How to Start Your Journey to Data-Driven Manufacturing · How to Start Your Journey to Data-Driven Manufacturing Welcome! Questions will be addressed during the Q&A session at the

How to Start Your Journey to Data-Driven Manufacturing

Welcome!

Questions will be addressed during

the Q&A session at the end of the

presentation.

• Please submit questions using the

“question” button.

• You may also email your questions

to [email protected].

This webinar is being recorded.

• You will receive an email within 24

hours with a link to view the webinar

recording, presentation materials

and additional resources.

5 Steps to the Successful Realization of Smart Manufacturing

Step 3: Visualize - Real-time Data | June 19th, 2020

mailto:[email protected]

Introduction of the Webinar SeriesJay Foran – Senior VP of Industry & Innovation at Team NEO

2

• Overview of Smart Manufacturing Cluster

• Overview of webinar series;

o Each webinar builds on the first one;

o Each webinar includes content from and is presented by a partnering pair of Manufacturer and

Solution Provider;

o The progressive webinars are presented at the end of each week for starting on June 5;

o Emphasis will be on the operational excellence , improved efficiency and profitability of SME

Manufacturers;

o Concepts that help the SME Manufacturer address the influences of Covid-19 will be highlighted at

each step of the Journey.

“Visualize” Webinar OverviewRick Earles – Senior Director of Industry & Innovation at Team NEO

3

“Visualize” Webinar Overview

4

• Visualize: Receive Real-Time data on all levels of the operations and enable sharing of insights

o Determining the Form/s of HMIs to be use in the Distribution of Information to the Stake Holders and Decision Makers;

o Using Canned Visualization Software to Present Data in a Meaningful Form and to Invoke Actions in Real Time – (save cost of implementation by using what has already been created);

o Automating the Collection of Real Time Data to Feed the Analytics that Drive the Visualization of Critical Information and Calls for Response;

o Using AR/VR to enhance Productivity and Operational Support.

Visualize

3

“Visualize” Webinar Overview

5

• Agenda:

o Introductions

− Kurt Sardiga: Manufacturing Systems Engineer at Rockwell Automation (Twinsburg) - a Manufacturer

industrial control products such as programmable logic controllers (PLCs), electronic operator interfaces,

input/output (I/O) devices, and various distributed on-machine products.

− Dave Knowles: Account Manager, Rockwell Automation – a Solution Provider that provides a full stack

of capabilities for industrial automation and information systems.

o Manufacturers’ Use Case and “Visualize” for Data Driven Manufacturing Journey

o Implementation by Solution Provider of “Visualize” concepts

o Question and Answer Session

Visualize Rockwell

Twinsburg

Opened in 1979.

Connected

Enterprise started in

2009.

Twinsburg production

258,000 square feet for

manufacturing

• 7 printed circuit board

assembly lines and final

assembly

ISO 9001, 14001 and

OHSAS18001 certified

Primarily produces Logix

and visualization products

Approx. 300 production

employees, 40 salaried

• 7x24 operations

(EA – 4 shifts)

Other functions on-site

• Cleveland sales office

• Systems solutions

business

• Shared service functions

(IT, purchasing)

Plant overview

The value of FactoryTalk®

Information is an enabler for change

All of manufacturing uses the data

• Manufacturing engineering

• Supervision

• Manufacturing leads

• Production control

• Quality

Specific reports that we use

• Output reports

• Pareto reports

• Quality reports

• Downtime reports

• Work order history

• Unit history

• Yield reports

PUBLIC | Copy right ©2019 Rockwell Automation, Inc. | 9

TW INSBURG PRODUCTIVITY


PLANTS

18

FactoryTalk® Production Centre | 387,000 SKUs

AVG ORDER

200 SKUsUP TO

AVG PRODUCT LIFE

20 YEARS STOCK + CONFIGURED

TO ORDER, ENGINEERED TO ORDER

PRODUCTS

Implementation & transformation

The Connected Enterprise

Rockwell Automation journey video

Rockwell Automation transformation

The Connected Enterprise

INVENTORY120 days to

82 days

CAPEX30% in capital

avoidance

DELIVER82% to 96%

LEAD TIMESReduced 50%

QUALITY60% reduction

in PPM

5% PER

YEARPRODUCTIVITYProductivity gains offset inflation and fund investments


https://www.youtube.com/watch?v=ZSHTFBz0dik

https://www.youtube.com/watch?v=ZSHTFBz0dik


What was our issue?

