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- 1. C O N N E C T E V E R Y T H I N GC O N N E C T E V E R Y T H I N GC O N N E C T E V E R Y T H I N G CONNECT EVERY THING Kyle Goodmanson Account Manager, EAC December 8th 2020 Cadence Inc
- 2. 22 AGENDA 2 AGENDA • Introductions • Current State • Desired State • Solution Overview • Next Steps
- 3. C O N N E C T E V E R Y T H I N GC O N N E C T E V E R Y T H I N GC O N N E C T E V E R Y T H I N G Our Business… The Companiesway Design, Manufacture, Service, and Connect to Products.their Built around
- 4. C O N N E C T E V E R Y T H I N GC O N N E C T E V E R Y T H I N GC O N N E C T E V E R Y T H I N G The EAC Value Model • About you • About us • Business Initiatives • People, Process, Team, & Tools • Plan • Deliverables • Business Case • Measures • Accountability • Problem Solve • Process Improvement • Install/Configure • Educate • Design & Develop • Learn, LEAN, Optimize • Go! • Measure • Validate • Get it right Learn M.A.P Implement Score Card
- 5. C O N N E C T E V E R Y T H I N GC O N N E C T E V E R Y T H I N GC O N N E C T E V E R Y T H I N G Current State • Primarily Support Med Dev OEMs • Secondary Markets: Aerospace & Automotive OEMs • Five Factories (VA, RI, PA, WI, CT) • 4 running Visual, 1 running Global Shop for ERP • Instances of Automation • Maturity 5/10 • Limited IoT Connectivity • Maturity 1/10
- 6. C O N N E C T E V E R Y T H I N GC O N N E C T E V E R Y T H I N GC O N N E C T E V E R Y T H I N G Future State • Accelerated IoT Across 5 Facilities • Connection & Analytics • Implement Data Warehouse • Need for Consolidation/Standardization of Data & Analytics • Growth via Acquisition • Plan to Implement Master Control for QMS
- 7. C O N N E C T E V E R Y T H I N GC O N N E C T E V E R Y T H I N GC O N N E C T E V E R Y T H I N G Engineering, Analysis, Strategy & Design Services Performance Tuning CAD, PLM, SLM, AR, and IoT Data Conversion and Migration Business Assessments/Process Improvement PTCU Instructor or Virtual Training Software Installation & Customization System Integration & Administration Our Offerings
- 8. C O N N E C T E V E R Y T H I N GC O N N E C T E V E R Y T H I N GC O N N E C T E V E R Y T H I N G IoT & AR Capabilities Solution Suite Guidance • From present state to desired • Future IoT enabled state: SCO,SCP, & AR Engineering & Implementation Services Full Breadth of PTC ThingWorx and Vuforia Platforms Consulting & Workshops Proof of Concept Pilot Development
- 9. C O N N E C T E V E R Y T H I N G Purpose-Built for Industrial Innovation Quickly Create & Deploy Industrial Apps & AR Experiences Wrap & Extend Existing Technology Agile & Flexible Expansive Ecosystem
- 10. C O N N E C T E V E R Y T H I N G 10 Digital Manufacturing - No Regret Use Cases ASSETS | PEOPLE | PROCESSES Asset Optimization Combine asset awareness and machine analytics to begin a predictive maintenance journey Real-time Production Performance Monitoring Aggregating disparate data streams to make more powerful decisions immediately. Digital Shift Hand-off Eliminates procedural gaps with a platform and process which unites across batches, products, shifts & facilities Connected Work Cell Bringing automation & quality control to shop floor operations. Implementing a Digital Thread tying together manufacturing back to design
- 11. C O N N E C T E V E R Y T H I N GC O N N E C T E V E R Y T H I N GC O N N E C T E V E R Y T H I N G 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 Future State L3 Visual Factory for MES and work instruction L2 L1 IoT sensors, CNC machines and gateways L4/L5 Epicor ERP/MRP ISA-95 IOT GATEWAY CNC Machine IOT GATEWAY CNC Machine Operations Scheduling/Purchasing Quality FactoryWiz for CNC scheduling and programming
- 12. C O N N E C T E V E R Y T H I N GC O N N E C T E V E R Y T H I N GC O N N E C T E V E R Y T H I N G Pfizer’s IIoT Digital Transformation 5 SITES ADOPTED 12 SOLUTIONS DEPLOYED 3 REGIONS IMPACTED OF THE THINGS INDUSTRIA LINTERNE T 18 Months
- 13. C O N N E C T E V E R Y T H I N GC O N N E C T E V E R Y T H I N GC O N N E C T E V E R Y T H I N G Pfizer’s IIoT Digital Transformation 5 SITES ADOPTED 12 SOLUTIONS DEPLOYED 3 REGIONS IMPACTED OF THE THINGS INDUSTRIA LINTERNE T 18 Months Increased Visibility Reduced Emissions Reduced Energy Consumption Better Decision Making Improved Equipment Reliability & Uptime Improved Product Quality
