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Microsoft Manufacturing Solutions: Plant Operations. Collaborative Enterprise . Chris Colyer WW Director, Process Manufacturing. Agenda. Manufacturing Industry Trends and Key Challenges Key Required Capabilities Solution Overview and Benefits Summary .

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microsoft manufacturing solutions plant operations

Microsoft Manufacturing Solutions: Plant Operations

Collaborative Enterprise

Chris Colyer

WW Director, Process Manufacturing

agenda
Agenda
  • Manufacturing Industry Trends and Key Challenges
  • Key Required Capabilities
  • Solution Overview and Benefits
  • Summary
operational performance initiatives key manufacturing opportunities have been addressed
Operational Performance InitiativesKey Manufacturing Opportunities Have Been Addressed

Assets

People

Uptime, OEE

Visibility, Role-based Desktops, Flexibility

Processes

Information& Events

Workflow & Business Process Automation

Exchange, Access & Analytics

people enablement heightened realization of roles and context
People EnablementHeightened Realization of Roles and Context
  • Issues
    • Too many systems, applications, concepts, views, …
    • Too much data - insufficient relevant information
  • Improve
    • Productivity
    • Reaction Time
    • Quality of Decisions
  • Strategy: Context
    • Visibility and focus: Aggregate and filter information
    • Roles: Integrate, simplify and optimize user interface
    • Enablement: Role-specific tools and environments
physical assets optimal planning fast reaction eliminating waste
Physical AssetsOptimal Planning, Fast Reaction, Eliminating Waste
  • Issues (information related)
    • Insufficient performance and status information
      • Only local access, no history, …
  • Improve
    • Planning and Utilization
    • Quality
    • Cost
  • Strategies
    • OEE – Overall Equipment Effectiveness
    • Aggregate & share performance information
    • Drill-down analysis
    • … Design-Operate-Maintain Interoperability
business processes workflow one form of knowledge how things get done
Business Processes & WorkflowOne Form of Knowledge - How Things Get Done
  • Issues
    • Not defined, manual, …
    • Sustained improvement is difficult
    • New compliance challenges require change
  • Improve
    • Consistency
    • Speed
    • Visibility
  • Strategies
    • Analyze and plan from a process perspective
    • Document existing processes
    • Automate workflow (integrate) - e.g. schedule, actuals, …
    • … Flexibility
information events knowledge understanding insight
Information & EventsKnowledge, Understanding, Insight, …
  • Issues
    • Rapidly growing data stores
    • Locked within applications, domains, manual exchanges
    • Confidentiality, compliance, security, …
  • Improve
    • Management
    • Access, visibility & utilization
    • Create knowledge & understanding
  • Strategies
    • Integrate, aggregate, federate, … filter, present
    • Application specific analytics
    • Analytic tools
agenda8
Agenda
  • Manufacturing Industry Trends
  • Key Challenges
  • Key Required Capabilities
  • Solution Overview and Benefits
  • Summary
isa 95 functional hierarchy
ISA-95 Functional Hierarchy

Level 4

Business Planning & Logistics

ERP

Quality

Maintenance

Manufacturing Visibility

Manufacturing

Execution

Level 3

Manufacturing

Operations & Control

MES

Levels

2,1,0

Manufacturing Control Systems

Batch

Control

Continuous

Control

Discrete

Control

Control

enterprise applications integrated with plant operations

Customer Relationship Management (CRM)

Control Systems, DCS and Automated Equipment

Enterprise Asset Management (EAM/SAM)

Shipping/Receiving Materials Handling

Supply Chain Management (SCM)

Production Control/MES

Business Intelligence and

Enterprise PerformanceManagement

Plant Operations

SCADA and HMI

Enterprise Resource Planning (ERP)

Quality Management

Plant Floor Visibility Enterprise ManufacturingVisibility

Laboratory Information Management

Product Lifecycle Management (PLM)

Document Management Regulatory Affairs EH&S

Missing Link: Plant Operations Impact on Results Inventory, Processes, Orders, Resources, Status, Downtime, Products, Lab Results, Exceptions

Enterprise Applications Integrated With Plant Operations
standardization reduce diversity across organizational geographic boundaries
Standardization Reduce DiversityAcross Organizational & Geographic Boundaries

Suppliers

Customers

Corporate

R&D

Logistics

Operations Asia

Labs

Operations NA

Operations EMEA

Operations LA

standardization is an ongoing program the business case methods and tools
Standardization is an Ongoing ProgramThe business Case, Methods and Tools

Why?

How?

Benefits

What?

