La soluzione BPM e SOA per l esecuzione dei processi di produttivi

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1 La soluzione BPM e SOA per l esecuzione dei processi di produttivi From the Operations Execution System to the collaborative Global Manufacturing Suite Create Improve Process Deploy Luca Introini Apriso Sales Manager mobile Monitor Execute 1

2 Apriso Operation Execution Complexity Global Operations GMS cgms GMS OES AEP Enterprise OES Plant Centric MES Mono Functional Unified Data Model BPM SOA Apriso Execution Platform 2

3 A BPM/SOA solution FlexNet is: The only manufacturing suite to incorporate BPM/SOA architecture Able to support a broad range of industries and applications Built on a Unified Data Model Tightly integrates ERP with process control Includes hundreds of business components and business process flows The only BPM solution for mission-critical manufacturing processes Support for Cluster and Fault Tolerant Security and Administration BPM software allows a company to be more responsive to changes in business strategy by managing business processes without retooling, recoding, or replacing underlying enterprise software. - AMR Research GMS OES AEP 3

4 What is a Business Process A true BPM that go beyond traditional MES allowing graphic modeling any business processes including Material Flows and Routings Recipes and Operating Procedures Step by step Work Instructions Validation workflows with Multi-users Collaborative tasks coordination Can coordinate activities combining Production, Quality, Warehouse, Maintenance, Labor Designed for robust industrial execution Automatically generates Users Screens without coding Persist information and status in database Synchronize activity and reporting with ERP transactions Configurable application versus development tool-kit Over 130 Standard Business Process Flows used for quicker implementation of business processes Business Process Flows can be augmented to include customer business logic and best practices without custom coding Over 410 functions Business Components consistently exposing basic manufacturing execution logic as services (SOA) then preserving ascending compatibility for easier upgrades GMS OES AEP 4

5 The more standard implementation solution Statistics from project in Mills Element Procedures Business Components Screens Database Tables Number of elements in standard FlexNet Number of Novelis specific elements Ratio of Standard to Custom 97,23% 99,22% 98,80% 98,97% GMS OES AEP Because BPM tools take development out of IT and place it in the hands of the business user, process automation and change become easier, faster, less expensive, and more flexible. Source: AMR

6 Define flows, from routing to screen GMS OES AEP 6

7 Global Performance Manager Monitors production status, product attributes, SPC and quality Benchmarks real-time results against plans, targets and trends. Offers event-based alerts, personalized threshold specification Robust drill-down down capability GMS OES AEP 7

8 Visibility and KPIs GMS OES AEP Create Improve Deploy Process Monitor Execute 8

9 Ready for industrial Administration Integrated professional tools for high quality of service Archiving Audit trail Service monitoring Security (roles and access rights) FDA 21 CFR part 11 SOX compliance GMS OES AEP 9

10 Leverages Service-Oriented Architecture (SOA) From Large Modules/Code Base 2-tier/Client-Server (wrappers) Function oriented Monolithically built and deployed To FlexNet Component based N-tier & Web based Service oriented Incrementally built and deployed GMS OES AEP Organically grown solutions via numerous services efforts Tightly coupled Synchronous Interactions Many code modifications Orchestrated solutions Loosely coupled Message oriented Few code modifications <10% For companies interested in becoming more demand driven, SOAs are mandatory. Existing monolithic enterprise applications alone are insufficient. AMR Research 9/8/05 10

11 Multiplication of disparate applications.* *Source SAP 11

12 Collaborative Supply Chain Execution Best Practices Life Cycle management & Support for Core Systems, but allows local specificities Processes can be authored centrally and dispatched Processes can be edited locally Processes can be authored locally Reporting and data can be consolidated Automation Definition Rollout Feedback Continuous improvement KPI benchmarking 12

13 FlexNet: sviluppo e implementazione Center Of Excellence Validation C.O.E. Configuration Processes Processes Processes Processes Processes Process Data Connector Process Deployment Plant 1 Operational Data Pant 2 Operational Data Pant n Operational Data 13

