speakers michael ford

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


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


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



•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.



•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


•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

https://info.aiscorp.com/free-consultation

The Digital Operator Cockpit: Human 4.0

Agenda


Have things really changed? The Rise of Electronic Work-Instructions The Untethered Operator


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


Thank You


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?


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

https://info.aiscorp.com/free-consultation

Visit www.aiscorp.com to learn more.

http://www.aiscorp.com/

speakers michael ford

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