

• Connect: Ensure production-critical machines (old and new) are sharing their dataon the corporate network;

o Useful KPI/Sensor Schemes Used for Popular Applications;

o Use of Gateways/Edge Computers to Acquire Data and Establish a Heartbeat Among Critical Assets (including employees);

o Data Storage on Premises or in the “Cloud” – Historian/Data Lake;

o Blending the Information Technology and Operational Technology functions – Including integration with ERP;

o Addressing Cybersecurity.

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Connect

“Connect” Webinar Overview

• Agenda:o Introductions

− Kurt Schron: Sr. Financial Analyst at Jergens - a Manufacturer of standard tooling components vises, and workholding equipment.

− Francis Martin: COO, Vice-President, VantageOne – a Solution Provider a custom software and on-demand application services to drive digital transformation located in Cleveland, Ohio.

− John Rattray: Senior Sales Executive of MEMEX – a Solution Provider that specializes in customized software consulting and development, and Internet of Things (IoT) solutions for growing, data-driven businesses.

o Manufacturers’ Use Case and “Connect” for Data Driven Manufacturing Journeyo Question and Answer Session

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“Connect” Webinar Overview

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Manufacturer: Jergens - Ready for IIoT - Connect

Kurt Schron - Sr. Financial AnalystE: Kurt.Schron@jergensinc.comT: 540-706-6856M: 540-818-2212

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Who is JergensIndustrial Manufacturer based in Cleveland, OH with 3 Divisions

TCD JIS

ASG

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What do we define as IIoT? Data Driven Manufacturing

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Jergens current IIoT background and Technology Deployment

• On Premise Install of Infor Syteline ERP

• Mixture of Systems for Loading CNC Programs

• QC Calc using Ethernet Output on 1 Machine

• Limited Hardwired Connections to Machines

• Shop-Trak Terminals for Job Cost Tracking

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Jergens Timeline - Preparation

12/2018Executives Attended Blockland Cleveland

3/2019- Attended 1st Team NEO Cluster Event- Identified IOT/Machine Monitoring

as Corporate Initiative

4/2019- Held Meetings Internally - Met with

- Executives- Supervisors- Operators

5/2019- Smart Manufacturing Workshop @ Jergens- SMEs meeting with All Members of Our Team

5/2019 to 10/2019- Vendor Selection

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Jergens IIoT Readiness

IIoT Readiness taken 3/18/201Key Advantages• Have C-Suite Executive Buy in• Have Staffed MFG Engineering Team • Identified Project Manager to Drive Project

Identified Goal: Increase Machine Utilization and Reduce Unplanned Downtime

Key DisAdvantages• Many Older Legacy Machines• Little Historical Data on Downtime• High Mix / Low Volume Environment• Multiple Product Lines with Very

Different Cycle Times

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Why IIoT? –Pain Points & Metrics Desired

Pain Points • Don’t Know When Machines Go Down• Reactive, No Notifications of

Active/Live Issues• Job Counts Inaccurate• Not Timely Data Availability• Operators Have to Leave Machines To

Track People Down• No Data About ‘Why’

Metrics Solutions• Utilization• Automated Good / Total Part Counts• UpTime Indicators• Downtime Reason Tracking

Results based on Interviews with:• Executives• Supervisors• Operators

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Vendor Requirements & Comparisons

• Full Data Access • Secure• Query able & Customizable• Alerts• Realtime Data• Triggers / Ping & Buzzer• Capture Sensor & PLC Data• Integrate with Syteline• Intuitive & Easy for Operators• Timeline of Implementation• Dashboards Available Everywhere• Full Data Capable of Predictive Maintenance

Nice to Haves:• Includes Tracking of Assembly Stations• Data Feed of Predictive Maintenance• Communication Protocol• Tracking of Physical Tools / Tool Life• Tracking of Assets within Jergens Facility

(RTLS)

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On Premise vs Cloud Hosted?

