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State-Of-The-Art Shop Floor Management
FORCAM, Inc. 250 East 5th St., Cincinnati, OH 45202
513-878-2780
www.forcam.com
FactoryFramework Advanced Shop Floor Management Mohamed Abuali Director Delivery Operations
http://www.forcam.com/index.php?id=209&L=209&id=261&tx_ttnews[tt_news]=164&cHash=168e44df771906d5bb88122ba4a21694
FORCAM 2014 Page 2
Presentation Agenda
FORCAM Introduction
Shop Floor Management with Factory Framework
Technical Capabilities Machine Data Collection Order Data Collection with SAP Integration Personnel Data Management SFM OEE Performance Reporting and Visualization Additional SAP Integration Functionalities
Configuration Capabilities with Live Demonstration
Project Plan and SFM Workshop
Summary and Conclusions
FORCAM 2014 Page 3
FORCAMs Passion
FORCAM provides proven manufacturing solutions to
Continuously Improve Productivity
To be the global solutions provider of the best-in-class Manufacturing Execution
Systems
FORCAM 2014 Page 4
FORCAM - History
Shareholder SAP Founder Dietmar Hopp
Web Technology SFM Evaluations
Founding FORCAM USA
Global Roll-Out (> 90 Plants)
Stamping Plants
Productivity + 20% within 12 months
SAP Spin Off
Research Partnership
Innovation Award
15,000 Monitored Assets
Release 5.0
+ 12% Efficiency Increase
within 6 Months
Machine-Connector 400 Heterogeneous Machines
Press Plants Asset worth
US$ 2.5 Billion
Founding FORCAM UK
SME Business
+ 25% increased operating
time and availability of all facilities
New Plant Mnchsmnster
Press Plant Leipzig & China
Frost & Sullivan
2014 Award
http://www.elektroauto-nachrichten.de/category/elektroauto-hersteller/audi/http://www.weirminerals.com/http://www.frustgefahr.de/mercedes_logo.jpghttp://www.elektroauto-nachrichten.de/category/elektroauto-hersteller/audi/
FORCAM 2014 Page 6
FORCAM International Presence
Head Office Germany
Friedrichshafen
FORCAM Ltd United Kingdom
Cheshire
FORCAM Inc. Americas
Cincinnati, OH, USA
Team Hungary
Team Switzerland
Benelux
Team France
Team China
Team India
Team Malaysia
Team South Africa
Team Poland
FORCAM 2014 Page 7
FORCAM Partner Network
FactoryFramework Network Over 150 MES Experts
IBM Global Partner
SAP Certified ERP Partner
IMS Center Univ. Of Cincinnati Research Partnership
TDM Systems Tool Management
Q-DAS Quality / SPC
FORSIS Industrial PCs
http://www.q-das.de/http://www.sap.com/index.epxhttp://www.q-das.de/
FORCAM 2014 Page 8
Our Customers
OEM Automobile + Automobile Suppliers
Aerospace/ Marine Aerospace Defence
Machinery
Medical Devices
Automotive
Other Industries - Minerals - Oil & Gas - Heavy Machinery - Food & Beverage - Pharmaceuticals
http://www.weirminerals.com/http://www.dieselpub.com/dp/images/news/M+H logo.jpghttp://images.google.com/imgres?imgurl=http://www.peplus.co.uk/ARBURG_logo_72_dpi_internet.jpg&imgrefurl=http://www.peplus.co.uk/last_weeks_news.htm&h=113&w=400&sz=36&tbnid=h0CycvPe4akJ:&tbnh=33&tbnw=120&hl=de&start=5&prev=/images?q=arburg+logo&svnum=10&hl=de&lr=&rls=RNWE,RNWE:2005-12,RNWE:en&sa=Ghttp://www.fissler.de/Home.1.0.html
FORCAM 2014 Page 9
AUDI
Due to Factory Framework the press plants have increased their productivity by 20 % within the first year. Investing in a new solution architecture was well worth it. Axel Bienhaus, Audi AG
FORCAM 2014 Page 10
BorgWarner
The FORCAM technology is unique and exceeded our expectations in all categories important to us - strategy, functionality, costs. J. Bischoff, BorgWarner
FORCAM 2014 Page 11
In just 6 months Factory Framework has given
us a 12% efficiency increase. Tony Locke MD, Weir Minerals
Weir Group
FORCAM 2014 Page 12
Productivity: Audi (Stamping)
+20% within 12 Months
Weir Minerals +12% within 6 Months
Technology and Scalability: From Machining Job Shops with 10+ Machines To Multi-Plant Shop Floor Management with 14,000 Machines
Connectivity: MTU Aero Engines: Shop Floor Management with
400 Machine Tools (25 Various CNC Controls / PLCs)
Seamless ERP Integration with Multiple Sites: FORCAM complements SAP ERP ideally.