- 14. C O N N E C T E V E R Y T H I N GC O N N E C T E V E R Y T H I N GC O N N E C T E V E R Y T H I N G o Condition, Run-time & Predictive Maintenance o Real-Time Process Condition Monitoring o Process Robustness Analytics o OEE, RTE o Energy Monitoring & Optimization o Artificial Intelligence (AI) & Machine Learning (ML) o Digital Twin Control LAN Manufacturing LAN DMZ Process Control Equipment Process Control Equipment Line2Line1 Operational Shop Floor Processes Fundamental to Our Digital Strategy is Our Ability to Access Shop Floor Equipment Data in Real-Time Unlocking Operational Technology Data IIoT PlatformData Historian Real-Time Aggregation of Operational Data in Context Real-Time Advanced Analytics
- 15. C O N N E C T E V E R Y T H I N GC O N N E C T E V E R Y T H I N GC O N N E C T E V E R Y T H I N G Real-Time Process Monitoring • Immediate and exact visibility into plant operations Energy Performance Management • Executed scheduling changes, which saved energy Reliability Engineering • Reduction in unplanned downtime, emergency maintenance What value did Pfizer see?
- 16. C O N N E C T E V E R Y T H I N GC O N N E C T E V E R Y T H I N GC O N N E C T E V E R Y T H I N G 16 of industrial companies are investing in digital factories 91% of the 2,000 largest manufacturers will rely on digital platforms as the foundation for their industrial ecosystems by 2020 60% of all technology spending will go towards digital transformations40%TRANSFORMATION… In a world where your success hinges on
- 17. C O N N E C T E V E R Y T H I N GC O N N E C T E V E R Y T H I N GC O N N E C T E V E R Y T H I N G Increase Asset Efficiency Support Revenue Growth Reduce Operational Costs Manufacturing Objectives Haven’t Changed
- 18. C O N N E C T E V E R Y T H I N GC O N N E C T E V E R Y T H I N GC O N N E C T E V E R Y T H I N G Our Mission
- 19. C O N N E C T E V E R Y T H I N GC O N N E C T E V E R Y T H I N GC O N N E C T E V E R Y T H I N G Digital Journey Digitization Connectivity Visibility Understanding Predictive Capacity Optimization
- 20. C O N N E C T E V E R Y T H I N GC O N N E C T E V E R Y T H I N GC O N N E C T E V E R Y T H I N G
- 21. C O N N E C T E V E R Y T H I N GC O N N E C T E V E R Y T H I N GC O N N E C T E V E R Y T H I N G Other PLC/sensor/device Azure IoT Hub Other IIoT/Cloud On-premises apps (SCADA, MES) Third-Party RESTful Client TCP/IP
- 22. C O N N E C T E V E R Y T H I N GC O N N E C T E V E R Y T H I N GC O N N E C T E V E R Y T H I N G
Notes de l'éditeur
- Business Assessments/Process Improvement Software Installation and Customization System Integration and Administration PTCU Instructor or Virtual Training Engineering, Analysis, and Design Services Performance Tuning Data Conversion and Migration CAD, PLM, SLM, AR, and IoT
- Presented at LiveWorx 2019 (Enabling a Digital Plant – How Pfizer Manufacturing Sites are Leveraging IIoT to Transform Operations): https://ptcliveworx.app.box.com/s/tm55i2dsaowg569j1uyidudc08d1ikoc/file/484994405002 PPT notes: START WITH A VISION The IIoT Program was created with a goal of modernizing Pfizer’s global manufacturing operations, applying IoT to enable: Better Decision Making Improved Equipment Reliability & Uptime Reduced Energy Consumption Improved Product Quality Increased Visibility Reduced Emissions Execute pilot programs: Worked globally to identify high value opportunities that would be scalable & replicable ◊ Created 4 workstreams across: – Production & Quality Operations – Predictive Maintenance – Energy Performance & Optimization – Digital Plant ◊ Prioritized efforts using Weighted Shortest Job First (WSJF) to maximize economic benefit ◊ Delivered pilots – continuously learning and scaling up for the future ◊ Implemented Scaled Agile Framework (SAFe) to accelerate deployments and plan together with business stakeholders KEY LEARNINGS FROM PILOTS Importance of Business Partnership Advanced Analytics Drive Value All About The Data Focus on User Centric Design and Overall Experience Get ready for battle Top Down Alignment on Digital Priorities Creates Buy in • Accessing Securely • Contextualizing • Data Integrity • Augmenting with sensors • Be prepared for questions • Understand your architecture & security standards • Be resilient! You will be challenged • Aligned priorities • Critical to value creation • Identification of high value opportunities • Unified front SUCCESS TO DATE IIoT program has been expanded through a systematic approach, partnering with key site leadership and global teams to…… ✓ Build a fully connected plant by deploying leading edge technologies (IoT, AI, soft sensors, augmented reality, etc.) ✓ Harness the