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slides PTC smart factory.pdf

  1. 1. VCST’S SMART FACTORY IMPERATIVE: DELIVERING HIGHER PRECISION, QUALITY AND EFFICIENCY JOURNEY OF A DIGITAL TRANSFORMATION Tim POLLEUNIS Dirk LUWAERT Jordan CHAISSON 27th July, 2020 Thank you for joining. The session will begin shortly.
  2. 2. VCST’S SMART FACTORY IMPERATIVE: DELIVERING HIGHER PRECISION, QUALITY AND EFFICIENCY JOURNEY OF A DIGITAL TRANSFORMATION Tim POLLEUNIS Dirk LUWAERT Jordan CHAISSON 27th July, 2020
  3. 3. 3 SPEAKERS Tim POLLEUNIS Manager Smart Factory VCST Industrial Products Dirk LUWAERT Enterprise Solution Architect Manufacturing Industry AdUltima Group Jordan CHAISSON Senior Manager, Connected Operations Solutions PTC
  4. 4. AGENDA What’s Next? Solution & Results VCST & AdUltima introduction Digital Transformation with PTC
  5. 5. 5 INDUSTRIAL COMPANIES LOOK TO US TO MAXIMIZE THE USE OF TECHNOLOGIES TO BOOST THEIR EFFICIENCY, PROMOTE THEIR BUSINESS AND MAKE THEIR COMPANY SUSTAINABLE Data transformation and enrichment Collaboration on same data Data Synchronization Data quality Data associativity and traceability WHILE FACING THE FOLLOWING CHALLENGES ON THEIR ENTERPRISE DATA
  6. 6. 6 VCST & AD ULTIMA
  7. 7. 7 Oostkamp Sint-Truiden* Zanesville Léon Iasi Alba Reichenbach Brno Suzhou Changzhou Pune Distribution centre for NAFTA market & gearbox assy for rail. Manufacturing & assy site for railway gearboxes, overhaul and distribution centre for China. Manufacturing site for gears (up to  0.5m), shafts, subassemblies & gearbox assy. HQ BLR & manufacturing & assy site for railway gearboxes, overhaul service, R&D. Manufacturing site for gears & shafts. HQ BLA & manufacturing site for gears, shafts incl. heat treatment, R&D. Manufacturing site for gears & shafts incl. heat treatment. Manufacturing site for gears, shafts incl. heat treatment. Manufacturing site for aluminium components for brake systems. Manufacturing site for gears (up to  1m), shafts & spiral bevel gears incl. heat treatment. HQ BLI & manufacturing site for gears (up to  2m), shafts, aluminium components & castings incl. heat treatment. FTE: 443 TO: € 65m (incl. € 7m BLI) FTE: 13 TO: € 31.1m FTE: 420 TO: € 27.3m (incl. € 8.8m BLI) FTE: 467 TO: € 12.7m FTE: 343 TO: € 17.4m FTE: 173 TO: € 19m FTE: 315 TO: € 33.8m FTE: 161 TO: € 38.3m FTE: 162 TO: € 21,8m FTE: 1024 TO: €26.7m FTE: 207 TO: € 44.7m OVERVIEW BMT DRIVE SOLUTIONS
  8. 8. 8 OVERVIEW AD ULTIMA GROUP +350 employees 20y experience + 500 Satisfied customers Local Presence Trusted Advisor Industry Experts Faster to value AGILE
  9. 9. 9 SOLUTION & RESULTS
  10. 10. 10 • Automotive Industry – Innovative, very high quality standards and extreme cost pressures • Cost and the Efficiency of the shop floor – Supporting departments need to be stronger/automated • New strict NVH requirements – High Product & process requirements • Cost of poor quality – Automotive: High volume. Instability = Risk for high costs • Time to market - Non-automated workflows in different systems. Time consuming to determine impact of request/change. CHALLENGES
  11. 11. 11 Objectives of the digital transformation initiative • Improve OEE - Improvement in supporting functions like logistics, quality & maintenance • Reduce the costs of poor quality – run the system in a more stable way, reduce risk. Introduce closed-loop system • Improve Competitiveness/Revenue – Reduce NVH- Capture line parameters for customers – more data, the greater the chance of finding correlations • Improve Time to Market - Reduce the time it takes to implement a change by 25% • Scalable – Integrate in BMT-IT structure OBJECTIVES
  12. 12. 12 PROJECT TIMELINE POC - PILOT April 2019 January 2020 January 2020 Smart Factory Show Case (part 2) GO-LIVE Breakthrough with Marposs to Create Q-Digibox Blueprints Systems Integration Available July 2018 Approval POC Project Concept workshop November 2018 Start POC Thingworx Planning Full Roll-out Upgrade IT-landscape Smart Factory Show Case September 2019 New Smart Factory Manager June 2020 September 2020 Visit Event POC PILOT GO First CNC from machine connected
  13. 13. 13 SNAPSHOT OF THE SOLUTION Production Planning OEE NVH Optimization Material tracebility Closed loop Quality Plan for optimal efficiency with integrated visual planning from order intake to shopfloor A constant accurate view on efficiency by a (nearly) fully automated logging of events Towards Machine Learning in action … Overall material traceability by a complete digital chain, assuring compliance demand From PLM managed Control plan, over event-drive quality measurements enabling extended process control What is the approach taken and technology used for the Smart Factory platform at VCST?