Overall Impact on Customers
http://www.weirminerals.com/
FORCAM 2014 Page 13
FORCAMs Approach Advanced Shop Floor Management
If you cannot measure it, you cannot improve it. Lord Kelvin
Continuous process improvement with PDCA
Reliable performance measurement and metrics
Shop floor transparency based on real-time, objective data collection
FORCAM 2014 Page 14
Continuous Improvement Process at AUDI
Factory Framework delivered a 20% increase in overall productivity: Within the first 12 months at AUDI Within the first 3 months at SEW Euro-Drive
Target state
Actual state
Plan
Do
Check
Act PDCA
+20% AUDI and SEW
FORCAM 2014 Page 15
Presentation Agenda
FORCAM Introduction
Shop Floor Management with Factory Framework
Technical Capabilities Machine Data Collection Order Data Collection with SAP Integration Personnel Data Management SFM OEE Performance Reporting and Visualization Additional SAP Integration Functionalities
Configuration Capabilities with Live Demonstration
Project Plan and SFM Workshop
Summary and Conclusions
FORCAM 2014 Page 16
Architecture for Fully-Integrated OEE System
FORCAM 2014 Page 17
Factory Framework - Modular Functionality
Factory Framework
ERP Adapter
Alerting
Process Data (Traceability)
Visualization
Machine Data Connection
SFM Performance Analysis & Reporting
Personnel Data
Production Data Mgmt (PDM+DNC)
Order Data Management Dynamic Scheduling
PLM Adapter
TDM Adapter
PLM TDM PP CO MM HR PM
CAQ Adapter
CAQ
FORCAM 2014 Page 18
Factory Framework - Interface View
Heterogenous PLC integration: Fanuc Siemens Mazak MTConnect ...
Web- Portal Rights
Management Global access
Poke Yoke Ergonomic
(Touch) Easy access
SAP ERP Baan QAD Windshield Siemens
PLM Catia
ERP PDM
Worker Client
Machine Connection
Office Client
FORCAM 2014 Page 19
Seamless Integration with SAP ERP
PP CO MM
HR PM QM
ERP Portal / BO
Shop Floor Management
Shop Floor Realtime Event-oriented Detail & Mass Data Innovation Best Practice Solution
. .
Enterprise Transactional Booking-oriented Asynchroneous Processes Stability Platform
Performance
Shop Floor Enterprise
FORCAM + SAP
task sharing, independent operation, optimized costs,
riks-free investment
VIDEO LINK Seamless Integration with SAP
http://www.sap.com/index.epxhttp://www.sap.com/index.epxSAP01_EN_OrderManagement.aviSAP01_EN_OrderManagement.aviSAP01_EN_OrderManagement.aviSAP01_EN_OrderManagement.avi
FORCAM 2014 Page 20
Certified SAP Integration
FORCAM 2014 Page 21
CIP Organization: Role-based User Administration and Reporting
Factory personnel Work order/ work instruction
Maintenance Maintenance order Hit lists
Machine
Plant Manager Overall plant performance
Forman Production planning
Industrial Engineering Production data act vs. planned
FORCAM's Shop Floor Management technology supports all organizational roles within the CIP-organization.
