Smart Manufacturing Track

Track Sponsored by Kepware

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

Paresh Kalwani, Global Manufacturing ITS Solutions & Strategy Lead, Mondelez International

Erik Nistad, Director ITS, Global Mfg./ RDQ COE Lead, Mondelez International

Tuesday, May 9, 2017, 4:15-5:15 pm

Abstract:

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.

Takeaways:

  • 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 Journey of Gentex Optics from Manual Production Processes to Industry 4.0

Amit Agarwal, Sr. Manager, Automation Enginer & MIS, Gentex Optics

Tuesday, May 9, 2017, 11:15 am-12:15 pm

Abstract:

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.

Takeaways:

  • 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

Goran Novkovic, Professional Engineer, Toronto Water

Tuesday, May 9, 2017, 2:00-3:00 pm

Abstract:

Cloud computing is causing a transformational shift in the way we do business and protect sensitive data assets and mission critical software applications in an increasingly complex regulatory environment. Organizations are taking a cautious attitude to cloud computing because of concerns about security and compliance with their security policies and respecting regulatory obligations. Thus, the adoption of cloud technologies should always be subject to careful evaluation that is aligned and integrated with risk management processes and information security governance of the organization. What we regularly see in the practice, many times it is not clear who is responsible for data and software security and regulatory compliance in the cloud, whether it is the cloud service customer or cloud service provider, or perhaps hybrid of both. This presentation offers a practical approach and real solution for industry leaders from all industry sectors in the process of adopting cloud services and moving production and business data and software applications to the cloud.

Takeaways:

  • 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.

Real Time Process Control and Data Analytics in a High Volume “Smart Factory”

Gelston Howell, Senior Vice President, Marketing, Sanmina Corp

Srivats Ramaswami, CTO, 42Q

Tuesday, May 9, 2017, 9:00-10:00 am

Abstract:

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.

When Technology Enables Collaboration: An IoT Case Study

Maicon Jean de Oliveira, IT Industrial Support Manager, Faurecia Automotive

Alex Herbert, Strategic Accounts Manager, Kepware

Wednesday, May 10, 2017, 11:30 am- 12:30 pm

Abstract:

We’re at a tipping point with the Industrial Internet of Things (IIoT). A recent report from LNS Research shows that 34% of companies are either currently adopting or planning to adopt IIoT technology in the next year. Although adoption of IIoT technology is still in its early stages, organizations that are utilizing IoT processes are maximizing efficiencies and making smarter decisions across their organizations.

In this session, Kepware Strategic Account Manager Alex Herbert and Faurecia North American Industrial Support Manager Maicon Jean de Oliveira will discuss the benefits of introducing IT protocols like REST/HTTP to the plant floor to foster collaboration between IT and operations and enable smarter, more nimble decision making. Oliveira will share details of Faurecia’s transparency pilot program initiative to improve parts traceability throughout the entire manufacturing process and satisfy the company’s major automotive customers. The speakers will discuss best practices for selecting and implementing an IoT connectivity platform capable of connecting industrial data with enterprise systems. Finally, Oliveira will share Faurecia’s journey of scaling the transparency pilot program from one factory in Porto Real, Brazil, to the company’s worldwide factories operating in more than 30 countries.

Journey Toward a Connected Digital Manufacturing Enterprise

Ken Marapese, Manager, MES & Security, Rockwell Automaton

Wednesday, May 10, 2017, 7:30- 8:30 am

Abstract:

Existing and rapidly evolving technologies are transforming industry through the creation of an environment that affords real-time visibility into production status and the efficacious management of global operations. Profound insight into operator usage patterns, materials and equipment enables enriched performance and better efficiency. The information is readily available; companies with strategies to harvest it are equipped to become more productive and globally competitive.

In this session, examine the challenges of implementing a Connected Enterprise for a high-mix manufacturer and explore each step in operationalizing the rollout of plants and systems. Dissect the impact of the Internet of Things on the manufacturing industry and learn about available solutions that can aid in driving increased profitability and improved enterprisewide results, often illustrated through the experience of Rockwell Automation in its journey to achieve its own Connected Enterprise.

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.