Achieving Manufacturing Excellence Ramesh Subramanian, Practice Head - Connected Enterprise IT Tata Technologies. sme.

Transcription

1 Achieving Manufacturing Excellence Ramesh Subramanian, Practice Head - Connected Enterprise IT Tata Technologies

2 Agenda Tata Technologies - At a Glance Global Operations Connected Enterprise IT Connecting Top Floor to Shop Floor SCADA, MOM, MES Competencies The Future of Manufacturing Industry 4.0 Five Types of Enablers Platforms and Industrials Benefits of IoT Key Technology Trends Achieving Manufacturing Excellence: Case Study Manufacturing & Supply Chain, OEM Strategy & Goals

3 Tata Technologies Global Operations

4 Connected Enterprise IT Business Outcomes Core Competencies Enabling smart connected factories Enterprise Resource Planning (ERP) Dealer Management Systems (DMS/CRM) Telematics & Mobility Delivering global solutions for digital manufacturing Business Analytics (BA) ipromis (Parts Catalog) Application Management Services Extending the digital lifecycle into effective manufacturing through consulting and implementation complemented by world-class AMS Supplier Relationship Management Manufacturing Execution Systems System Integration & Testing

5 Connecting Top Floor to Shop Floor Traditional Manufacturing vs. Industrial IoT Business Analytics Hadoop Data Lake CRM ERP Integration Support MES SCADA PLC Automotive Aerospace Industrial Heavy Machinery Medical Devices Sensor/Smart Computer

6 SCADA, MOM/MES Competencies SCADA- HMI/MMI/PLCs OSI PI OPC, Tag browser, ProcessBook, Graphics, DataLink, ControlMonitor, Profile, Batch, managed PI(SMT) Honeywell Experion, Process graphic, Uniformance, Matrikon - ECM, TAIJI PID, Alarm Manager Siemens - Win CC. PLC s - S7, S5 Rockwell FT View ME/SE, RS View 32. PLC s ControlLogix, GuardPLC GE Proficy Cimplicty, ifix. PLC s 90/30, Versamax Schneider WonderWare InTouch. PLC s Modicon 984, 384, Quantum MOM/MES GE Proficy for Manufacturing Discrete suite, Proficy Plant Applications Siemens SIMATIC IT Intelligence, Production and R&D suite OSI - PI servers Rockwell Factory Talk Production Center MI,MES Components PI Data Historian Aspentech Historian, Desktop Historian SIMATIC IT Historian, Data Integrator, Line Monitoring Factory Talk Historian, Vantage point, FTTM Proficy Historian, Proficy SPC 6

7 Industry 4.0 Focus Digital manufacturing plants Digitized processes Internet of things Industrial Internet of things Mobile-enabled technologies End-to-end visibility Supply chain integration vertical & horizontal

8 Five Types of Enablers will drive IoT potential impact A Hardware technology B Software technology C Data ownership D Business Org and culture E Public policy Low power consuming sensors Cheap processing ability Ubiquitous connectivity/ low-cost mesh connectivity Further reduction in cost of cloud storage and computing Evolution of predictive analytics and algorithms Confidence in security across entire IoT ecosystem Standardization of the stack and interoperability Establish trust with consumers on sharing data Collaboration across companies and verticals Horizontal data aggregators Industry structure e.g., organized labor, third party servicing Committing to upfront investment based on clear business case HW-focused companies expanding core competency to SW Regulation for autonomous control Government and payor subsidy of healthcare IoT Agreement on fair data sharing practices Source: Digital & IoT: A Tale of the Haves and Have-Mores, McKinsey & Company, December

9 Platforms and Industrials Platforms Industrials Technology Convergence Sensors Bandwidth Processing Smartphones Ubiquitous wireless coverage Big data RFIP GPS Wearables IPv6 Machines & robots Humans & robots Applications for managing communications between devices, middleware, storage, and data analytics. Efficiency, control, asset monitoring. Productivity, through monitoring the factory floor. Source: Digital & IoT: A Tale of the Haves and Have-Mores, McKinsey & Company, December

10 Benefits of IoT Specifically, we expect IoT to impact three main verticals within industrials in the short term: 1. Automation 2. Manufacturing 3. Resources Any smart connected device can be intuitive. Real-time inbound & outbound logistics Products as a service Machine learning Next-generation operational intelligence Optimize Outcomes Unified key performance indicators Connected operations & paperless shop floor Supplier quality Mass customization Asset tracking Teachable robots Predictive analytics Flexible Connectivity Composer Codeless Mashup Dynamic Collaboration Administration Open collaborative design Real-time asset health monitoring

11 Key Technology Trends Expectation / Technology Trends Short Term i.e. Wearable Tech Connected Supply Chain Mobile Technologies Supply Chain Visibility Track and Trace Serialization Integrated plant floor system Medium Term i.e. 3D Printing in Supply Chain BIG Data in Supply Chain Industrial IOT, Industrie 4.0 Smart Digital Factories Electrical Architecture Connected Car Fuel Cells & batteries 3 to 4 years 5 years plus Long Term i.e. Autonomous Car New Production Materials Cooperative Robotics Ubiquitous Independent Logistics Grid In memory computing 4G,5G Pervasive bandwidth Kinematics, Image recognition RFID NFC QR Year

12 Manufacturing & Supply Chain OEM business strategy and goals Global business expansion Vertical integration NPI, innovation and technologies Operational excellence Capacity and flexibility Quality and customer delivery precision People and environment

13 Business goals and objectives Translation of business goals into business capabilities Mapping of business capabilities into ISA 95 model Target State Architecture (TSA) Strategic objectives 1. Increase number of cars sold by 2.5 times between 2013 and Set up state of the Data art smart plants 3. Modular solutions deployment across plants categorization Business considerations MES/MOM data 1. Transformation of legacy plant 2. Global business expansion 3. Centralised plant IT systems 4. Standardization of local manufacturing practices Order management MES Operations management Performance monitoring Maintenance operation Quality New Product Introduction Plant inventory Spares and equipments Assess Order tracking Design Inter-plant processing Engineering change mgt Plant capacity optimization Quality and lean improvement Part verification Core Master vehicle records Capability definition and relationship Identifying dependency between business Modular MES Generic MES module 47 Development approach Development Deployment Common Unique Business capabilities from manufacturing domain Batch control BP & L Global MOM MOM/MES template Continuous control Discreet control L 4 L 3 L 2 L 1 Production 1.Detail mapping, process documentation and L functional blueprint 0 2.Reusability and enhancement of baseline solution 1. End-to-end linkages of systems and strategies 2. Alignment between PLM, ERP vendors and service providers Nearly 100 man years worth of efforts (mapping and business validation) Live document, constant refresh 44 Business capabilities from Supply Chain domain Standards used: MESA, ISA 95 Benefit from retained knowledge across the organization

14 Key Contacts Ramesh Subramanian Practice Head Connected Enterprise IT (EU & NA) Raja Ganguly VP Connected Enterprise IT (EU & NA) Sandeep Bhandari Head Delivery Connected Enterprise IT (NA) Ashish Thakur Presales Consultant Connected Enterprise IT Pratim Banerjee Business Development linkedin.com/company/tata-technologies

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