VIDEO LINK SFM / OEE Reporting
Office Client 2- Report.aviOffice Client 2- Report.aviOffice Client 2- Report.aviOffice Client 2- Report.avi
FORCAM 2014 Page 22
Presentation Agenda
FORCAM Introduction
Shop Floor Management with Factory Framework
Technical Capabilities Machine Data Collection Order Data Collection with SAP Integration Personnel Data Management SFM OEE Performance Reporting and Visualization Additional SAP Integration Functionalities
Configuration Capabilities with Live Demonstration
Project Plan and SFM Workshop
Summary and Conclusions
FORCAM 2014 Page 23
SFM Reporting, Analysis & Visualization
Machine Data Collection (MDC) with Heterogeneous Adapters
Machine Data Collection (MDC) for Heterogeneous Controls/PLCs
Ethernet (Works LAN)
Plugin Modbus over
TCP/IP
Plugin OPC / OPC-UA
Client
Plugin Siemens
RFC 1006
Plugin Siemens
TCP/IP native
Rockwell Allen
Bradley
FANUC
Omron
OKUMA
Mitsubishi
Siemens
810/840D
PLC S5/S7
Plugin
MTConnect
FactoryFramework connects to and acquires real-time data from various machine controls using a variety of readily-available protocols.
Heidenhein
MAZAK
Makino
FORCAM Fieldbus Controller for Legacy (Non-Ethernet) Controls
(B&R / Elau / G&L / Koyo / Other)
FORCAM 2014 Page 24
Operating State Mapping Engine "Production" State
Target: Standard OEE Key Figure Examples: Definition for "Production" Operation State
Definition Production Schunk Coperion Mahle ZNF MTU
Automatic operation 1 Automatic operation 1 Automatic operation 1 Automatic operation 1
Program running 1 Program running 1 NC program start 1 Program running 1
Feed rate switch = 100% 1 Override 0 1 Override 0 0 NC ready for operation 1
Rapid traverse = 100% 1 Cycle start 1 Cycle end 0 Manual operation 0
Spindle speed = 100% 1 Warm-up bit 0 Semiautomatic
NC ready for operation 1 operation 0
Feed rate > 85% 1
NC alarm 0
Machine off 0
Program halt 0
FORCAM 2014 Page 25
Operating State Mapping Engine Fault Code" States
Alarms
Standardized Operation States
Machine-by-Machine Assignment
FORCAM 2014 Page 26
Case Study - Machine Data Collection (MDC)
MTU Aero Engines (400 Machines | 25 Heterogeneous Controls)
FORCAM 2014 Page 27
Real Time Signal Recognition and Web Visualization
VIDEO LINK Machine Data Collection with Visualization
Office Client 1- Visualize.aviOffice Client 1- Visualize.aviOffice Client 1- Visualize.aviOffice Client 1- Visualize.avi
FORCAM 2014 Page 28
Presentation Agenda
FORCAM Introduction
Shop Floor Management with Factory Framework
Technical Capabilities Machine Data Collection Order Data Collection with SAP Integration Personnel Data Management SFM OEE Performance Reporting and Visualization Additional SAP Integration Functionalities
Configuration Capabilities with Live Demonstration
Project Plan and SFM Workshop
Summary and Conclusions
FORCAM 2014 Page 29
Integrating Order Data with Machine Data (ODC + MDC)
Message Timeline
06:00 14:00 22:00 06:00 22:00 00:00 00:00
Op.
- s
tart
Op.
- en
d
WP
- dow
ntim
e
Op.
- co
ntin
ue
Op.
- p
art q
ty
Op.
p
arty
qty
Pe
rs.
log
on
Per
s. L
og o
ff
OP-
sta
rt
Op.
- st
art
WP
- dow
ntim
e
Op.