14 CRM ERP Ext. Appl. Legacy ERP PLM Partners Customers Suppliers XML Manager Excellence Center Of Workflow Manager Process Builder Reporting KPI Dashboard Execution Receiving Material Production Quality Maintenance Labour Fulfilment Product Traceability & Genealogy Machine Integrator Material WiFi PDAs RFID Machines Data I/O Terminals 14

15 Schema funzionale I2P Planning (non Exhaustive) System FlexNet Demand Management Capacity Planning Sales Order Management Distribution MRP / Shipping Master Planning Production Flow Planning Material Management Scheduling/Sequencing Production Execution Production Execution Quality Management Tools Management Labor Tracking Maintenance Management Material Mngmnt Execution Reporting_KPI_Dashboard Process Control Process Control Machine Control 15

16 FlexNet, cosa gestisce Connette i livelli della pianificazione e dell esecuzione Una vera piattaforma SOA e BPM Gestisce TUTTI i fattori del manufacturing: Operatori, machinari, materiali, fornitori, attrezzature/containers, specifiche/processi Integra l esecuzione tramite un unico database Lavoro, Produzione, Logistica, Qualità, Manutenzione Controllo Qualità integrato in tutti i moduli Garantisce la governance centrale (sviluppo del Core System / controllo e diffusione delle best practice / manutenzione) Aggiunge valore al sistema ERP 16

17 Apriso: esperienza consolidata in progetti strategici Client HQ Location Geography Number of sites installed / targeted Microsoft USA WW 111 / 120 Valéo France WW 77 / 82 International Paper USA US 80 / 92 Saint Gobain France Europe+ 45 / 50 Steelcase USA / France Europe 15 / 19 Becton Dickinson USA WW 35 / 45 Lockheed Martin USA US 3 / 5 Essilor France WW 9 / 161 Ansell Australia USA 3 / 8 L Oréal France EMEA + US 7 / 23 TetraPack Switzerland EMEA 3 / 9 Amcor USA WW 31 / 43 Lear USA Italy 5 / 6 Volvo Brussels WW 2 / 10 Haier China FarEast 1 / 30 17

18 FlexNet : aperto a tutti gli standard operativi Monitoring Interfaces (ERP, APS ) XML Reporting Labeling RDBMS RS-232 RFIDs b/g Mobile devices PLC, DCS, SCADA 18

19 Configurazione tipica 19

20 Case study Lear was founded in 1917 in Detroit as American Metal Products Today the company exclusively serves the global automotive industry and supplies product for all five major interior systems: seat, instrument panel/cockpit, door and trim, overhead and flooring and acoustics. Lear is also one of the leading global automotive suppliers in electronic and electrical products. There is a Lear product in more than 300 nameplates around the world. 20

21 Headliners Seats Door Panels Floor & Acoustic 21

22 implementazione curata da Synesis 2 sedi in Italia MILANO PESCARA Tecnologie software Business Intelligence Production & Logistic Applications ERP Web Development On Going Support Area commerciale 22

23 Grugliasco: H.Q., Engineering, Seat production plant Pozzo d Adda: Engineering, Seat production plant Pianfei: Engineering, Interiors production plant Pesaro: Engineering, Interiors production plant Cassino: 1 Seat production plant, 1 Interiors production plant Caivano: Seat production plant Melfi: 1 Seat production plant, 1 Interiors production plant Termini Imerese: Seat production plant 23

24 Caratteristiche degli stabilimenti Requisito Melfi (PZ) Grugliasco (TO) Termini I. (PA) Caivano (CE) Pozzo d'adda (MI) No. Linee Punti di controllo x linea (medi) No. Centri di lavoro fuori linea Cadenza linee di assemblaggio No. Turni No. Prodotti finiti x turno sec. 120 sec. 90 sec. No takt No takt ca. 500 ca. 350 ca. 200 ca. 80 ca. 40 Funzionalità presenti: - re/sequencing tasks di lavorazione X - Gestione movimentazione pezzo (reworks) X X X X X - traciabilità lotto e/o SN X X - traciabilità dati di processo X X X - Interfaccia utente di produzione X X X 24

25 SHIP. DOC INVOICE Sync. Msg. CUSTOMER Customer dependent part LEAR plant FlexNET ERP interface Interface to shop floor sys LABELS Cartellini di produzione S/N sedili ODETTE 25