Making confident decisions

off of known good data

was hard to do

Best practices or greatest difficulties were

tough to compare or contrast since they

were defined by different sources of

information or points in the process

We did not have clear

visibility into every

plant’s operation


Where we are now

Best practices are more

accurately identified and

proliferated using consolidated

analytics

Using real-time data,

more profitable decisions are

faster and easier to make

We have clearer visibility

into every plant’s operation


CONVERGENCE

ERP MRP FINANCIALS HR LOGISTICS QUALITY CRM…

SENSORS, ACTUATORS CONTROLLERS MATERIALS & TRANSPORT MACHINES & EQUIPMENT…

Business systemsTRANSACTIONAL

OperationsREAL-TIME

TRANSPARENT – LIVE DATA

OPERATIONS

QUALITY

IT

EXECUTIVE

FINANCE

HIERARCHICAL - HISTORICAL DATA

ENGINEERING

MAINTENANCE

OPERATOR

IIoT Information InfrastructureTransformationDIGITAL


Paper process verification

Work order chasing

Sub-optimized processes

Disparate data without context

PLANT-LEVEL PROCESS CONTROL

Real-time global CTQ parameter monitoring

Integrated order management

Data driven process optimization

Machine information & intelligent tools

MES / REPORTING LEVEL


PRINTED CIRCUIT BOARD ASSEMBLY

FactoryTalk® ProductionCentre55,000 transaction per day in PCBA cell

6,450Raw materials

300W/Os released per day

1.3MPlacements per day

10,000Boards per day

64Changeovers per day


Meaningful data driving

meaningful results

Processcapability

Time series plot of Rockwell Automation global mispick ppm by week


ANALYTICS VALUEIncreasing Intelligence & Improving Performance

6 Plants 24 Lines50

Machines2,000

Nozzles

Source: Universal Instruments


Nozzle monitoractivity

Shows single “flyaway”

nozzle that contributes to

42% of all rejects

Copyright © 2018 Rockwell Automation, Inc. All Rights Reserved.PUBLIC

Data Visualization to the Part Level

• 0402 MM Capacitor with a very small mass.

• Pick rate was ~2000 ppm or (.02%) when RH

> 30%

• Pick rate was over 30,000 PPM or (3%) when RH dropped to 9%

• Efficiency loss at the line of 18%





> 30%



10

20

30

40

50





> 30%



• Humidification was justified.

10

20

30

40

50

Data Visualization

for Context

v

Correlation Mining


Why ThingWorx?Mash Up Disparate

Data Sources

Ease of Use

IoT Capabilities

Copyright © 2018 Rockwel l Automation, Inc. Al l Rights Reserved.PUBLIC

WRAP

THING

EXTEND

TRANSFORM

THING

+

IoT Platform

Apps Analytics

AR

ML

Dig

ital Tra

nsfo

rmation

A

dop

tion

Pla

n

View

Chalk

Expert Capture

Engine

Integrated Architecture, Connectivity, Network, Control,

Security, Automation, Data Historization,

Infrastructure…

WR

AP

EX

TE

ND

TR

AN

SF

OR

M


ThingWorx Use Cases

▪ Kitting

▪ Cell Performance Displays

▪ Downtime TV

In Closing…

• Recommended Readingo Smart Manufacturing Guidelines

https://literature.rockwellautomation.com/idc/groups/literature/documents/wp/cie-wp007_-en-p.pdf

• Recommended Viewingo Getting Real-Time Results

https://www.rockwellautomation.com/en_NA/events/detail.page?pagetitle=FactoryTalk-InnovationSuite%2C-powered-by-PTC%3A-Getting-Real-time-Insights-into-Operations&content_type=webinar&docid=29e030e9bbfaa939839358debece6534

• Recommended Resources

o …https://www.rockwellautomation.com/en_NA/capabilities/digital-transformation/overview.page?

29

https://literature.rockwellautomation.com/idc/groups/literature/documents/wp/cie-wp007_-en-p.pdf



https://www.rockwellautomation.com/en_NA/capabilities/digital-transformation/overview.page?

In Closing…

• You will receive an email within 24 hours with a link to view the webinar recording,

presentation materials and additional resources.

• Please join us for Part 3 of the series:

“Analyze - Key Performance Indicators ” featuring Logan Aluminum and Hitachi

Friday, June 26th from 9:00 am – 9:45 am

Register now at smartmanufacturingcluster.org/events

• On behalf of the Smart Manufacturing Cluster and our presenters, thank you for joining

us today!

30

https://smartmanufacturingcluster.org/events/webinar-series/

ContactTeam NEO

Rick Earles

Senior Director Industry & Innovation

216.363.6888

[email protected]

Rockwell Automation

Dave Knowles

[email protected]

Where we are in the Journey

33

Establish a high level understanding of data-driven manufacturing (DDM) and

identify applications where it can improve your type of business

Ensure production-critical machines (old and new) are sharing their data on the

corporate network

Evaluate metrics and determine key performance indicators (KPIs) that

require optimization

Receive Real-Time data on all levels of the operations and enable

sharing of insights

Make business decisions based on data analytics to continuously improve

productivity, profitability, and efficiency

Presented on

June 5

Today’s Presentation

Presented on

June 12

June 19

Presented on

June 26

Presented on

July 2

Documents

How to Start Your Journey to Data-Driven Manufacturing · How to Start Your Journey to Data-Driven Manufacturing Welcome! Questions will be addressed during the Q&A session at the