transforming operation strategies with mom and isa-95 standards
DESCRIPTION
Global competitiveness requires increasing manufacturing agility while maintaining quality, production performance and on-time shipments. To meet these needs market leading companies incorporate ISA-95 Maturity Models as a core strategy to improve agility. The strategy depends on manufacturing intelligence solutions to deliver role specific reporting to support decision making and enable people to take process ownership and drive manufacturing transformation through maturity levels from ad-hoc operations to continuous improvement: • Level 1: Ad-hoc Operations • Level 2: Planning and Control • Level 3: Standardized Processes • Level 4: Predictable Performance • Level 5: Continuous Improvement For over fifteen years ISA-95 has been the standard to model these processes. Maturity Models map the manufacturing transformation strategy that integrates real-time process systems with the supply chain as a business and operational strategy to drive operational excellence. Rod Parry explains how to use Maturity Models to develop a Manufacturing Transformation Strategy to achieve the flexibility, agility and process optimization required for global competitiveness. These strategies enable companies to deploy these cohesive strategies for operations excellence. Presenter: Rod Parry is the Managing Director at Factory IQ a consulting practice in manufacturing operation management, MES systems and energy that integrates ISA standards, IT, vendor systems and a common information model to connect the manufacturing plant with the supply chain and ERP systems. Rod is currently chair of the MESA Metrics Reference Model working group. Mr. Parry is a thirty year veteran developing and integrating MOM/MES and process automation with enterprise applications. Prior to founding FactoryIQ, he held positions at Intel, Microsoft and MCS Technology. http://www.nwasoft.com/resources/webinars/transform-operations-strategies-deliver-more-agility-flexibility-isa-95-maturity-TRANSCRIPT
© Copyright 2010 - Factory IQ
Monitoring Facilities and Energy Assets with Real Time Intelligence and Analytics
Transforming operation strategies to deliver more
agility & flexibility using an ISA-95 Maturity Model
Rod Parry
Managing Director
Factory IQ
MCP, PMP, CSSBB
Office: 503-530-8740
BIO & Background
Monitoring Facilities and Energy Assets with Real Time Intelligence and Analytics
28 Years – 100 Plants - 200 Projects
• Business and Operations Strategy
• Engineering
• Plant Operations and Maintenance
• Plant-wide Systems
• MES/MOM Systems integrated with Process
Automation
Agenda
Monitoring Facilities and Energy Assets with Real Time Intelligence and Analytics
1. Global Competition in the Supply Chain
2. Gaps with Supply Chain Planning & Logistics
3. Gaps with Manufacturing Plant Operations
4. Culture change with Operational Excellence
5. Mapping the Gaps with to the Business Strategy
and Operation Strategies.
6. Introducing MOM, ISA-95 Standards and the
Manufacturing Maturity Model.
7. New adaptable architectures to support legacy
systems.
8. Metrics, Costs, and Scorecards.
Competing Globally
Monitoring Facilities and Energy Assets with Real Time Intelligence and Analytics
1. Global Competition is Fierce.
2. Managing Customers and delivering products is complex.
3. Variability with SOP Planning and Forecasting Demand.
4. Fluctuations in demand with seasonality, promotions, trends,
cycles.
5. Warehousing & Distribution, Fulfillment, On-Time Delivery.
6. Planning manufacturing capacity, resources, equipment, people.
7. Manufacturing Operations – inventory, WIP, metrics, cycle / down
time, setups.
8. Product Definition, production efficiency, dispatching, quality, &
maintenance.
9. Corporate governance, regulations and reporting.
Supply Chain Gaps
Monitoring Facilities and Energy Assets with Real Time Intelligence and Analytics
1. Large increase in product variants by region and season
2. Much shorter new product development and time-to-volume (TTV)
cycle times
3. Increasing and wide demand forecast errors
4. Diverse global regulatory and customer compliance requirements
5. Competition = continuous cost reduction
6. More dynamic supply networks
Monitoring Facilities and Energy Assets with Real Time Intelligence and Analytics
Business Drivers Impacting Manufacturers
© 2010 Gartner, Inc. and/or its Affiliates. All Rights Reserved.
Which business drivers are most important to overall success of your organization?
