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Speakers
Michael Ford
Sr. Director Emerging Industry Strategy
Lee Hitchins
European Applications Manager
Industry 4.0: How to Make to Order with Mass Production Efficiency
Agenda
Industry 4.0: How to Make to Order with Mass Production Efficiency
Manufacturing Trends Essential Engineering tools Relevance To Industry 4.0
Michael FordSenior Director Emerging Industry StrategyAegis Software
1) Volume:• Lot sizes: (1 – 10 / 100 – 1,000 / 1,000 – continuous flow)
2) Mix:• Frequency of change: (minute, hour, day, month, none)
3) Tailoring:• Personalization to customer specification / options
Today’s Reality:• All of the above need to be possible, together
The Three Dimensions Of Manufacturing
One or The Other, or both?
During Set-up / Changes:• Production is in a wait-state (machines & people)• Mistakes can be made, confirmation required• Productivity 80% -> 50% -> 30%, but always “busy”
Repeated Work:• Setup cost divided by number of products made• Intermediate stock created: lines, cells, warehouse• Does production rate meet customer demand rate?
Manufacturing Trends: Opportunities & Challenges
Does It Need To Be A Trade-off?
FactoryLogix Mix & Match Essential Engineering Tools:• Engineer To Order:
• On-demand routing for immediate jobs• Which preparation area / oven is available?
• Configure To Order:• Easy choice of variants on demand• Execute the customer’s choice of ingredients
• Automate To Order:• Dynamic work-instructions for bespoke specification• You want a 16.5” Pizza, with toppings arranged by color?
• Adaptive Planning:• Agile, near-term planning optimization of lots• Combination of like customer orders, within delivery promise
FactoryLogix: One Solution In All Scenarios
You could even use it to make Pizza!
When Do I Need It?• Frequent, smaller lots, high mix• Urgent jobs, business opportunity / commitment• MRO / RMA, trials, repair work, personalization
What Does It Do?• Creates a route and configuration immediately• Automatically integrates the work into the plan• Checks resources and dependencies, consequences
What Benefit Do I Get?• Lower cost of agility and risk of disruption• Improved productivity and control• A quicker service for the customer
FactoryLogix: Engineer To Order
We All Do It Already
FactoryLogix: Configure To Order
Easier Than Buying A New CarDid you see the options list?
When Do I Need It?• Making multiple variants of products • Personalized products / regionalized / user-option list
What Does It Do?• A single, dynamic Bill of Materials (BOM)• Part number selection when creating work-order
What Benefit Do I Get?• Reduce complexity: Far fewer BOMs• Reduce effort: Eliminate duplicate BOM management• No mistakes: Improve quality, reduce re-work
FactoryLogix: Automate To Order
Any Product “Made To Measure”
When Do I Need It?• Making bespoke products / options / adjustments• Tailored products, bespoke
What Does It Do?• Automated creation of unit-specific work-instructions• Exact amount of materials, method and finish• Part numbers stay the same
What Benefit Do I Get?• Lower cost of flexibility• Reduced stress of production team members• Improved quality, customer satisfaction, differentiation
FactoryLogix Essential Engineering Tools:
Industry 4.0 Engineering = Engineer To Order + Configure To Order + Automate To Order + Adaptive Planning
FactoryLogix: For Your Digital Factory
Automation of agility is Industry 4.0
Thank You
Michael FordSenior Director Emerging Industry StrategyAegis Software
How We Can Help:What is driving your interest?
• Need for a high-mix business case?• Avoid mistakes / rework / delays?• Become more flexible / responsive?
FactoryLogix: Make To Order
Practical insightsin FactoryLogix
Demonstration
Practical Example – Engineer to Order
Customer A Setup:•On-Demand Cell for small batches and prototyping of electronic assemblies for the motorsport industry.•Very High mix, high technology and low volume•Works with customer design data/BOM’s and consignment material
Challenges:•Difficulty in Meeting the 24hr turn around time the service offers due to data handling and engineering issues.•No accurate visibility of asset availability when planning•Change over and setup times, in production, are extended
Practical Example – Engineer to Order
How FactoryLogix has Addressed the Challenges
•FactoryLogix has extensive, native, data handling capability making the handling of specific customer order data easy•System automatically recognizes and identifies usable data from large customer folders or archives.•Engineer is able to choose optimal data sets to expedite data entry through guided steps
Practical Example – Engineer to Order
How FactoryLogix has Addressed the Challenges
•Automated creation of the required process flow, routing logic and visual aid templates expedites engineers work load•Visualization of the engineering tasks required, plus engineering capacity increases efficiency and shortens engineering lead time.