power of data to drive real time decision making ✓ Implement the use of Machine Learning to eliminate future failure points, provide pre-emptive alerting and drive manufacturing efficiencies Improved product yield Minimized product loss Reduced energy cost Increased asset utilization HIGHLIGHTS OF IIOT PROGRAM Real-time Process Monitoring: Scope of solutions: Process Parameter visibility and consolidation | process monitoring with predictive analytics | process monitoring through risk identification Solution breakdown - Real time data availability: Real-time visibility and predicted process performance Reduced time investigating process variability Improved product yields Improved product quality Energy performance management: Scope of solutions: Energy consuming system availability | Energy producing system availability | Batch, equipment, and process energy variance visibility Solution breakdown – Energy process and utilities monitoring: Energy consumption by batch and process step Real-time utility production system monitoring and alerting Improved response time for energy saving opportunities / issues Energy savings from effective scheduling of equipment Golden batch to baseline across production campaigns Reliability engineering: Scope of solutions: Equipment efficiency monitoring | Predictive maintenance technologies | Machine learning and predictive analytics using equipment data Solution breakdown – Equipment Predictive Monitoring: Improved OEE through increased equipment availability Reduction of unplanned downtimes Reduction in emergency maintenance costs Continuous online monitoring of critical assets via IoT sensors
- Presented at LiveWorx 2019 (Enabling a Digital Plant – How Pfizer Manufacturing Sites are Leveraging IIoT to Transform Operations): https://ptcliveworx.app.box.com/s/tm55i2dsaowg569j1uyidudc08d1ikoc/file/484994405002 PPT notes: START WITH A VISION The IIoT Program was created with a goal of modernizing Pfizer’s global manufacturing operations, applying IoT to enable: Better Decision Making Improved Equipment Reliability & Uptime Reduced Energy Consumption Improved Product Quality Increased Visibility Reduced Emissions Execute pilot programs: Worked globally to identify high value opportunities that would be scalable & replicable ◊ Created 4 workstreams across: – Production & Quality Operations – Predictive Maintenance – Energy Performance & Optimization – Digital Plant ◊ Prioritized efforts using Weighted Shortest Job First (WSJF) to maximize economic benefit ◊ Delivered pilots – continuously learning and scaling up for the future ◊ Implemented Scaled Agile Framework (SAFe) to accelerate deployments and plan together with business stakeholders KEY LEARNINGS FROM PILOTS Importance of Business Partnership Advanced Analytics Drive Value All About The Data Focus on User Centric Design and Overall Experience Get ready for battle Top Down Alignment on Digital Priorities Creates Buy in • Accessing Securely • Contextualizing • Data Integrity • Augmenting with sensors • Be prepared for questions • Understand your architecture & security standards • Be resilient! You will be challenged • Aligned priorities • Critical to value creation • Identification of high value opportunities • Unified front SUCCESS TO DATE IIoT program has been expanded through a systematic approach, partnering with key site leadership and global teams to…… ✓ Build a fully connected plant by deploying leading edge technologies (IoT, AI, soft sensors, augmented reality, etc.) ✓ Harness the power of data to drive real time decision making ✓ Implement the use of Machine Learning to eliminate future failure points, provide pre-emptive alerting and drive manufacturing efficiencies Improved product yield Minimized product loss Reduced energy cost Increased asset utilization HIGHLIGHTS OF IIOT PROGRAM Real-time Process Monitoring: Scope of solutions: Process Parameter visibility and consolidation | process monitoring with predictive analytics | process monitoring through risk identification Solution breakdown - Real time data availability: Real-time visibility and predicted process performance Reduced time investigating process variability Improved product yields Improved product quality Energy performance management: Scope of solutions: Energy consuming system availability | Energy producing system availability | Batch, equipment, and process energy variance visibility Solution breakdown – Energy process and utilities monitoring: Energy consumption by batch and process step Real-time utility production system monitoring and alerting Improved response time for energy saving opportunities / issues Energy savings from effective scheduling of equipment Golden batch to baseline across production campaigns Reliability engineering: Scope of solutions: Equipment efficiency monitoring | Predictive maintenance technologies | Machine learning and predictive analytics using equipment data Solution breakdown – Equipment Predictive Monitoring: Improved OEE through increased equipment availability Reduction of unplanned downtimes Reduction in emergency maintenance costs Continuous online monitoring of critical assets via IoT sensors