- co
ntin
ue
Event-Driven Message Entry
Workplace / Machine (WP) Order / Operation (Op) Personnel (Pers)
ODC MDC
FORCAM 2014 Page 30
Order Transparency with Order and Machine Data Integration
SAP ERP
Person/Group, Quantity, Yield, Scrap, Rework
PP
Transparent Production Environment - Detailed Production Status in Real Time
Production Shop Floor
Factory Framework
FORCAM 2014 Page 31
Actual versus Target Peformance Reporting
Target/Planned Throughput
Actual Performance
Opportunity for Improvement
Actual Throughput
ERP Data
Machine Data
VIDEO LINK Order Data Management at Worker Client
VIDEO LINK Actual vs. Target Performance
Worker Client 0- Orders.aviWorker Client 0- Orders.aviWorker Client 0- Orders.aviWorker Client 0- Orders.aviWorker Client 3- Visualize.aviWorker Client 3- Visualize.aviWorker Client 3- Visualize.aviWorker Client 3- Visualize.avi
FORCAM 2014 Page 32
Presentation Agenda
FORCAM Introduction
Shop Floor Management with Factory Framework
Technical Capabilities Machine Data Collection Order Data Collection with SAP Integration Personnel Data Management SFM OEE Performance Reporting and Visualization Additional SAP Integration Functionalities
Configuration Capabilities with Live Demonstration
Project Plan and SFM Workshop
Summary and Conclusions
FORCAM 2014 Page 33
Employee Order / Operation Machine(s) Booking Type
Individual Work Centers can be allocated to several machines
One to Multi-Operation
Multi-Machine Multi-Operation Group Booking
Personnel Management - Booking Types
VIDEO LINK - Personnel Management at Worker Client
Worker Client 0- Log On Off.aviWorker Client 0- Log On Off.aviWorker Client 0- Log On Off.aviWorker Client 0- Log On Off.avi
FORCAM 2014 Page 34
SAP ERP
Exact Production Cost Determination
WorkdayBook on Book off
Works order 1
Works order 2 Op
Op
Sta rtOperator
Sta rtOperator
Sta rtMa chine 2
Sta rtMa chine 1
EndMa chine 1& Opera tor
EndMa chine 2& Opera tor
A B C D
Person, Group, Quantity, Yield, Scrap, Rework Overhead costs, Cost centers
PP CO
Actual-time-tracking of all activity types including multi machine operation
Production Shop Floor
Factory Framework
FORCAM 2014 Page 35
Quick Cost Transparency
Direct Analysis of Labor Costs in Production Order Display (SAP Standard)
FORCAM 2014 Page 36
Presentation Agenda
FORCAM Introduction
Shop Floor Management with Factory Framework
Technical Capabilities Machine Data Collection Order Data Collection with SAP Integration Personnel Data Management SFM OEE Performance Reporting and Visualization Additional SAP Integration Functionalities
Configuration Capabilities with Live Demonstration
Project Plan and SFM Workshop
Summary and Conclusions
FORCAM 2014 Page 37
Target-Oriented Performance Measurement & Benchmarking
Group: M1 M2
Machine Performance
Plant Performance
Hall, Cell, Line, Group Performance
Multi-Plant Performance Benchmark
Plant 2 Plant 3
Machine 1 Machine 2
Plant 1
Machine 3 Machine 4 Machine 5
Group: M3 M5
Plant 1
Group: M1 M2
60,5%
TRUE OEE Target 60,5%
60,5% 49,5% 51,7%
60,5% 60,5%
66,0% 55,0%
66,0%
66,0%
72,0% 60,0% 70,0% 40,0% 55,0%
FORCAM 2014 Page 38
Web Visualization (with ANDON Capability)
Real-time web visualization of current production status worldwide via web data access with Factory Framework
Creation of one's own displays with the editor and operation of multiple views independent from each other - e.g. machine, production line or shop floor layout
Fully Configurable with a Report/Visualization Editor Display on large format screen in the production / ANDON board
FORCAM 2014 Page 39
Performance Reporting and Optimization
Transparency in real-time through detailed imaging of TPM methods to uncover bottlenecks and improvement potentials
Plant-wide transparency in real-time through web technology Coherent key figures (OEE, NEE, TEEP) Large selection of predefined reports with different views:
workplace, order, material, personnel Creation of one's own reports with the report editor
FORCAM 2014 Page 40
Reporting Dashboards and OEE KPI Cockpits
Individually Adjustable Graphic Screen All key figures that are important to you in one single overview.
