Integrating Shop Floor Machinery and Microsoft Dynamics AX

Transcription

1 Integrating Shop Floor Machinery and Microsoft Dynamics AX Gregor Newland February 25, 2014

2 Agenda 2

3 Manufacturing Execution Systems (MES) Shop Floor Machinery MES Wonderware MERLIN Custom Developed Microsoft Dynamics AX

4 Why Should We Integrate? Shop Floor to Top Floor visibility, interaction, and management For those who need more than Shop Floor Control (AX2009) and Manufacturing Execution System (AX2012) Connect Microsoft Dynamics AX to shop floor in real time Know exactly what is happening at machines through bisynchronous communication with Dynamics AX 4

5 Why Should We Integrate? Automatic Data Collection from the machines Have accurate and objective data collected directly from machines and manual workstations, including part counts, run time, down time and reject counts by reason codes. Minimize reliance on the machine operator for information, eliminating errors. 5

6 Why Should We Integrate? Feed Dynamics modules with automatic and accurate data: Shop Floor Control with Production Order completion data, accurate times and counts Inventory Management with quantities produced and consumed Product Management with accurate job standards, viscosity, heat measurements, run rates EAM with machine cycles, run hours, down time, reason codes, asset utilization HR Time and Attendance with operator log in, time on machine and piece count Quality Control with rejects and reasons 6

7 Why Should We Integrate? Production improvements in the 10% - 50% range 10% Operational improvement 20-60% Profit improvement Average ROI in < 3 months Real-time machine visibility + OEE numbers including alerts - 2% - 5% Operator Productivity increases - 1% - 10% Reduce Downtime - 3% - 8% Minimize Rejects - 2% - 4% Root Cause analysis - 2% - 4% Value stream data collection and analysis - 2% - 4% Labor productivity tracking - 3% - 6% Usage-based Preventive Maintenance - 1% - 2% Benchmark scheduling and value streaming - 2% - 6% 7

8 The Bi-Synchronous Advantage Simple monitoring (data harvesting) often Phase 1 but does not provide: Real time process monitoring from within AX production planning and scheduling functionality Instant communications of BOMs & BOM revisions to the shop floor On the fly changes of order priorities in real-time A single version of the truth Production Orders Scheduling Planning Inventory Updates BOMs BOM Revisions 8

9 Production Order Steps MES Integration Workflow Master data Production order Microsoft Dynamics AX Create BOM, Route Estimate MES Schedule Release Start Route/Job Card Production Picking Report as Finished End 9

10 Production Order Steps Single Version of the Truth Reliance on a Single Data Base One-Step Order Creation One source for BOMs and Routes Faster Roll-Out of BOM Changes Faster Roll-Out of New Products No Need to Manage/ Reconcile Multiple Scheduling Tools Only Available in Bi- Synchronous Model 10

11 Production Order Steps Real Time Monitoring of Shop Floor Processes Routing and Job Card Updates as They Happen Approved BOM Substitutions Automatically Updated Automated Inventory Entries (Components, Raw Materials, Scrap & Finished Goods) Production Scheduling Experiences Finished Orders In Real Time Use AX Reporting Tools for Performance Analysis 11

12 MES Integration Example Click the following link to view the Video - Integration of Shop Floor Machinery and Microsoft Dynamics AX Demonstration 12

13 Things to Remember Most older machines can be retro-fitted Licensing Considerations Operational returns easier to justify Examine and consider ROI from granular gains Bi-synchronicity is a must the other glass is half empty Start with a single pilot line/project 13

14 Questions 14

15 Contact: Gregor Newland (937) or Ellipse Solutions LLC 7917 Washington Woods Drive Dayton, OH (937) , (866) FAX