Using Digitalisation to Increase OEE

BILL O’LEARYGeneral ManagerCONFIRM Smart Manufacturing

ReactiveCondition/TimePredictive & Prescriptive

Smart Manufacturing

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€47 million funding

36 investigators

42 industry partners

8 core RPO’s

8 national research and technology centres

16 international collaborators

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Community of PracticeTo embrace the 4th Industrial revolution together

Research To develop future smart manufacturingtechnologies

Talent & engaged public Positive perception of manufacturingin Ireland

WHAT WE DO

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AGENDA

1. What are Digitalisation & OEE

2. Why digitalisation & OEE are important

3. What Digitalisation means

4. Challenges

5. Deployment

6. What then?

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What are ManufacturingDigitalisation & OEE Digitalisation of Manufacturing

The digitalization of manufacturing (operations) is the application of Information & Technology to transform and optimize production, maintenance, supply chains, product design energy management & supply chains

Arguably the greatest disruption ever within manufacturing (operations)

(Fundamentally more transformative than – TQM, LEAN, etc)

Digitalization ofManufacturingINSIGHTS

OEEOverall Equipment Effectiveness is a multiple of –

Productivity x Quality x Availability (Mechanical & Operational)

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What are Manufacturing Digitalisation & OEE

• Increasing System integration & aggregation

• Lower costs• High compute power

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Why Digitalisation is important

• 20%-50% Faster time to market

• 30%-50% Reduced machine downtime

• 20%-40% Increased machine life

• 45%-55% Increased staff productivity

• 3%-5% Increased process productivity

• 10%-20% Increased production quality

• 20%-50% Reduced inventory costs

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Smart Manufacturing cost and efficiency gainsarising from smart manufacturing =

US$493 bn p.a. Source: PWC 2016

Why OEE is important

Reputation

Cost –VC & FC

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• Measures overall asset health & optimises

utilisation

• Helps benchmark a company cross

sectorally & globally

• Helps identify Opex & Capex requirements

• Quantifies VA & NVA within an organisation

• Aids in alignment of maintenance activity &

with business outcomes

Employee Engagement

Employee Morale

Time to Market

Market Share

WHAT IS DIGITALISATION

Digitalisation – What it Means

Holistic Perspective

• Increasingly automated

• Interconnected

• Modular & Agile

• Responsive

• Not all about costs!

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Digitalisation – What it Means

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Asset Care perspective

CURRENT USE CASE 1 Predictive Maintenance and Bespoke Algorithms

Digitalisation – What it Means

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Asset Care perspective

CURRENT USE CASE 2

Virtual Reality – Training, Induction, and operator suitability Augmented Reality – remote Equipment servicing

Digitalisation – What it Means

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Asset Care perspective

POTENTIAL USE CASE 1 Digital Twin – potential centralised platform for collation of all asset related activity

Digitalisation Challenges

Customer

Competition

Technology Corporate Strategy

Knowledge Gaps

ROI

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Drivers Inhibitors

Costs Regulation

Asset Care Digitalisation

Focus On Critical AssetsFactory Level

DEPLOYMENT

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Engage & Educate Key stakeholdersInhouse Training / HEIs/ State schemes

Integrate into existing processesCMMS, workflows, SOPs, Change control, Training, Validation, ERP - Purchasing, suppliers

Develop & Track new KPIsOEE - Uptime, Quality, Output, safety, customer retention

What then?

Machine Learning

Advanced AI

Predictive Alogrithms

Digital Twin AR/VR

Data Analytics

17Confirm – Smart Manufacturing

Questions ?