On Premise Cloud

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Jergens IIoT Installation, Network & Security

• Additional Wireless Access Points

• 40 Twin Cable Drops

• Created an additional VLAN network Just for the machines. No outside connection

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We prioritized starting with 10 Machines

• 10 ‘Easiest’ Machines to Connect– Transfer Machines– Mills– Lathes

• Machines From Across Multiple Product Lines

• Needed Software and Additional Hardware for 7 Machines

• No additional sensors

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Training

• 10 Hours of Training – Dashboards– Reporting– Admin– Advanced Features– ERP Integration (Currently In Process)

• Met with Supervisors & Operators throughout

• Supervisors & Operators Participated in initial fact gathering through vendor selection

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IIoT Growing Pains

• Still Working on our ERP Integration– We are on schedule

• 1 Machine Still not Connected– Our Ethernet Port is used by our QC Calc Software

• 2 Machines No Part Counts– No Machine Schematics at Time of Install

• 2 Machines Inaccurate Part Counts– Challenge is for each machine if there isn’t a dedicated part count how to

capture? – Chuck Open / Close is currently being used

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Dashboards on Shop Floor

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Integration with ERP

• ShopTrak (The Lake Co.) is Integrating Product with Merlin Software

• Operators Currently Use Single Terminal To Enter Job Start / End, Qty Information

• Operators will Login to Personal ShopTrak– Enter Job Start– Qty Pulled From Machine– Enter Scrap Qty– End Job– Idle/Downtime Reasons will be entered by

Operators• Tablet/Computers Installed at Operator

Stations, Some already have Computers

ShopTrak Code DescriptionS01 SetupB01 Break/LunchW01 Run Approval

W02 First Piece InspectionM01 MaintenanceW03 No OperatorW04 Waiting on MaterialW05 No JobW06 No GagesW07 Program IssuesT01 Tooling IssuesT02 Waiting On ToolingB02 Training/ShopTalkT03 Troubleshooting

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Next Steps

1. Finish Integration with ERP2. Begin Continuous Improvement (CI) Plans on first 10 machines3. Work in Stages of ~10 Machine Implementations Until Full Floor

Rollout4. Continue to Identify Additional Uses of Data

– Preventative Maintenance– Lead Times / Supply Chain Optimization– Tool Life Tracking

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Next Steps – Continuous Improvement

STEP 1 STEP 2 STEP 3 STEP 4 STEP 5

High-level Plan for Data-Driven Manufacturing

Connect to any machine, old

and new, KPI/Sensors

Monitor and Identify

Bottlenecks and

Constraints

Analyze causes for Downtime and Rejects

then eliminate them

Discover the hidden factory

and monetize the

benefits

Prepare Connect Visualize Analyze Optimize

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Solution Provider: VantageOne Software - IT & OT

Francis Martin - COO, Vice-PresidentE: francis@vantageonesoftware.com M: 440-413-5539

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Solution Provider: VantageOne Software - IT & OT

• Systems Integrator• Software development provider • Custom web, mobile, desktop and enterprise

application software and service solutions• Focus on IIoT• Bridge Information Technology (IT) and

Operational Technology (OT)

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Convergence of IT and OT

IT OTIT/OT convergence is the integration of Information Technology (IT) systems used for data-centric

computing with Operational Technology (OT) systems used to monitor events, processes and devices and make adjustments in enterprise and industrial operations.

The Common Ground - IIoT:• Identifying and authenticating all devices and machines within the system• Encrypting all communications between these devices• Ensuring the integrity of the data generated from these systems• Assuming the manufactured goods contain software or firmware themselves, enabling the

ability to perform remote upgrades down the road and ensuring the integrity of those updates.

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Solution Provider: Memex Inc. – Measuring Manufacturing Excellence

John Rattray – Senior Sales ExecutiveE: John.Rattray@MemexOEE.comM: 416-460-7637

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IIoT Innovation in Manufacturing - Connect

0101COSTIN

GRDATA101

Connected MFG Model

$$$

IIoT is being applied successfully in manufacturing today – generating a 300% IRR on average. The path is known, the benefits are extremely compelling.