- Presented at LiveWorx 2019 (Enabling a Digital Plant – How Pfizer Manufacturing Sites are Leveraging IIoT to Transform Operations): https://ptcliveworx.app.box.com/s/tm55i2dsaowg569j1uyidudc08d1ikoc/file/484994405002 PPT notes: START WITH A VISION The IIoT Program was created with a goal of modernizing Pfizer’s global manufacturing operations, applying IoT to enable: Better Decision Making Improved Equipment Reliability & Uptime Reduced Energy Consumption Improved Product Quality Increased Visibility Reduced Emissions Execute pilot programs: Worked globally to identify high value opportunities that would be scalable & replicable ◊ Created 4 workstreams across: – Production & Quality Operations – Predictive Maintenance – Energy Performance & Optimization – Digital Plant ◊ Prioritized efforts using Weighted Shortest Job First (WSJF) to maximize economic benefit ◊ Delivered pilots – continuously learning and scaling up for the future ◊ Implemented Scaled Agile Framework (SAFe) to accelerate deployments and plan together with business stakeholders KEY LEARNINGS FROM PILOTS Importance of Business Partnership Advanced Analytics Drive Value All About The Data Focus on User Centric Design and Overall Experience Get ready for battle Top Down Alignment on Digital Priorities Creates Buy in • Accessing Securely • Contextualizing • Data Integrity • Augmenting with sensors • Be prepared for questions • Understand your architecture & security standards • Be resilient! You will be challenged • Aligned priorities • Critical to value creation • Identification of high value opportunities • Unified front SUCCESS TO DATE IIoT program has been expanded through a systematic approach, partnering with key site leadership and global teams to…… ✓ Build a fully connected plant by deploying leading edge technologies (IoT, AI, soft sensors, augmented reality, etc.) ✓ Harness the power of data to drive real time decision making ✓ Implement the use of Machine Learning to eliminate future failure points, provide pre-emptive alerting and drive manufacturing efficiencies Improved product yield Minimized product loss Reduced energy cost Increased asset utilization HIGHLIGHTS OF IIOT PROGRAM Real-time Process Monitoring: Scope of solutions: Process Parameter visibility and consolidation | process monitoring with predictive analytics | process monitoring through risk identification Solution breakdown - Real time data availability: Real-time visibility and predicted process performance Reduced time investigating process variability Improved product yields Improved product quality Energy performance management: Scope of solutions: Energy consuming system availability | Energy producing system availability | Batch, equipment, and process energy variance visibility Solution breakdown – Energy process and utilities monitoring: Energy consumption by batch and process step Real-time utility production system monitoring and alerting Improved response time for energy saving opportunities / issues Energy savings from effective scheduling of equipment Golden batch to baseline across production campaigns Reliability engineering: Scope of solutions: Equipment efficiency monitoring | Predictive maintenance technologies | Machine learning and predictive analytics using equipment data Solution breakdown – Equipment Predictive Monitoring: Improved OEE through increased equipment availability Reduction of unplanned downtimes Reduction in emergency maintenance costs Continuous online monitoring of critical assets via IoT sensors
- What does this investment tell you? 40% of all technology spending is robots, servers, computers, heavy equipment, forklifts etc etc ----------------------------------------------------------- Sources: https://news.aucotec.com/factory-future-digital-13-statistics-know-heading-2018/ IDC https://www.ptc.com/en/product-lifecycle-report/digital-transformation-statistics