Display of crucial key figures and machines Ergonomic and well-arranged Individually configurable
FORCAM 2014 Page 41
Presentation Agenda
FORCAM Introduction
Shop Floor Management with Factory Framework
Technical Capabilities Machine Data Collection Order Data Collection with SAP Integration Personnel Data Management SFM OEE Performance Reporting Additional SAP Integration Functionalities
Configuration Capabilities with Live Demonstration
Project Plan and SFM Workshop
Summary and Conclusions
FORCAM 2014 Page 42
SAP ERP PP CO MM HR PM QM
Bi-Directional SAP ERP Integration
Order Data Management
Booking of Order Messages Personnel Messages Statistics, Notes, Warnings
Quantities, Stoppages
3
Quantities, Stoppages
Machine Data Collection
Quantities, Stoppages
3
1 2
4
Master Data
Order, Op, dates, PT
Status, Quantities, Stoppages
5
VIDEO LINK SAP Work In Progress
FactoryFramework
SAP02_EN_WorkProgress.aviSAP02_EN_WorkProgress.aviSAP02_EN_WorkProgress.aviSAP02_EN_WorkProgress.avi
FORCAM 2014 Page 43
SAP ERP Integration with Corrections
SAP ERP PP CO
MM
Order Data Management
Automatic in SAP: Cancellation and New Booking
Simple and Quick corrections in FF Office Client Quantities Scrap Stoppage Reasons
Factory Framework
VIDEO LINK Corrections
SAP03_EN_OrderCorrection_Scrap.aviSAP03_EN_OrderCorrection_Scrap.aviSAP03_EN_OrderCorrection_Scrap.aviSAP03_EN_OrderCorrection_Scrap.avi
FORCAM 2014 Page 44
SAP ERP PP CO MM HR PM QM
Alert Management (with optional SAP PM integration)
Order data management
Booking
3
Machine data
Factory Framework
Process data
Control, compare, alarm, transfer
Alerting
1 1
2 Alerting, Notification
FORCAM 2014 Page 45
Presentation Agenda
FORCAM Introduction
Shop Floor Management with Factory Framework
Technical Capabilities Machine Data Collection Order Data Collection with SAP Integration Personnel Data Management SFM OEE Performance Reporting Additional SAP Integration Functionalities
Configuration Capabilities with Live Demonstration
Project Plan and SFM Workshop
Summary and Conclusions
FORCAM 2014 Page 46
Configuration Capabilities with Live Demonstration
Factory Framework Software Overview - LIVE
Hierarchic Configuration
Machine Data Collection (Formula Engine)
OEE Time Basis
User Rights Access Management
Language / Literal Editor
Web Visualization and Reporting Editor
Alerting with Auto-Reporting
FORCAM 2014 Page 47
Presentation Agenda
FORCAM Introduction
Shop Floor Management with Factory Framework
Technical Capabilities Machine Data Collection Order Data Collection with SAP Integration Personnel Data Management SFM OEE Performance Reporting Additional SAP Integration Functionalities
Configuration Capabilities with Live Demonstration
Project Plan and SFM Workshop
Summary and Conclusions
FORCAM 2014 Page 49
Factory Framework - Phased Project Plan
FactoryFramework Universal ERP Adapter
SFM Performance Analysis & Reporting
Process Data Management
Visualization
Machine Data Collection
Alerting
Personnel Data
Production Data Management + DNC
Order Data Management Detailed Scheduling
Top Floor (ERP)
Shop Floor
Phase 1 Phase 2
- Machine Data Collection - Web Visualization, Reporting - Alerting
- ERP Data (Orders/Ops)
- Personnel Data
Phase 3
- PDM/DNC
Phase 4
- Dynamic Scheduling