Cost effective, proven solutions exist which drastically reduces the risk of an IIoT project failure.

The last meter problem has been solved. Data can be cost effectively collected from ALL MFG equipment and processes.

Metrics require data to function, real-time data is the most accurate, as it streams from the machine.

There is a direct link to increased productivity and increased profitability.

Internet Security applied to the factory floor should be part of the discussion.

Leverage IIoT

For big dollars

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Work Order Scheduling and Results Reporting

Direct To / From ERP

Evidence Based Real time data collection at each machine and Discrete Process on the

shop floor

Process Improvement , Benchmark Analysis,

Corrective Action, Repeat

Drive costs out of the manufacturing process,

leading to higher capacity utilization and higher

profits for the same level of effort

WIP, Raw Material, Valuable Tooling, and Finished Goods Tracking with RFID

& ERP

Horizontal & Vertical Integration

Vertical: Shop Floor To Top Floor, Integrating and optimizing all equipment and processes, from machine sensors to the ERP system

Horizontal: Across the Complete Plant, Integrating, communicating and optimizing the production operations.

Smart Manufacturing: How it comes alive

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Data-Driven Manufacturing – The Benefits

Real-time machine visibility + OEE numbers including alerts

Operator Productivity Increase

Reduce Downtime

Minimize Rejects

Root Cause analysis

Value Stream data collection & analysis

Labor productivity tracking

Usage-based Preventive Maintenance

Benchmark scheduling & value streaming

2 - 5%

1 - 10%

3 - 8%

2 - 4%

2 - 4%

2 - 4%

3 - 6%

1 - 2%

2 - 6%

10% - 50% Productivity

increaseThe

benef

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5 Steps to the Successful Realization of Smart ManufacturingConnect

5 steps to success

#1: Connect

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ISA-95 standard for machine connectivity

ERP – Business System

Manufacturing Execution System

Distributed Control System

Connection

Machine

$Profit

ERPLevel 4

Manufacturing MachineLevel 0

OEE ApplicationLevel 3

MERLIN Server AgentLevel 2

Machine AdapterLevel 1

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Plant of the future – No machine left behind

CORPORATE HQ

Corporate-widereporting

Shop floor to top floor visualization

CorporatedashboardReal-time metrics,

on-time delivery

ERPMERLIN HMI

Adds bi-directional operator control of

any machine

MERLIN SERVER

LEGACY machines FOCAS enabled machinesMTConnect

enabled machines OPC enabled machines

Level 0

Level 1

Level 2

Level 3

Level 4

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Machine Connectivity – SoftwareLevel 1 Software Adapter on

machine

OPC

Proprietary Protocols

Serial to Ethernet Adapters

Fanuc Focas 2

MTConnect

Ethernet Port on Machine

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Machine Connectivity – Legacy MachinesAx760-MTConnect Adapter : A quick and easy way to find

and monitor signals from your machine

Provides Ethernet connectivity to any machine or device

Embedded Webserver for configuration and

monitoring

Outputs MTConnect Industry Standard

data tags

Plug compatible with Fanuc I/O link bus and passively detects data as well as 16

additional digital inputs, 12-24 VDC Power Supply from

machine

MTConnect Compliant, field upgradeable to newer

releases

Allows Feed Rate and Spindle Override tracking from Fanuc i

series controls

Ax760-MTC

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Customer Installations

Machine Description

Fanuc Series 18i-TA with I/O LinkAx760MTC –MTConnect enabled

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Customer Installations

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Customer Installations

Machine DescriptionWNT 2000 Panel Saw with MTConnect enabled

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Solution Stack: Connectivity Hardware

Take control of your shop floor, equip your machine

tools, and assembly, production or

processing line with the true power of edge computing.

and optimize efficiency

MERLIN MTC-One

Ax 760 - MTCWith Ax760-MTC enableolder machines on your shop floor to output available machine state, alarm states, controller modes, and muchmore in Real-Time.

The Ax650 monitors and controller’s I/O. It supports up to eight signals in addition to power.