- Really, your manufacturing objectives haven’t changed. You want to reduce your operational costs, support revenue growth, and increase asset efficiency. What if I could see exactly where production was limited? What if my antiquated injection molding machines automatically reported their scheduling to ops? What if I could apply analytics to answer what was causing my material defects? Can I sell more widgets by providing a connected, cohesive product for my customer? I’m not getting a new factory tomorrow wrapped up with a bow – so how do I get more miles out of this one?
- Visit https://www.ptc.com/en/case-studies/hirotec to learn about Hirotec’s journey. Webinar link: https://www.youtube.com/watch?v=LFERUIcRNhY Hirotec is a $1.6B global automotive tier1 supplier. They produce 7 million doors and 1.5 million exhaust systems annually. Being an automotive tier1 suppliers puts a lot of pressure on delivery commitment and thus, one of Hirotec’s critical priority is to ensure continuous operations, and to minimize unplanned downtime in its manufacturing facilities. According to industry benchmarks, in North America, the cost of unplanned downtime to automobile OEMs is $1.3M per hour. That’s $361 per second. If it takes a 3 minute phone call to report an issue, you can lose $70,000 just to tell someone you have a problem. They turned to ThingWorx and PTC to get started on their industry 4.0 journey. Within just 6 weeks, they deployed their first pilot and went live with remote real-time visibility into critical manufacturing equipment. They also use ThingWorx for analytics and are looking at augmented reality. SUMMARY Early benefits at Hirotec include a better understanding of what is happening on the shop floor, but automation is the goal Hirotec believes IoT isn’t just about receiving information but making at least automated suggestions if not taking automated action Initial project at CNC machine shop in Detroit - machines of different vintages with different data available and techniques for obtaining data Hirotec has connected eight CNC machines to a server from Kepware that collects data using various protocols and sends it up to the cloud where PTC ThingWorx does the analytics and the data visualization for us Agile aproach - small projects, six-week sprints The next step in North America is to tie this data into our scheduling ERP system so we can start doing real time scheduling of parts to our CNC machines We did evaluate other vendors. We started with our traditional automation partners, Siemens and Rockwell, Mitsubishi, all these companies, and they all have interesting solutions. We also looked at nontraditional suppliers like Microsoft. No one other than PTC, in our opinion, was able to bring this robust ecosystem to the floor Don’t need hardcore professional programmers PTC with ThingWorx and Kepware, because they’re a leader that understands the manufacturing space DETAIL Hirotech has big plans for its IoT effort Early benefits include a better understanding of what is happening on the shop floor, but automation is the goal. And there are organizational implications for IT Hirotec America recently embarked on its first IoT effort and, as new as it is, the effort is already paying dividends. Hirotec is a $1.4 billion tier one parts and tooling supplier to automakers, specializing in closures (such as doors and hoods) and exhaust systems. Hester was instrumental in getting the IoT effort off the ground at the company’s US headquarters in Auburn Hills, Michigan, but has since moved to Japan to work on Hirotec’s global IoT efforts from the company’s global headquarters in Hiroshima. In our opinion, IoT isn’t just about receiving information. IoT really is a closed loop automated system where we’re collecting data from all our devices, whether in our production facility or our customer’s production facility, automatically analyzing the data, automatically tying it to other datasets -- whether they’re public or private -- then making at least automated suggestions if not taking automated action. We knew we couldn’t get there right away, so we started looking at how we could do this in little chunks. What we realized was our CNC shop here in metro Detroit, which is the manufacturing headquarters where we make production tooling we sell to the North American automotive industry, was a perfect area to start -- it has machines of different ages, so we have to connect them differently, and they spit out various data types. And while the machines themselves