Monitoring Facilities and Energy Assets with Real Time Intelligence and Analytics
Business Drivers Impacting Manufacturers
© 2010 Gartner, Inc. and/or its Affiliates. All Rights Reserved.
Monitoring Facilities and Energy Assets with Real Time Intelligence and Analytics
Silo
Silo
Silo
Silo
Silo
Silo Silo
Manufacturing Gaps – No Visibility
Monitoring Facilities and Energy Assets with Real Time Intelligence and Analytics
Driving Operation Excellence with People
Transformation
Monitoring Facilities and Energy Assets with Real Time Intelligence and Analytics
ISA-95 Model
Monitoring Facilities and Energy Assets with Real Time Intelligence and Analytics
ISA-95 Operation Models
Monitoring Facilities and Energy Assets with Real Time Intelligence and Analytics
Manufacturing Operation Information Models
Production
Operations
Maintenance
Operations
Quality
Operations
Schedule
Information
Definition
Information Capability
Information
Performance
Information
Production Schedule
Maintenance Schedule
Quality Test Schedule
Product Definition Information
Maintenance Definition Information
Quality Definition Information
Production Performance
Maintenance Performance
Quality Test Performance
Production Capability Information
Maintenance Capability Information
Quality Capability Information
Visualizing Information
Monitoring Facilities and Energy Assets with Real Time Intelligence and Analytics
Process Workflow
Monitoring Facilities and Energy Assets with Real Time Intelligence and Analytics
Process Islands
Connected Systems
Manual
Orchestrated Processes
Benefits: Examples
Monitoring Facilities and Energy Assets with Real Time Intelligence and Analytics
1. Increasing production visibility from 15 days to less than a minute.
2. Decreased manufacturing cycle time – example: 23.5 days to 4 days.
3. Increasing material and production throughput.
4. Increased Finished Goods and Production Capabilities.
5. Increased Capacity and ability to take on more demand.
6. Improved overall equipment effectiveness.
7. Reduced inventories.
8. Increased employee productivity.
9. Reduced work order fulfillment lead time from two weeks to two days
10. Improving customer response and service.
ISA-95 Operation Production Flows
Monitoring Facilities and Energy Assets with Real Time Intelligence and Analytics
ISA-95 Model
Monitoring Facilities and Energy Assets with Real Time Intelligence and Analytics
Production data
collection
Production execution
management
Production resource
management
Production dispatching
Production tracking
Production performance
Detailed production scheduling
Production schedule
Product definition
management
Production level 1-2 functions
Production performance
analysis
Production capability
Product definition
Equipment and process specific production rules
Equipment and process specific data
Operational responses
Operational commands
ISA-95 Standards Based
Manufacturing Systems
Monitoring Facilities and Energy Assets with Real Time Intelligence and Analytics
Equipment Capability
Equipment Specification
Equipment Requirement
Equipment Segments
Equipment Actual
Consumable Expected
Consumable Actual
Material Capability
Material Segment
Material Specification
Material Produced Requirement
Material Consumed Requirement
Material Produced Actual
Material Consumed Actual
Personnel Capability
Personnel Segment Capability
Personnel Specification
Personnel Segments
Personnel Requirement
Personnel Actual
Site
Area
Product segments
Process segments
Equipment Units
Equipment Operations
Material Operations
Routes
Transformations
Process Workflow
Monitoring Facilities and Energy Assets with Real Time Intelligence and Analytics
Process Work Cell
Operations Management
A orchestrated sequence of manual and equipment
operations performed for material transformations
Execution: Compliant, Traceable, and Validated
States,
Events,
Alarms, KPIs
Recipes
Changeovers
Fixtures, Kits Equipment
Ou
tgo
ing
QA
Te
st
Manual
Operations
Operation N ….
Operation 2
Tooling Mgmt.
SOPs, Work
Instructions
Inc
om
ing
QA
Te
st
Consumed
Materials
In Materials Out
Materials
QA Data QA Data
Genealogy Genealogy
Tooling
Inventory
Operations Request:
Definitions/ Rules
Operations Performance:
Actual/ Alerts/
Alarms/ Triggers
Operation 1
Equipment
Interface
Existing Legacy Systems
Monitoring Facilities and Energy Assets with Real Time Intelligence and Analytics
Legacy 10-20 years
Disconnected Vendor
Systems
SCADA/HMI
Recipe & Batch
Historians
Legacy Databases
Old PLC’s, Controllers
Proprietary OEM sys.
