Vel K

Product Manager – Market Strategy

IPF: Intelligent Plant Framework

Cisco Covacsis Solution

Manufacturing Business Challenges

How can we improve

production by double

digit without any Asset

investment ?

How do we reduce the operation cost of the

plant ?

How do we align Plant operations to Business

KPI ?

How do we improve the production

bench marks

without any Asset

investment ?

How can we see the plant’s

financial performance in real time?

How do we get a 360 degree

visibility of the plant

operations in real times?

Productivity Improvement : A Continuous Journey

Intelligent Plant Framework enables faster efficient, decision making by providing real-time, end-to-end business visibility of the plant

IPF Framework

Operator

Data

Real-time

Analysis and

Collaboration

Plant

Machinery

Discrete

Devices

Mgmt.

system

ERP

system

Analytics

Operator

Supervisor

Line

Manager

Plant

Head

Costing

Team

Mfg.

Head

HR - IR

CxO

Data Acquisition

Data Analytics

•Batch Entries

•Manual stoppages

•Process variables

Operator Data

•Meters, VFD, PID, Sensors

•Power consumption

•Chemical consumption

•Consumables

Discrete Devices

•PLC / DCS / SCADA

•Technical downtime

•Run-time and cycle time

•Process parameters

•Machine performance

Plant Machinery

•QMS / LIMS

•Energy system

•Building mgmt. systems

Management system

•Planning Data

•Production

•WIP inventory

•Conversion Cost

ERP system

IPF Framework

Operator

Data

Real-time

Analysis and

Collaboration

Plant

Machinery

Discrete

Devices

Mgmt.

system

ERP

system

Analytics

Operator

Supervisor

Line

Manager

Plant

Head

Costing

Team

Mfg.

Head

HR - IR

CxO

Data Acquisition

Data Analytics

• Utilities consumption

• Consumables Consumption

• Asset utilization

• Availability

• OEE

• Machine Uptime

• Stoppage Reason Analysis

• Batch Cycle Time

• Yield and Throughput

Operational Metrics

• Conversion Cost

• Floor Financial Quotient

• Production Opportunity Loss

• Financially Most Inefficient

• Cost of Deviation

• Cost of inefficiency

Financial Metrics

IPF Framework

Operator

Data

Real-time

Analysis and

Collaboration

Plant

Machinery

Discrete

Devices

Mgmt.

system

ERP

system

Analytics

Operator

Supervisor

Line

Manager

Plant

Head

Costing

Team

Mfg.

Head

HR - IR

CxO

Data Acquisition

Data Analytics

• Trend Analysis

• Real-time plotter

• machine performance

• process parameters

• projected performance of the machine

Operator

• Cycle-time

• line efficiency

• Top reasons for downtime

• Operator Comparison

Line Manager

• Overall Conversion Cost

• Cost of Inefficiency

• Relative Asset Utilization

• Worst performing section

• Overall power consumption

• WIP Inventory

Plant Head

• Top plants

• Highest WIP inventory

• Least energy efficient

Manufacturing Head

• Cumulative economic loss

• Most efficient plant

• Best financial index

CxO

IoT Cloud Challenges

Limited Bandwidth Latency Network Availability

Distributed “FOG” Computing Traditional Computing Model

(Terminal/Mainframe, Client-Server, Web)

Assumes Infinite Bandwidth, Zero Delay

IoT Computing Model

Data Center/ Cloud

Endpoint

Assumes Limited Bandwidth, Variable Delay, and Intermittent Connectivity

Data Center/ Cloud

Device

IOX

Assumes Limited Bandwidth, Variable Delay, and Intermittent Connectivity

Speed of Light Latency-Critical

Responsiveness Required

Resiliency

Security

Data Grows Faster Than Bandwidth

Cisco – Covacsis Solution Implementation Architecture

Operator

Cisco Router

With LIU

Server

Machine

Serial /

Ethernet

I/O

Machine

Operator

Cisco router

With LIU

Server

Serial /

Ethernet

I/O

LAN / WAN BLOG Analytics Server

in

Data Center/Cloud

Customer Case Studies - India

• 44% increase in tablet production

• 70% reduction in average batch turnaround time

Leading Pharma Company

• 50% increase in production rate in 9 months period

• 30% reduction in water consumption

• Increase in production of A-Grade fabric from 94% to 97.89 %

Leading Textile Company

• 28% increase in production of fatty acid

• 44% reduction in reflux emission

Leading Chemical Company

Improvement : A Continuous Journey

IPF

Automation

ERP

Consultant

Cisco Covacsis Solution Enable Manufacturers to…

Have Plant Wide

Visibility of Business Impact

Make Faster Decisions

Stay Ahead of

Competition