Smart Manufacturing Track
Many people are tired of hearing about Smart Manufacturing in theoretical terms. We are too, so we've assembled speakers* who:
- have shown real, quantifiable business value through “Smart” approaches,
- embrace innovation,
- can openly discuss projects/initiatives, their pitfalls and results, and
- will articulate key, actionable takeaways for session attendees.
A Simple Start to Smart Manufacturing - Mondelēz International
Tuesday, May 9, 2017, 4:15-5:15 pm
There is much “hype” today about Smart Mfg., Industrie 4.0, IIoT (Industrial Internet of Things), AI (Artificial Intelligence), Machine Learning, Predictive Analytics, Cloud Computing, Big Data, Social, Mobile, and the list goes on. While there is a lot of potential and definitely significant opportunity for today’s manufacturers to take advantage of today’s burgeoning technology landscape, where to start can sometimes be quite overwhelming.
At Mondelēz International over the last 2 years, we have taken what we are calling a “Simple start to Smart Manufacturing”. Our approach has been built around first being extremely clear regarding our business objectives for manufacturing and linkage with the corporation’s strategy. Then we looked at how the evolving technology landscape could support these objectives. While the manufacturing strategies we applied are really no different than those from the last few decades (TPM, TQM, SPC, Lean, 6-Sigma, etc.), we have begun to apply newer technologies in conjunction with these strategies. Results we are seeing are speed of deployment, faster adoption / time to value, and increased employee engagement.
Attendees of this session will be able to walk away with ideas toward a practical approach to “start simple” on the journey of Smart Manufacturing.
- Prerequisites to think about as you plan the start of the journey
- Ensuring clear linkage with manufacturing and corporate objectives
- The role of people in “Smart Manufacturing” plant
- Start small while determining what newer technologies can do for your journey
- Tracking results
The Future of Manufacturing: Industry 4.0; Data Analytics; Manufacturing Apps - Gentex Optics
Tuesday, May 9, 2017, 11:15 am-12:15 pm
Creating the business case for the automation that includes Paradigm shift from a customer's requirement perspective, paradigm shift in terms of how the company could evolve in 5-10 years end to end, tangible financial benefits in terms of productivity, support organizations optimization, asset utilization, real time information, track & trace capability, improved quality & yield and intangible benefits in terms of skill development, culture change, hiring new skills. Having this part done well helps with getting funding as well as buy-in from all parties.
Through our journey on this project we have a good idea of the kind of leadership that is required both at management and project level, team member skillsets (Mechanical, Controls, Electrical, Network, Server, Database etc) that are required.
Also we learnt very early and merged the Engineering and MIS/IT groups under one group to gain the benefits of IT/OT collaboration. Also a key takeaway within skills was what skills to have in-house versus what to outsource. What skills will be required to run the automated department 24X7 in production. What is the relation (who does what) between the automation design and product support department. What to develop and build for machines/technology internally vs outsource to 3rd party vendors should be carefully planned and discussed. "People learning by doing and making mistakes and we did too.
- Having a clear defined goal and requirements document is important.
- Doing small prototypes before spending tons of money is key to long term success even if it costs some extra money. It helps with getting buy-in, prevents from delays and builds confidence among team members
- Understanding flow of product and required buffers in between 2 processes is key to prevent the starving and blocking conditions. It extremely important to understand bottleneck conditions.
- Understanding abnormal flows, extreme conditions, current and future product requirements is key to future flexibility.
- Legacy equipment and interfacing with them in a connected smart factory needs to be predefined with the supplier of the legacy equipment"
Cybersecurity- Data and Software Regulatory Compliance in the Cloud - Toronto Water
Tuesday, May 9, 2017, 2:00-3:00 pm
- Identify roles and responsibilities for securing data and software assets in the cloud.
- Understand the difference between "Security of the Cloud" and "Security in the Cloud."
- Implement a cloud security life-cycle model based on a risk management framework to manage data and software security and regulatory compliance.
- Classify data assets based on sensitivity and criticality for the business and utilize phases of data life-cycle model to manage data security in the cloud.
- Implement secure software development life-cycle (S-SDLC) model to software engineering and quality assurance in the cloud.
Journey Toward A Connected Digital Manufacturing Enterprise - Arconic (former Alcoa)
Wednesday, May 10, 2017, 7:30-8:30 am
It is an exciting time for Alcoa these days. While the metals industry in general is struggling, aluminum is enjoying a boom in demand from automotive (think Ford F150), aerospace, and general industrial supply. Alcoa is also in the midst of rebranding themselves with the split in their business of the upstream traditional processing to the value-add rolled and engineered products.
Hear how Alcoa Global Rolled Products business unit, the leading supplier for aluminum plate and coils, is responding to the market demands by transforming their legacy systems to implement real-time manufacturing technology and advance their Smart Manufacturing cause. Alcoa has set an aggressive schedule and approach by tackling their flagship facility as the first location. Alcoa is taking their world-class company and transforming its operations by embracing manufacturing technology and building up its people and processes to support it.
Alcoa’s people are world-renown metallurgical, quality, process and mechanical entrepreneurs driving improvements and innovation in an already exciting, fast-past advanced materials world. But only in the last several years has the company embraced Smart Manufacturing (through MES/MOM real-time operational solutions) to move its business forward.
The session will take the audience through the journey to date – why Smart Manufacturing is critical to operations, and how there is no looking back. The session will go over the many different initiatives Alcoa is currently undertaking including world class operations initiatives, advancing R&D and commercializing these new customer requirements – and how the real-time layer glues many of the components together.
- Practical lessons learned around the real-time technology space – what works, what doesn’t, what to look out for
- Compelling insights from an exciting, dynamic company in the middle of transformation – how they have started on this journey, lessons learned from previous attempts, and setting a vision for moving forward.
Real Time Process Control and Data Analytics in a High Volume “Smart Factory” - Sanmina
Tuesday, May 9, 2017, 9:00-10:00 am
This presentation will review three different implementations of real time data analytics, closed loop process control and in process OCR (optical character recognition) implemented in high volume factories at Sanmina in 2016. All of these technologies were implemented on high speed production lines with significant ROI. These production lines use all electronic travelers, and all electronic process and test data upload to the travelers. For each of these three cases, the problem, solution and ROI will be reviewed. Videos of the implementations will also be shared.
- Implementations of IIOT and Industry4.0 are happening in factories, and can provide substantial ROI.
- Real time data analytics and process control is achievable, even in high volume factories where the computations involve thousands of measurements per minute.
- These implementations all occur in a more or less "paperless" factory.
- These technologies have a significant and measurable impact on product quality.
mesa 'smart manufacturing track'
A dedicated track within the M&T Conference with MESA-selected speakers highlighting the business value of solving plant and enterprise-level manufacturing challenges with IT-based solutions.
*speaker bios will be added soon