Cummins Next Generation Manufacturing Process · PDF fileLeveraging People, Process & Tools • Off the shelf reporting and dashboards • No need to build Ad- Hoc queries for big

1

Community Summit 2013

© Apriso Corporation 2013, All rights reserved.

Cummins Next Generation Manufacturing Process Intelligence

Robert D. Borchelt, Ph.D.,

Director, Manufacturing IT Systems and Industrial Controls Corporate Manufacturing

Apriso Community Summit | Germany June 19 & 20, 2013

2



About Cummins

• Cummins Inc., a global power leader, is a corporation of complementary business units that design, manufacture, distribute and service diesel and natural gas engines and related technologies.

• Headquartered in Columbus, Indiana, (USA) Cummins employs approximately 44,000 people worldwide and serves customers in 190 countries.

• Cummins earned $1.66 billion on

sales of $17.3 billion in 2012, www.cummins.com.

http://www.cummins.com/

3



Cummins NGMES Overview

4



5



NGMES Project Milestones

Cummins Public

2008: Columbus In. –

Global CORE System Definition

2008: Darlington UK –

1st Engine Assembly – Significant performance increase in quality / efficiency

2010: Beijing China –

1st JV Engine Assembly – 500% larger plant / deployment $$ ~ 50% less cost

2011: Wuhan China –

1st Fuel System plant – 85% reuse of CORE / deployment $$ ~ 90% less cost

2011: Phaltan India –

2nd JV Engine Assembly – Size = Darlington / Deployment cost ~ 75% less cost

2012: Houston Texas -

Specialty Apps – 1st site for ‘Mobile MES’ deployment

2012: Izmir Turkey –

Filtration – 1st filtration - > 80% reuse of CORE solution @ 10% of 1st site $$

6



NGMES Benefits to Cummins

Efficiency Quality Process Global

25+% throughput

increase realized in 1st

plant deployment

Order of magnitude

improvement (90%+) in Defects to Customer

metric

Cross-plant and BU

process reuse 95%+ for engine

assembly and 85% for

component operations

Initial deployments

outside of U.S. aligned to Corporate Growth Plan

10+ plants deployed ongoing per year across all business units

7



Original NGMES Reporting Requirements

Accuracy • Integrated reporting for efficiency, quality and availability

Availability • Real-time reporting access from within and outside the

plant

Impact • No impact on production operations from report requests

History ● Immediate access to production history

8



Today’s Reporting

• Operational Reporting • What parts I need for pending assembly operations for the

engines on-line? • What are the BOM/Item Assembly changes that happened

over a period of time? • What are the production faults open at this moment? • What are the changes required for Engine Conversion? • What is the status of Engines on the line? • What is the next “N” number of work orders to be

processed?

• Aggregate / Analytical Reporting • How does Plant 1 compare to Plant 2 for: • Delivery performance • Quality performance • Capacity utilization • People/Engine/Day • What’s my total production in a given period of time? • What’s the overall delivery performance?

9



Why Change NGMES Reporting Plan?

• Corporate BI report s are premium cost

• Focus skilled Mfg resources on NGMES process improvement & deployment

• IT storage costs reduced

• Business users do their own Ad-hoc development w/o local IT support

• Dashboards and standard KPI’s improve data availability for management decision-making

• Simplifies support and accelerates global deployment of NGMES

10



Next Step: Manufacturing Intelligence

Analytics

Com

petit

ive

Adva

ntag

e

Degree of Intelligence

Reporting

Transactional Data

Align reporting to needs for maximum ROI

What actions are needed? What “exactly” is the problem? Static, fixed layout Doesn’t address different scenarios Hour, shift, day, week, month

What truly happened? Drilldown with Slice and Dice What if these trends continue? Hour, shift, day, week, month, year

Decision Optimization Flexibility Statistical models Time Frame

Alerts Query/ limited drill down Ad hoc reports Standard reports Timeframe

11



Cummins Chose MPI from

12



MPI Advantages as Defined by Cummins

• “Out of the box” pre-defined Intelligence Packs

• Off the shelf product that is Manufacturing focused

• Improved global deployment of reports

• Dashboards will strengthen visibility and performance

• Improved sharing of common analysis, KPI’s and reports globally

• Provides global view of operations

• Mobile AND fixed UI device support

13



Cummins MPI Deployment Update

• MPI deployment plans being developed

• Q114 launch for new plant deployments targeted • Includes operational and executive information

requirements • Includes UI platform consideration across fixed

workstations, laptop PCs, tablets & smartphones

• Deployment Considerations • Central Level 2 Support team process changes • ETL modifications to use MPI DB instead of TODS • RAP development for Cummins built functions

14



Summary of Expected Benefits

• Leveraging People, Process & Tools • Off the shelf reporting and dashboards • No need to build Ad-Hoc queries for big data analysis • Reduce development, maintenance and storage costs • Cross-functional tool supporting shop-floor to top-floor global

manufacturing intelligence requirements • Re-affirms executive support for NGMES program

• Engaged Cummins Leadership (CMO, SVP) in ‘real-world‘ requirements gathering for FlexNet EIC mobile app

15



Thank You!

Documents

Cummins Next Generation Manufacturing Process · PDF fileLeveraging People, Process & Tools • Off the shelf reporting and dashboards • No need to build Ad- Hoc queries for big