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How Orbital ATK is Leveraging the IIoT and Visual Factory Technology to Drive Continuous Improvements
PRESENTERS:
Paul Hardy Application Architect at Orbital ATK Aerospace Structures
John MaherVice President of Product Strategy at Synchrono®
Presentation Overview
1. IIoT – Connecting Orbital ATK
2. Enabling the Visual Factory
3. Metrics for the Factory of the Future
Quick Facts:
• $4.5 Billion Global Aerospace and Defense Systems Company
• Innovative, Affordable Products for Government and Commercial Customers
• 12,000 Employees, Including over 4,000 Engineers and Scientists
• Over 19 Million Square Feet of R&D and Production Facilities in 18 States
Commerical • Rolls-Royce Aft Fan Case• GE Engine Cases• Airframe Structures• 767 Composite Door Springs• A350 Fuselage Stringers • A350 Fuselage Frames• 787 Primary Stiffening Structures• A400M Wing T-Stringers
Aerospace Structures Division (ASD)A leader in composite automation innovation
Military • F-22 Fiber Placed Pivot Shafts• F-35 Wing Skins• F-35 Fixed Skins• Nacelles• C-17 Counter Balance Assembly• Apertures / Radomes / Antennas • Survivable Structures• Performance Verification• Sensor Technology• Low Observable Technology• F-18 Next Generation Jammer
Launch • Atlas & Delta Launch Structures• Rocket Motor Cases • Composite Overwrapped Pressure
Vessels
Part 1:
IIoT - Creating a Connected
Environment at Orbital ATK
• Increase rate from 4x to 12x in 24 months
• Become more competitive and increase market share
• Improve communication, collaboration and decision-making by connecting all layers of manufacturing and the extended supply chain
Business strategy
How Orbital ATK is Leveraging the IIoT and Visual Factory Technology to Drive Continuous Performance Improvements
“Start with the end in mind”
– Stephen Covey
“Quick access to data we can take action on to improve”
- Orbital ATK ASD
1. Implement a connectivity Platform – and continually build upon it
2. Provide fast, easy access to actionable data (NOT another data warehouse)
3. Enable more focused continuous improvement
Business strategy
How Orbital ATK is Leveraging the IIoT and Visual Factory Technology to Drive Continuous Performance Improvements
• Enterprise visibility and communications• Instant manufacturing intelligence• Flexible, scalable architecture for today – and
tomorrow
Factory of the Future
How Orbital ATK is Leveraging the IIoT and Visual Factory Technology to Drive Continuous Performance Improvements
Gateway
E n t e r p r i s e S e r v i c e B u s : W e b S p h e r e
L o c a l S e r v i c e B u s : S y n c O p e r a t i o n s
Costpoint Crane 3PL SABA Cost View ePic Teamcenter UA PeopleSoft CIMS Maximo Timecard
Material Prep Machine
Linear Forming Machine
EMS Wonderware HMI Autoclave AUIS Machining
Center
Kanban for Costpoint
Sync Manufacturing TipQA
SyncAlert SyncExecution TC Mapping
Solumina AssetSmart
InfinityQS Historian RFID
Parts Attributes
1 2 3 4 5 6 7 8 9 10
A
B
11 13 15
23
14 16
2218 20
17 19 21
24 25 26 27 28 29
12
Data Exchanged: Item, Work Centers, Work Orders, Process Data, Bill of Materials, Tools, Schedules, Event/Alerts/Alarms
Data Exchanged: Item, Purchase Orders, Projects, Inventory, labor, Budget, MBOM, EBOM, Tools, Human Resources
Data Exchanged: Item, Purchase Orders, Work Centers, Projects, Inventory, Process Data, Budget, Receipts, MBOM, Tools, Suppliers, Event/Alerts/Alarms
1. Understand your data – and what will translate into meaningful information
2. Constantly refine your focus
3. Identify categories of data and what they mean
Examples: Quality, Availability, OEE
Getting started
How Orbital ATK is Leveraging the IIoT and Visual Factory Technology to Drive Continuous Performance Improvements
Part 2:
Enabling the Visual Factory with SyncView
EXAMPLES
Converting data into meaningful information through visualizations
How Orbital ATK is Leveraging the IIoT and Visual Factory Technology to Drive Continuous Performance Improvements
Gemba walkReal-time visibility of current priorities, KPIs and metrics.
• Single version of the truth• Clear priorities• Actionable metrics
How Orbital ATK is Leveraging the IIoT and Visual Factory Technology to Drive Continuous Performance Improvements
(NEW – Ticket A000134) Call M. Smith at 801-555-6565. Machine C3 has a status of Machine is Down. Drill head needs replacement.
< Messages SyncAlert Contact
Saturday 10:13 AM
SyncManufacturing Planning, Scheduling & Execution
Safety AppMES
SyncOperations – fault detection, SyncAlert – alert
notification, Asset Management
Quality SoftwareSyncView, via Operator Input
SyncManufacturing
SyncOperations – machine connectivity
Database
HMI
Single view; multiple data sources
How Orbital ATK is Leveraging the IIoT and Visual Factory Technology to Drive Continuous Performance Improvements
Equipment Status and OEE
Drill-down to determine root-cause of issues
• Minimize downtime• Direct preventative
maintenance
How Orbital ATK is Leveraging the IIoT and Visual Factory Technology to Drive Continuous Performance Improvements
(NEW – Ticket A000134) Call M. Smith at 801-555-6565. Machine C3 has a status of Machine is Down. Drill head needs replacement.
< Messages SyncAlert Contact
Saturday 10:13 AM
Sample Work Cell Dashboard
Access to actionable information
Single version of the truth
Enterprise-wide communication
Focus continuous improvement
Outcomes
Increased Throughput
Increased rate by 400%
Reduced downtime
New business growth = Increased market share
Business results
Part 3:
Metrics for the Factory of the Future
Wealth of Data
CI!
Actionable Information
Metrics that you can take action on to improve operations
“To measure everything is to measure nothing.”
Simple set of operations metrics that drive action
Monitor these metrics to:• Improve flow• Manage constraints• Direct Continuous Improvement
Metric for Action: Perfect Order Percentage
Metric for Action: Queue Turns
Metric for Action: On-Time Delivery
Metric for Action: Stock Buffer Health
Metrics for Action: Schedule Adherence and Queue Turns
Questions & Answers
Download the white paper:
Demand-Driven Manufacturing Metrics that Drive Action
How Orbital ATK is Leveraging the IIoT and
Visual Factory Technology to Drive Continuous
Improvements