are very complex, the data we need to collect isn’t very complex. Is the machine running or not? Is the machine being set up or is the machine turned off? Very basic data points that we can pull. So that was a great place to start because it’s a small area, it’s local, it exposes us to variation between machines and it will bring some value to the organization. We’re actually in the midst of the project right now. We are connecting eight CNC machines to a server from Kepware that collects data using various protocols and sends it up to the cloud where PTC ThingWorx does the analytics and the data visualization for us. The idea of small projects, six-week sprints, adding incremental value and providing us with a proof of concept. But one of things we found was that uptime data, cutting data, etc., was available, but not in a usable sense. It couldn’t be consumed in real time with relevant context around it. That’s really where the value is. So even with this small project we’re bringing value to the organization because the data is available in a quick, labor-free or real time fashion. A lot of scheduling in the CNC shop is based on after-the-fact analysis and conjecture. Now we’re going to be able to give our manufacturing leadership real time data on what’s actually happening on the floor, which is helpful in itself, and start giving great data to help streamline schedules and help understand our asset and resource allocation. Do we maybe need to add more resources? Are we overtaxing the resources? You can make those decisions without this tool, but it is harder and not as accurate. The immediate value we can bring is providing that data upfront in real time. And as we continue to grow, we’re going to use that as our basis to add more and more value. The next step in North America is to tie this data into our scheduling ERP system so we can start doing real time scheduling of parts to our CNC machines. If we know when the machines are running and we know how often they can be on and manned, then it’s very easy for a computer to take the hours of the jobs coming in and optimize the schedule. We call Kepware our universal translator. We don’t have to worry about what protocols our machines use, whether it Ethernet/IP, PROFINET, Modbus, DeviceNet, any of those industrial communication protocols. With Kepware, I don’t have to force my machine builders or my production teams to support a certain protocol that might not fit their application. They may have a legacy machine that requires a legacy protocol. They may need high speed communication which requires a different protocol. It’s not our place to make the business conform to the tool. This IoT tool should conform to the business, and that’s where Kepware plays a huge, but behind the scenes, role. In the first project we’re using ThingWorx as a visualization tool to give us this real time look into our CNC shop, but within the next couple of years we’ll potentially be using it to do things like rescheduling the line in real time and for predictive maintenance, telling us a machine is going to break before it breaks, those kinds of things. PTC calls any type of screen you create a mashup because you take these different data types and put them wherever you want on a screen and it does all the hard coding in the background. That’s another thing that drew us to ThingWorx -- I don’t need hardcore professional programmers. I can take engineers or business leaders who understand their section and with limited training they can get what they need out of the system quickly. That was very important to us, because Hirotec’s expertise lies in automotive manufacturing and automotive production. We’re not programming experts. That’s one of the benefits of working with a leader like PTC with ThingWorx and Kepware, because they’re a leader that understands the manufacturing space, and you know they are helping to set some of those standards. We did evaluate other vendors. We started with our traditional automation partners, Siemens and Rockwell, Mitsubishi, all these companies, and they all have interesting solutions. We also looked at nontraditional suppliers like Microsoft. We think of Microsoft as a business software provider, but we looked at them and some of the other major players. They all have great solutions. But no one other than PTC, in our opinion, was able to bring this robust ecosystem to the floor. Everyone had a solution for a portion of our business, but they couldn’t give us that overarching toolset to solve all our problems. Network World interview of Justin Hester, Research & Development Project Manager July 2016 http://www.networkworld.com/article/3098084/internet-of-things/auto-parts-supplier-has-big-pla