  14. 14. 14 14 PRODUCTION PLANNING
  15. 15. 15 15 OEE
  16. 16. 16 NVH OPTIMIZATION
  17. 17. 17 NVH OPTIMIZATION Reishauer Argus • Partner: Reishauer • Goal: Process, Machine & Component Monitoring • Remark: Extra features available on Reishauer platform Digibox • Partner: Siemens WCC • Goal: Access to PLC & NC Data • Remark: 110 parameters traced every 1-3 seconds. Measurement Data • Partner: Marposs – AdUltima • Goal: Risk-Based Measurements • Remark: No solution on the market. Prototype developed together with Marposs Tools • Partner: AdUltima – Delaware • Goal: Minimize Risk Critical Tools • Remark: Incoming inspection on tools (ex. Dresser) combined with performance monitoring on serialized tool level. Shopfloor Monitoring - OEE • Partner: AdUltima • Goal: Link Events from the Shop Floor • Remark: Give insight to the events that happened linked to the process VIBMON • Partner: Enginity – Flanders Make • Goal: Predict Gear Quality • Remark: Measuring vibrations/accelerations on the grinding head with accelerometer Waviness • Partner: (Self-Development) • Goal: Predict NVH Behaviour • Remark: In-house developed GEWA software re-engineered to make it future proof Machine Monitoring Tool Monitoring Part Monitoring Environment Monitoring NDA
  18. 18. 18 SNAPSHOT OF THE SOLUTION Production Planning OEE NVH Optimization Material tracebility Closed loop Quality Plan for optimal efficiency with integrated visual planning from order intake to shopfloor A constant accurate view on efficiency by a (nearly) fully automated logging of events Towards Machine Learning in action … Overall material traceability by a complete digital chain, assuring compliance demand From PLM managed Control plan, over event-drive quality measurements enabling extended process control What is the approach taken and technology used for the Smart Factory platform at VCST?
  19. 19. 20 APPROACH TAKEN TO BUILD A SMART FACTORY PLATFORM AT VCST IT-OT convergence Data-driven operations Operator Advisor ISA-95 datamodel Translate backend processes using industry standard ThingModel Hybrid capabilities close to the ground and the events
  20. 20. 21 EXTENDED INDUSTRY 4.0 ARCHITECTURE AT VCST Production Devices Maintenance Execution Guided instructions Siemens Legacy ERP Equipment monitoring Phase 1 Transport Personnel Time registrations Maintenance, Transport, HRM, ... Resources Production Order Materials & BOM Inspection Lot Production Status Actuals Inspection Results mBOM Process Plan Control Plan ECN Product Definition and Information Tool Definition and Information Process Definition en Information Shop Floor Execution & Monitoring Production Scheduling Quality Planning Demand Mgmt and Forecasting Warehouse Phase 2 Measuring Devices Quality Control / Capture Inspection Reporting Quality Analysis Inspection Results VCST & AdUltima Actual Time/Cost Discrepancies Corrective Actions Process Plan Instructions Transport Devices Wearables
  21. 21. 22 SNAPSHOT OF THE SOLUTION Production Planning OEE NVH Optimization Material tracebility Closed loop Quality Plan for optimal efficiency with integrated visual planning from order intake to shopfloor A constant accurate view on efficiency by a (nearly) fully automated logging of events Towards Machine Learning in action … Overall material traceability by a complete digital chain, assuring compliance demand From PLM managed Control plan, over event-drive quality measurements enabling extended process control What is the approach taken and technology used for the Smart Factory platform at VCST?
