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
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 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 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 & 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 & 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
Agenda • Manufacturing Industry Trends • Key Challenges • Key Required Capabilities • Solution Overview and Benefits • Summary
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
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 DiversityAcross Organizational & Geographic Boundaries Suppliers Customers Corporate R&D Logistics Operations Asia Labs Operations NA Operations EMEA Operations LA
Standardization is an Ongoing ProgramThe business Case, Methods and Tools Why? How? Benefits What? Scope Organization Standardization Architecture Principles Processes Platforms Deliverables: CorporateStandards
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
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
Manufacturing Partner EcosystemOperational Performance
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
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
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
.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
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
Collaboration In & Beyond Plant
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 Future:PredictingLikely Outcomes,PreventingProblems Present:IndicatingStatus, Issues,Performance Past:Reporting History
Final summary Agenda • Manufacturing Industry Trends • Key Challenges • Key Required Capabilities • Solution Overview and Benefits • Customer Proof Points • Summary
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