26 Handling Line Cassioli,, PSB, Transtecnica, Jofa, Cooper P.C. + Printer Component Bar-code Plant Shop Floor Control JIT / JIS Warehause A.S.R.S. Traceability H.Q. Grugliasco E.R.P. MFG/Pro 26

27 J.I.T. FIAT = consegnare le sequenze ordinate correttamente Shop Floor Control = verificare lo stato di avanzamento della produzione Traceability = raccogliere il serial number dei componenti ed i dati dei controlli qualitativi svolti durante il processo produttivo ed associarli al serial number di ogni sedile 27

28 Distinta di produzione gestitata da FlexNet KIT 3 P 5 P Coppia sedili Anteriori Kit sedili posteriori Intero Sdoppiato Avvitature Anteriore Dx Anteriore Sx Cuscino/i Schienale/i Test JOFA Schienale Dx Cuscino Schienale Sx Fisso Scorrevole Avvitature Colore Fodera Side-bag Cavo Guide Riscaldato Fodera Side-bag Cavo Guide 28

29 Functional Overview JIT features Customer Message acquisition via EDI (Datagram, Forecast, Setup) Sequence Management (manual management of sequence) Customer data correctness (Sequence check, Part Number check, range check, ) Load Management (automatic recall of Shipping Container from ASRS, parametric algorithms for load definition, Shipping Container ner order by) Configuration based on customer parameter (via CDM tool) 29

30 Functional Overview Production Launching features Synchronous Launching (Each sequence is dispatched in production at the same time it s s received from customer) Synchronous-Kanban Launching (In this case the system check the stock target before releasing the production order) Kanban Launching (Automatic production order generation to reach the finish good stock target defined for each FG item) Configuration based on product parameters (via CDM tool): Product Master, Bill of Materials, Routing, 30

31 Functional Overview Shop Floor Control features Production Order Generation (based on multilevel BoM generation) (based on BoM and Routing, Launching Control (Production dispatch monitor, manual orders, label prints, ) Production declaration and traceability (based on routing operation and BoM information, FGI warehouse receipt) Resource Management (Work Center, Machine, Pallets) Interface with Shop Floor equipment (PLCs JOFA, RF terminals) PLCs,, Screwdrivers, 31

32 Functional Overview Shipping features FGI warehouse management (interface with ASRS for automatic Load recalling) Shipping Container management Generation of Shipment Documents (Odette labels, packing list, delivery notes, ) Shipping Confirmation 32

33 IT Strategy PDM UG Metaphase C O Lear Corp. ERP QAD Mfg/Pro V I S Lear Grug. HQ I Shop Floor Control APRISO N Lear Plants FlexNet 33

34 Sistemi Informativi LEAR Corporation Italia S.p.A. FIAT Stake Jtstake Plant SEEBURGER E.D.I. MFG/Pro H.Q. Grugliasco COGNOS FLEXNET Master Data J.I.T. module Shop-Floor Control PDM PLM Other Applications Master Data Planning Purchasing Sales Stocks Accounting Controlling Business Intelligence (KPIs) StreamServe Reposrts Printing 34

35 Technical Overview System Architecture ORACLE 9i 35

36 Pallet tagging Read / write system designed to interface to all poka yoke and conveyor systems. The pallet tagging system is designed to send (Write) to poka yoke equipment product data (Options / Sequences / bar code info / data values etc.) to ensure operator option selection is eliminated and send / receive traceable real time quality data that is to be stored and / or monitored. Can also be used to make decisions in the closed loop scenario where seat pass or fail control is required and pallet conveyor direction control is required eliminating operator dependence / choice. 36

37 Benefits The use of a pallet tagging system and tracing / logging all the Poka yoke data from Poka yoke stations eliminates the need for manual paper logging systems which have the potential for operator error. With this system all data can be traced / logged on a data management system and used for data collation in an accurate manor. Duplicate elementary information on TAG Rfid 37

38 Thank You! Via Properzio 4, Via G. Pacini, PESCARA MILANO Tel Tel Fax Fax

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