  22. 22. 23 23 MATERIAL TRACEABILITY
  23. 23. 24 24 MATERIAL GENEALOGY RAW Component A (Semi) Finished Component B Material Supplier Batch Boxnr
  24. 24. 25 25 CLOSED LOOP QUALITY
  25. 25. 26 AD ULTIMA’S PROJECT DRIVERS ❑ Introduced MVP approach ❑ Trained VCST to secure upscaling ❑ PLM/ERP/MES experience linked to MDM ❑ Match requests to ISA-95 model and MES “light” “Agile” Bring instant value in the Factory “Future proof” Build platform based on industry standards “Smart” Continuously designed “Smart Factory” proof ❑ Process design starting from Machine data ❑ “Closed loop” thinking
  26. 26. 27 WHICH APPROACH TO CHOOSE? MES Application Industrial IOT Platform Works well for “greenfield” implementation and when processes will not change much over time Brownfield implementation requires flexibility to fully support mature shopfloor processes Transactions based logic focusses on optimal processes Data (“Thing”) centric allows for a “Smart” approach linking in to processes Integration is often tied to specific limitations (data and UX level) depending on vendors product strategy Easy integration to business systems like ERP, PLM, … Easy access to UX devices (handhelds, wearables, …) Customization can be time and cost consuming. Risk of lock-in. Low-code platform allows for balanced level of ownership
  27. 27. 28 • Increase overall efficiency in the organization by E2E approach and de- ”Silo”… • Reduce operational costs by tracing the behavior of the machines and tools real-time. • Reduce MTTR and OEE losses • Time to implement a change – 25% anticipated • Scalable – VCST / Division / Group TARGETED BENEFITS
  28. 28. 29 WHAT’S NEXT?
  29. 29. 30 • Further develop machine & Q-device connectivity • Use power of PTC suite – Creo: 3D models with MBD – Windchill “full”: optimize engineering process – Vuforia: Expert capture – Chalk: remote support plants (accelerated through COVID-19) • Connect to the Smart Factory platform – Automated warehouse – AMR/AGV – Customer/ Supplier data WHAT’S NEXT
  30. 30. 31 DIGITAL TRANSFORMATION WITH PTC
  31. 31. 32 ENTERPRISE EFFICIENCY WITH DIGITAL TRANSFORMATION CREATE A COMPREHENSIVE DIGITAL THREAD WITH PTC Unlock double digit value from digital engineering, to smart manufacturing with connected solutions that deliver impact, speed, and scale
  32. 32. 33 A CONNECTED ENTERPRISE WITH PTC CLOUD | HYBRID | ON-PREM Requirements, Systems & Software SIMULATION MFG SUPPLIERS CUSTOMERS Source Data MBSE Authoring Tools REQ & TEST Lifecycle Management including XBOMs, Documents, Variability, Change & Configuration Management, 3D Mockup, RAMS, Technical Documentation Spare Part Management Test and Validations Device Cloud Physical Product ERP MES MRO CRM … … Crosscutting Link & Context Extended PLM ROLE & TASK BASED APPLICATIONS Enterprise Roles Engineering Manufacturing Procurement Configuration Manager PLM Expert Sales Service Others… Sourcing ENTERPRISE DOMAIN APPLICATIONS PLATFORM Extend the PLM: Source - Contextualize - Synthesize - Orchestrate - Engage
  33. 33. 34 WANT TO LEARN MORE? CHECK OUT THESE GREAT RESOURCES: LNS Research Spotlight: Transforming Frontline Operations with Augmented Reality The PLM Deployment Handbook Report: Increase the Asset & Machine Efficiency of your Hidden Factory
  34. 34. 35 QUESTIONS? Tim POLLEUNIS Manager Smart Factory VCST Industrial Products Dirk LUWAERT Enterprise Solution Architect Manufacturing Industry AdUltima Group Jordan CHAISSON Senior Manager, Connected Operations Solutions PTC
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