FORCAM 2014 Page 50
Systematic Project Plan
FORCAM 2014 Page 51
Shop Floor Management (SFM) Workshop AGENDA (8:00 AM - 5:00 PM) Shop-Floor Muda Walk (8:00 AM)
Introduction (8:30 AM)
Participants Goals of the SFM Workshop Roles & Responsibilities
FORCAM Lessons Learned and Case Studies (9:00 AM) Shop-Floor Management Solution Fundamentals & Technology (9:45 AM)
Factory Framework System Overview (30 Min) Module Requirements and Detailed Specifications
FF - Order Data Management with SAP ERP Integration (45 Min) FF Machine Data Collection (30 Min) FF - SFM Performance Reporting, Visualization, Alerting (30 Min)
LUNCH BREAK (NOON) Shop-Floor Management Solution continued (1:00 PM)
Office-Client and Worker-Client Specifications Processes, Interfaces, Usage
Shop Floor Management Reporting Dashboard Reporting/Cockpit: OEE, GANTT, Actual vs. Planned
System Administration and Rights Access Management Machine (Shop Floor) Integration Requirements (2:00 PM)
Machine Types / PLC Types / Signal Acquisition ERP (Top Floor) Integration Requirements (2:30 PM)
ERP Specifications - Orders, Operations, Bookings IT Requirements (Hardware / Server / Networks) (3:30 PM) Summary, Action Items and Next Steps (4:00 PM)
Required Attendees: Project Manager All Project Team
All Project Team
Project Team (Select)
Plant Maintenance
IT (ERP)
IT (Infrastructure) Project Manager
FORCAM 2014 Page 52
SFM Workshop - Schedule, Attendees, and Deliverables
Schedule
1 Day On-Site with 2 FORCAM Consultants
Attendees Suggested Attendees (CIP Team)
Project Leader / CIP Director / Plant Manager (Champion) Production (Lean) Manager Production Supervisor(s) IT Manager Maintenance Manager ERP Manager Production Engineers
Deliverables
1. SFM Checklist - Requirements Specification Document 2. Fixed Price Quotation 3. Project Management Plan
FORCAM 2014 Page 53
Global Template Approach (Multi-Site Project Deployments)
Shop Floor Management
(SFM) Workshop
PILOT
Pilot Site
All Sites
FORCAM 2014 Page 54
Presentation Agenda
FORCAM Introduction
Shop Floor Management with Factory Framework
Technical Capabilities Machine Data Collection Order Data Collection with SAP Integration Personnel Data Management SFM OEE Performance Reporting Additional SAP Integration Functionalities
Configuration Capabilities with Live Demonstration
Project Plan and SFM Workshop
Summary and Conclusions
FORCAM 2014 Page 55
Architecture for Fully-Integrated OEE System
FORCAM 2014 Page 56
Our Value Proposition
Top Customer References in Discrete Manufacturing State-of-the-Art Technology, Awarded by Frost & Sullivan
Server-centric J2EE Web-based Technology Architecture
Outstanding Scalable Shop Floor Management System
Seamless Universal ERP Integration with Order Data Management Real Time Machine Data Collection with Heterogeneous Adapters Performance Measurement and Reporting with OEE Personnel Data Management Alerting and Alarming Strong Configuration Capabilities
Global Delivery Team for Template-based Rollout (for Multi-Site Deployments)
FORCAM 2014 Page 57
Thanks for your attention! FORCAM, Inc. 250 E. Fifth Street, 15th Floor Cincinnati, OH 45202
(513) 878-2780
www.forcam.com
http://www.forcam.com/index.php?id=209&L=209&id=261&tx_ttnews[tt_news]=164&cHash=168e44df771906d5bb88122ba4a21694