Practical Example – Engineer to Order
How FactoryLogix has Addressed the Challenges
•Provide full asset, resource and material availability, visually to the planning team. Deal with overruns, asset and material issues quickly and effectively.•Allow Grouping of orders with commonality to reduce change over times•Provide stepped guidance to operators on change over tasks, including machine and material setup.
Practical Example – Configure to Order
Customer B Setup:•Builds electric bikes for the consumer market•Customers purchase online and configure their bike with available options•Each bike is built in its own cell by a technician
Challenges:•As the bikes evolve and increase in complexity and configurable options, BOM and Variant management are a problem.•Vast amounts of mixed paper and digital information leads to mistakes
Practical Example – Configure to Order
How FactoryLogix has Addressed the Challenges•Single Bill of Materials, with all required option codes defined, reduces engineering work load•Customers can chose from list of options to create a custom bike within the bounds of the options available, creating control.•Option codes can be grouped to form fixed value variants speeding up and simplifying the process•Customers can choose from fixed variants along with custom option codes to create semi custom product•All this work was done by hand before and is now completely automated at the time the order is produced. Reducing time taken and errors
Practical Example – Automate to Order
Customer C Setup:•Builds automatic window shades•Has multiple factories supporting manufacturing•Customers can order shades with fixed options as well unlimited variation for length, depth etc..
Challenges:•Due to bespoke nature of product individual orders have low commonality causing high changeover and setup times.•Increasing variation in product, causes quality and efficiency issues due to the manual nature of managing the orders.
Practical Example – Automate to Order
How FactoryLogix has Addressed the Challenges
•FactoryLogix allows each individual order to be personalized whilst maintaining process control and optimization of production time and material usage
OrderNumber WEB20223 US20045 US20046 WEB20224 WEB20225CustomerName APJones LKBurnham LKBurnham DWLee TYMarriott
TableName MainDining DiningRM-TBL DiningRM-SERVER Dining DiningRoomWood-Tabletop Walnut Ash Ash Pecan Ash
Wood-Legs Oak Ash Ash Pecan AshShape Rectangle Rectangle Rectangle Round Oval
ShapeCode 1001 1003 1001 2009 3002Stain Brand Minwax Minwax Minwax Minwax Minwax
Stain Number 224 209 209 245 286TT-OverallLength 84.0 96.0 54.0 45.0 72.0TT-OverallWidth 42.0 42.0 14.5 N/A 42.0
TT-Thickness 1.0 1.0 0.8 1.0 1.0TT-EdgeStyle BEVEL ROUND ROUND ROUND STRAIGHT
TT-EdgeBevelAngle 75 0LeafCount 0 2 0 0 0
Leaf-Width 42.0Leaf-Length 14.0
Leaf-Thickness 1.0Leg-Length 28.0 25.0 29.0 27.0 28.0
Leg-Diameter 2.0 5.0 1.5 5.0 2.0Leg-Style 203 302 202 302 202
Leg-Count 4 2 4 1 4
Book a free consultation and get ourexpert advice on your challenges
Submit your request on our dedicated consultation page:https://info.aiscorp.com/free-consultation
Questions
The Digital Operator Cockpit: Human 4.0
Agenda
The Digital Operator Cockpit: Human 4.0
Have things really changed? The Rise of Electronic Work-Instructions The Untethered Operator
Michael FordSenior Director Emerging Industry StrategyAegis Software
Traditional Craftsmanship:• We Like:
• Skills passed from the master to apprentice• Flexible, repeatable & bespoke manufacturing• Customers value the personalized quality product
• In Today’s Economy However:• Very long learning curve• Unacceptable lead-time• Dependency on key skills, unlikely to be automated• Only for the most expensive, prestige products
Have Things Really Changed?