2D Barcodes
Vendor Drivers
Proprietary Systems
Windows NT, 95, VMS,
Unix, etc.
Excel, Access
Manufacturing Service Buss
Monitoring Facilities and Energy Assets with Real Time Intelligence and Analytics
New MOM Approach
Monitoring Facilities and Energy Assets with Real Time Intelligence and Analytics
Reusable services
enable a nimble IT
infrastructure that
adapts to meet changing
business needs
Reusable building blocks
… allows decomposition of
applications into services
Dashboards & Reporting
Monitoring Facilities and Energy Assets with Real Time Intelligence and Analytics
New MOM 2.0 Approach
Monitoring Facilities and Energy Assets with Real Time Intelligence and Analytics
Business Process 1 Business Process 2
… …
IT
Component IT IT IT
IT
IT IT IT IT IT
Business
Service
Business
Service
Business
Service
Business
Service
Business
Service
Business
Service
Business
Service
Business
Service
Change
these
without
impacting
these
Change
these
without
redeveloping
these
courtesy of
New MOM 2.0 Framework Approach
Monitoring Facilities and Energy Assets with Real Time Intelligence and Analytics
7
6
Business processes are optimized, changed,
scaled based on quantitative feedback
Foundation framework assures repeatable content for business processes with consistent delivery at all sites without ‘hand-carving’ implementations
a)Measure/manage effectiveness of key bus processes
b)Measure/manage effectiveness of bus services
OPTIMIZED
REPEATABLE
QUANTITATIVELY
MANAGED 5
1
2
3
4
INITIAL
MANAGED
INTEGRATION
WORKFLOW
EXECUTION
PROCESS
ORCHESTRATION
Application-centric integration architecture centers on enterprise bus and/or select web services
Point-to-point connectivity – No SOA –
No web services
Business processes interpreted and managed on
a central resource, e.g. rules engine
Business processes decomposed to activities: Mapped into services or objects and managed by a work flow and execution engine
Mfg 2.0
FRAMEWORK
New MOM 2.0 Framework Approach
Monitoring Facilities and Energy Assets with Real Time Intelligence and Analytics
28
1
2
New MOM 2.0 Work Flows
Monitoring Facilities and Energy Assets with Real Time Intelligence and Analytics
Metrics
Monitoring Facilities and Energy Assets with Real Time Intelligence and Analytics
© 2011, Aberdeen Group. All Rights Reserved.
Metrics and Root Causes
Monitoring Facilities and Energy Assets with Real Time Intelligence and Analytics
16 Wed 07-Mar-2012 Thu 08-Mar-2012 Fri 09-Mar-2012 Sat 10-Mar-2012 Sun 11-Mar-2012 Mon 12-Mar-2012 Tue 13-Mar-2012
OEE 43.11% 28.52% 63.68% 91.98% 49.90% 88.14% 62.90%
Planned Downtime %
Unplanned Downtime % 0.00% 0.00% 7.65% 0.00% 0.00% 2.11% 14.89%
Performance Loss % 56.89% 71.48% 19.85% 8.02% 50.10% 0.00% 22.21%
Quality Loss % 0.00% 0.00% 8.82% 0.00% 0.00% 9.74% 0.00%
Downtime 100.00% 100.00% 91.32% 100.00% 100.00% 97.85% 83.47%
Performance 43.11% 28.52% 77.48% 91.98% 49.90% 100.00% 75.35%
Quality 100.00% 100.00% 90.00% 100.00% 100.00% 90.08% 100.00%
43.11% 28.52% 63.68%
91.98%
49.90%
88.14% 62.90%
-20.00%
0.00%
20.00%
40.00%
60.00%
80.00%
100.00%
120.00%
Daily OEE
OEE Unplanned Downtime % Performance Loss % Quality Loss %
Metrics
Monitoring Facilities and Energy Assets with Real Time Intelligence and Analytics
© 2011, Aberdeen Group. All Rights Reserved.
Thank You !
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Monitoring Facilities and Energy Assets with Real Time Intelligence and Analytics