Ax 650

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Confluence of 3 data streams – IT and OT

AUTOMATED APPROACHMACHINE-CENTRIC

TRADITIONAL APPROACHOPERATOR--CENTRIC

HistorianSQL Database

PROACTIVE ALERTS

Real-time data

MTConnect/OPC/Hardware adapter

DATA PRODUCER

Connect directly tothe machine, automated

data collection in real-timeData collection dependsentirely on operator action

Two-way,Bi-synchronous

Open Database

REACTIVE INFORMATIONGenerating lagging metrics

ERP, MESDashboardDATA Consumer

Machine Data Operator Data

Business Systems Data

500+ API calls to any software

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Hidden Capacity: Eliminating The 5 Big Losses

0%

20%

40%

60%

80%

100%

120%

ACTUAL DESIRED AVAILABILITY

Productive Machine Shop Reporting Job MaintenanceThe improvement opportunities are always in one of

the following “buckets”

Machine

Shop

Reporting

Job

Maintenance

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MERLIN Performance Management Model

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MPMM Categories

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Baseline and measure the output by hour, by shift, by day. Actual vs Target

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Analytics – Analysis with dashboards and report detail

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Dashboard View

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Plant Utilization View

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Event Chart – know exactly to the second

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MERLIN: Value Proposition

Delivers a 10% - 50%

average productivity

increase

Earns 20%-plus profit improvement based on just a 10%

increase in OEEA fast ROI

Achieves payback in less than 4 months

with an IRR greater than 300%

Ensures no machine is left behind Connect ANY

machine

Reveals ongoing & sustainable factory productivity gains for years to come

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Questions & Answers

Francis Martin 440-413-5539francis@vantageonesoftware.com

John Rattray416-460-7637John.Rattray@MemexOEE.com

Kurt Schron540-818-2212Kurt.Schron@jergensinc.com

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Why Act Now

More value than buying a new machine.

By measuringRPM – Real-time Performance Management

Increase capacity 10+%, saves machines, space, labor & more.

Increase profitability60+%

Competitive advantage, retain and capture more customers

Validation, traceability, efficiency, accurate data, lower costs.

Visibility for everyone means better performance

Culture of efficiency means extend job security

Increase company

profits

Strategic Competitive

Edge

Visibility = Efficiency

Productivity Increases of 10-50%

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In Closing…

• If you have any other questions, please contact Rick Earles at rearles@teamneo.org• Recommended Reading

o OEE-College.com - Book on OEE - R. C. Hanseno ISA95-Standards - Machine Connectivity Standardso Smartbox – Cyber Security for machines

• Recommended Viewingo SME Manufacturing Resource Center – Society Manufacturing Engineerso Modern Machine Shop – Data Driven Manufacturingo YouTube – Videos of Industry 4.0 Software functionalityo Improved Utilization Through Machine Monitoring – MC2 Conference

• Recommended Resourceso MTConnect.org – Industry Standard for connecting machines. o OPCFoundation.org – OPC connectivity to machines.o Fanuc Focas Library – For connecting Fanuc controlled machines.

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In Closing…

• You will receive an email within 24 hours with a link to view the webinar recording,

presentation materials and additional resources.

• Please join us for Part 3 of the series:

“Visualize – Real-time Data” featuring Rockwell Automation

Friday, June 19th from 9:00 am – 9:45 am

Register now at smartmanufacturingcluster.org/events

• On behalf of the Smart Manufacturing Cluster and our presenters, thank you for joining

us today!

ContactsTeam NEORick EarlesSenior Director Industry & Innovation216.363.6888Rearles@teamneo.org

VantageOne SoftwareFrancis Martin COO, Vice-President440-413-5539francis@vantageonesoftware.com

Jergens, Inc.Kurt SchronSr. Financial Analyst540-818-2212Kurt.Schron@jergensinc.com

Memex Inc.John Rattray Senior Sales Executive416-460-7637John.Rattray@MemexOEE.com

Thank You