- Visit https://www.ptc.com/en/case-studies/hirotec to learn about Hirotec’s journey. Webinar link: https://www.youtube.com/watch?v=LFERUIcRNhY Hirotec is a $1.6B global automotive tier1 supplier. They produce 7 million doors and 1.5 million exhaust systems annually. Being an automotive tier1 suppliers puts a lot of pressure on delivery commitment and thus, one of Hirotec’s critical priority is to ensure continuous operations, and to minimize unplanned downtime in its manufacturing facilities. According to industry benchmarks, in North America, the cost of unplanned downtime to automobile OEMs is $1.3M per hour. That’s $361 per second. If it takes a 3 minute phone call to report an issue, you can lose $70,000 just to tell someone you have a problem. They turned to ThingWorx and PTC to get started on their industry 4.0 journey. Within just 6 weeks, they deployed their first pilot and went live with remote real-time visibility into critical manufacturing equipment. They also use ThingWorx for analytics and are looking at augmented reality. SUMMARY Early benefits at Hirotec include a better understanding of what is happening on the shop floor, but automation is the goal Hirotec believes IoT isn’t just about receiving information but making at least automated suggestions if not taking automated action Initial project at CNC machine shop in Detroit - machines of different vintages with different data available and techniques for obtaining data Hirotec has connected eight CNC machines to a server from Kepware that collects data using various protocols and sends it up to the cloud where PTC ThingWorx does the analytics and the data visualization for us Agile aproach - small projects, six-week sprints The next step in North America is to tie this data into our scheduling ERP system so we can start doing real time scheduling of parts to our CNC machines We did evaluate other vendors. We started with our traditional automation partners, Siemens and Rockwell, Mitsubishi, all these companies, and they all have interesting solutions. We also looked at nontraditional suppliers like Microsoft. No one other than PTC, in our opinion, was able to bring this robust ecosystem to the floor Don’t need hardcore professional programmers PTC with ThingWorx and Kepware, because they’re a leader that understands the manufacturing space DETAIL Hirotech has big plans for its IoT effort Early benefits include a better understanding of what is happening on the shop floor, but automation is the goal. And there are organizational implications for IT Hirotec America recently embarked on its first IoT effort and, as new as it is, the effort is already paying dividends. Hirotec is a $1.4 billion tier one parts and tooling supplier to automakers, specializing in closures (such as doors and hoods) and exhaust systems. Hester was instrumental in getting the IoT effort off the ground at the company’s US headquarters in Auburn Hills, Michigan, but has since moved to Japan to work on Hirotec’s global IoT efforts from the company’s global headquarters in Hiroshima. In our opinion, IoT isn’t just about receiving information. IoT really is a closed loop automated system where we’re collecting data from all our devices, whether in our production facility or our customer’s production facility, automatically analyzing the data, automatically tying it to other datasets -- whether they’re public or private -- then making at least automated suggestions if not taking automated action. We knew we couldn’t get there right away, so we started looking at how we could do this in little chunks. What we realized was our CNC shop here in metro Detroit, which is the manufacturing headquarters where we make production tooling we sell to the North American automotive industry, was a perfect area to start -- it has machines of different ages, so we have to connect them differently, and they spit out various data types. And while the machines themselves are very complex, the data we need to collect isn’t very complex. Is the machine running or not? Is the machine being set up or is the machine turned off? Very basic data points that we can pull. So that was a great place to start because it’s a small area, it’s local, it exposes us to variation between machines and it will bring some value to the organization. We’re actually in