Scope

Organization

Standardization

Architecture

Principles

Processes

Platforms

Deliverables: CorporateStandards

agenda13

So far, we have sold the Pain, the required

  • capabilities to address the pain
  • Now we should highlight how the Microsoft
  • and Microsoft Partner solutions enable the
  • required capabilities,
  • and address the WHY MICROSOFT question
Agenda
  • Manufacturing Industry Trends
  • Business Challenges
  • Key Requirements/Enablers
  • Solution Overview and Benefits
  • Summary
microsoft s plant floor visibility pillars

EnterpriseBusinessProcesses

Enterprise

ManufacturingVisibility

Collaboration

Integration

Analytics

Security

Infrastructure

PlantOperations

  • More on the solution
Microsoft’s Plant Floor Visibility Pillars

Integration– aggregating data from various sources and interoperating between groups

Analytics – converting aggregated data into information

Collaboration – sharing the right information with the right people at the right time

plant floor to enterprise integration with microsoft technologies

Enterprise Systems

HR

FIN

SCM

CRM

Manufacturing Execution

Systems

SQL 2005 IS

HIS

MSMQ

Inventory,

Labor,

Maintenance

Quality

SQL 2005 SSB

Products, BOMs,

Routings, Recipes,

Procedures

Plans,

Schedules

Information Bridge Framework

HMI / SCADA / Cell Controllers

Alarms &

Events

History

Production & Process Data

Indigo

(WS)

Automation & Control Systems –

DCS / PLC / LIMS

Tags

Variables

Data Points

BizTalk

Plant Floor to Enterprise Integration with Microsoft Technologies
slide17

1996-FutureSCOR Make

Model &Metrics

2002-Future

WBF

B2MML

XML Schemas

1994-FutureOAGISXML Bus. ObjDocs/Msgs

Manufacturing Integration Standards Timeline

1995-2001

OPC

DeviceConnectivity

1988-2003

ISA SP88

BatchControl

1997-Future

ISA 95

Enterprise

-Control SI

2005-Future

ISA, WBFOAGIS

Unify models

Integration Progress in ManufacturingStandards boost interoperability over time.Multiple vendors build to standards

Integration

slide18

OAGIS BOD

SAP API

Solumina API

OAGIS BOD

PILOT SCENARIOSSAP Integration Discussed

MES Apps

  • Part Numbers to CAPP from ERP
  • Bill of Material to CAPP  from ERP
  • Master Routing from CAPP to ERP 
    • Support part families
  • Issue Production Order from ERP to SF MES 
    • Work Order Header 
    • Make part serial assignment, if required, assigned in SAP in the beginning
    • Work Order Operation Detail
      • Work Center and Schedule Assignment, etc
    •  Material/component list (reference to BOM)
  • Material/component issue to MES Work Order (serialized)      
  • Operation Complete SF MES to ERP    
  • Work Order Status SF MES to ERP 
    • Qty Complete, Qty Reject
  • Distributed Labor from T&A to ERP

OAGIS BOD

NetWeaver XI

iDOC/RFC/BAPI

SAP Web Service

SAP R/3 ERP

slide19

.Net Apps

IBM Apps

Solumina/AT

OAGIS BOD

SAP API

Adapter

Adapter

Solumina API

OAGIS BOD

XML Msg

XML Msg

PILOT ROADMAPNPD Facility

Defined to support NPD Windows 2003 platform and application architecture

OAGIS BOD

BizTalk

Message Handling

Business Process Mgmt

OAGIS BOD

NetweaverXI

BizTalkmySAP Adapter

iDOC/RFC/BAPI

SAP Web Service

iDOC/RFC/BAPI

.NET Connector

SAP R/3 ERP

collaboration in manufacturing with microsoft technologies

Enterprise Systems

HR

FIN

SCM

CRM

Manufacturing Execution

Systems

Inventory,

Labor,

Maintenance

Quality

Products, BOMs,

Routings, Recipes,

Procedures

Plans,

Schedules

HMI / SCADA / Cell Controllers

InfoPath

Alarms &

Events

History

Production & Process Data

Automation & Control Systems –

DCS / PLC / LIMS

Tags

Variables

Data Points

Collaboration in Manufacturing with Microsoft Technologies

Enterprise Content

Management

SharePoint Portal

Automation & Workflow

Presence & Real Time

Communication with LCS

manufacturing intelligence with microsoft technologies

Enterprise Systems

HR

FIN

SCM

CRM

Office Business

Scorecard Mgr

Manufacturing Execution

Systems

Strategic

SQL 2005

Reporting Services

SQL 2005

Analysis Services

SQL 2005

Integration Services

Inventory,

Labor,

Maintenance

Quality

Products, BOMs,

Routings, Recipes,

Procedures

Plans,

Schedules

Tactical

Excel Add-in

SQL / AS

HMI / SCADA / Cell Controllers

Alarms &

Events

History

Operational

Production & Process Data

Automation & Control Systems –

DCS / PLC / LIMS

Tags

Variables

Data Points

Manufacturing Intelligence with Microsoft Technologies
analysis for history current future
Analysis for History, Current, Future

Future:PredictingLikely Outcomes,PreventingProblems

Present:IndicatingStatus, Issues,Performance

Past:Reporting

History

agenda24

Final summary

Agenda
  • Manufacturing Industry Trends
  • Key Challenges
  • Key Required Capabilities
  • Solution Overview and Benefits
  • Customer Proof Points
  • Summary
plant operation improvements
Plant Operation Improvements
  • Visibility: “You cannot improve what you cannot see” Dr. Deming
  • Improved Yield/Throughput
  • Regulatory Compliance
  • Efficiency & Lower Costs
  • Consistent Product Quality
  • Inventory Management & WIP reduction
  • Manufacturing Performance Visibility
  • Flexibility/Agility – Demand Driven” Operation