Ye olde transfer of knowledge
Work-Instruction Evolution: Mass Production
Most Famous Industrial Revolution
Have Things Really Changed?
Early Mass Production:• We Like:
• High-volume efficiencies• Many automated processes• Team-work following simple work-instruction
• In Today’s Economy However:• Setup-times limit flexibility & productivity• Lack of bespoke options• Operator / engineering “fatigue”
Work-Instruction Evolution: Paper
Paper-Based Work-Instructions: Operator:
Do I need to display and read my instructions? Do I even have the latest information? What changed since last time?
Engineering: Do I need to issue new documentation every time? Will the printer work, do I have enough paper? How to ensure visibility vs. consume assembly space?
Frustration, cost, delays and mistakes
Operator / Engineering Fatigue
Work-Instruction Evolution: “AAD”
Eliminated simple mistakesReduced creation effort
Electronic Like for Like Replacement
Static Electronic Work-Instructions: Operator:
Instructions always displayed I always have the latest information Did anything change since last time? I can't query information, rotate or animate parts
Engineering: Documentation automatically issued One small change can trigger hundreds of edited pages Investment, energy & IT support costs Cost-effective use of space?
Work-Instruction Evolution: “DDD”
Full operator engagementfor zero defect manufacturing
Electronic Work Instruction Intelligence
Dynamic Work-Instructions: Operator:
Fully interactive, with supporting information Always relevant, step by step confirmation Small or large changes easily handled Feedback & involvement
Engineering: Reduced training & learning curve Expanding performance drives ROI Instructions easy to create systematically
Work-Instruction Evolution: Augmented Reality
Hands-free Operator Cockpit: FactoryOptix Augmented Reality (AR) Mobile work-Instruction intelligence Hands-free, voice command / ID reading Video capture for traceability Same step by step confirmation Uses the identical information as workstations
Doubling my productivity
Intelligence Beyond The Line / Cell
Hardware Cost & Savings: AR Hardware:
Affordable, comfortable, robust (unlike VR, MR)
Hardware Cost Reduction: No PCs, monitors, keyboards, mouse, barcode readers No IT infrastructure investment or support Hardware per operator vs. per each work-cell
Untethered Operators
It was not the most exciting environment for a young person
The FactoryOptix Experience: Operator:
Reduced distraction / repetitive strain Escape from repetitive, boring work Eliminate frustration waiting between jobs
Engineering: Ability to support previously inaccessible areas Virtually eliminate training & learning curve Increase productivity 2-fold Closed-loop traceability and work optimization
Untethered Operators
The new most memorable industrial revolution
Human Roles In Industry 4.0: With AR
The Industry 4.0 Human Operator: Operator:
Become a digital master crafts-person Continuous interesting work assignments Job satisfaction & security
Engineering: Increased operator flexibility Dynamic assignment of tasks Assembly, test, inspection, quality, material logistics etc. All guided by Industry 4.0 intelligence
Humans Have An ImportantRole In Industry 4.0
The Digital Operator Cockpit: Human 4.0
Thank You
Michael FordSenior Director Emerging Industry StrategyAegis Software
How We Can Help:What is driving your interest in AR?
• Extend the reach of manufacturing intelligence?
• Increase flexibility of manual assembly?• Reduce costs of manufacturing IT support • Increase productivity?
The Digital Operator Cockpit: Human 4.0
Practical insightsin FactoryLogix
Demonstration
Practical Example – Operator interface
•Configurable layout ensures operators see information in a way that suits their needs reducing waste real estate•All documentation, including works instructions and supporting documents are delivered electronically, ensuring revision control and operational efficiency•Works instructions are interactive reducing training time and allowing for lean operations.
Practical Example – Challenging environments
Augmented Reality Example – Visual Work Instructions
Book a free consultation and get ourexpert advice on your challenges
Submit your request on our dedicated consultation page:https://info.aiscorp.com/free-consultation
Questions
Visit www.aiscorp.com to learn more.