the midst of the project right now. We are connecting eight CNC machines to a server from Kepware that collects data using various protocols and sends it up to the cloud where PTC ThingWorx does the analytics and the data visualization for us. The idea of small projects, six-week sprints, adding incremental value and providing us with a proof of concept. But one of things we found was that uptime data, cutting data, etc., was available, but not in a usable sense. It couldn’t be consumed in real time with relevant context around it. That’s really where the value is. So even with this small project we’re bringing value to the organization because the data is available in a quick, labor-free or real time fashion. A lot of scheduling in the CNC shop is based on after-the-fact analysis and conjecture. Now we’re going to be able to give our manufacturing leadership real time data on what’s actually happening on the floor, which is helpful in itself, and start giving great data to help streamline schedules and help understand our asset and resource allocation. Do we maybe need to add more resources? Are we overtaxing the resources? You can make those decisions without this tool, but it is harder and not as accurate. The immediate value we can bring is providing that data upfront in real time. And as we continue to grow, we’re going to use that as our basis to add more and more value. The next step in North America is to tie this data into our scheduling ERP system so we can start doing real time scheduling of parts to our CNC machines. If we know when the machines are running and we know how often they can be on and manned, then it’s very easy for a computer to take the hours of the jobs coming in and optimize the schedule. We call Kepware our universal translator. We don’t have to worry about what protocols our machines use, whether it Ethernet/IP, PROFINET, Modbus, DeviceNet, any of those industrial communication protocols. With Kepware, I don’t have to force my machine builders or my production teams to support a certain protocol that might not fit their application. They may have a legacy machine that requires a legacy protocol. They may need high speed communication which requires a different protocol. It’s not our place to make the business conform to the tool. This IoT tool should conform to the business, and that’s where Kepware plays a huge, but behind the scenes, role. In the first project we’re using ThingWorx as a visualization tool to give us this real time look into our CNC shop, but within the next couple of years we’ll potentially be using it to do things like rescheduling the line in real time and for predictive maintenance, telling us a machine is going to break before it breaks, those kinds of things. PTC calls any type of screen you create a mashup because you take these different data types and put them wherever you want on a screen and it does all the hard coding in the background. That’s another thing that drew us to ThingWorx -- I don’t need hardcore professional programmers. I can take engineers or business leaders who understand their section and with limited training they can get what they need out of the system quickly. That was very important to us, because Hirotec’s expertise lies in automotive manufacturing and automotive production. We’re not programming experts. That’s one of the benefits of working with a leader like PTC with ThingWorx and Kepware, because they’re a leader that understands the manufacturing space, and you know they are helping to set some of those standards. We did evaluate other vendors. We started with our traditional automation partners, Siemens and Rockwell, Mitsubishi, all these companies, and they all have interesting solutions. We also looked at nontraditional suppliers like Microsoft. We think of Microsoft as a business software provider, but we looked at them and some of the other major players. They all have great solutions. But no one other than PTC, in our opinion, was able to bring this robust ecosystem to the floor. Everyone had a solution for a portion of our business, but they couldn’t give us that overarching toolset to solve all our problems. Network World interview of Justin Hester, Research & Development Project Manager July 2016 http://www.networkworld.com/article/3098084/internet-of-things/auto-parts-supplier-has-big-pla
- This is what Hirotec’s future looks like. They were able to connect their machines to a cloud platform, contextualize the CNC data and make improvements to their bottom line opera