Global Process Optimization and MES Standardization
This automotive subsystems supplier wants to transform into a ‘Digital Enterprise’, to be able to serve its clients better, faster and reduce cost. To reach its goals it want to optimize and standardize its processes. In parallel the company wants to decrease its manufacturing IT cost.
The company IT landscape is based on SAP solution (FI/CO/MM/SD/PP/PS…) with SAP MII on the shopfloor and the company has decided to standardize on SAP ME Manufacturing Execution System for their more than 100 plants.
Two major production flows are followed:
• Batch Production
• Sequence Production
The flow is managed through JIT principle and Kanban.
The operational expectations for the program are:
• Support the standards;
• Provide production teams with the right and reliable insight to focus performance and process improvement
• A consistent core model of functionalities and KPIs
• Become paperless
• Decrease manual data input
• Support operators to execute tasks and manage their machines
• Insight for production management to take the right decisions, at the right time at the right level
The Challenge
A first phase of the program is to roll out to three plants to build experience and capture lessons learned to enable toll out to the other over 100 plants.
The following processes need to be covered:
• Production flow
• Logistic Flow
• Quality flow
• Traceability and Conformity flow
The following requirements need to be covered:
• Truck Preparation Area (TPA) Management
• Production Management
• Performance Management and Analysis
• Labor Management
• Standard Operations Procedures
• Maintenance Management
• Quality Management
• Alert Board Management
The company has followed a typical traditional approach of static documenting meaning in this case the such as the User Requirement Specifications, the Design Specifications, the processes and work instructions were all written in ‘word’ documents.
This causes misinterpretation, miscommunication and unawareness to manage and control interoperability and dependencies. The outcome was that the first phase of the program took more than twice the time, needed more funding and still have not met the defined expected outcomes.
Such traditional approaches makes it hard to impossible
• to capture and use lessons learned
• understand, manage and control interoperability and dependencies
Solution Approach
We recommended to use the unique Smart Industrial Transformation approach and Models4Insight holistic modelling platform to create and manage digital representations of the plant with regards to users, process and application transformation taking into account the current situation and the ‘To – Be’ SAP ME situation. This makes it possible to create a dynamic, model based MES template to manage the process and application lifecycle.
The Smart Industrial Transformation Approach is based on using models for all user groups throughout the complete transformation process providing the right level of information to the right people at the right time.
The approach uses models to describe the different constituents ranging from strategic goals down to the shopfloor infrastructure and physical assets. This approach allows to connect the different dimensions of, Users, Processes, Applications, Physical assets, Infrastructures and Data.
“Language” problems are directly identified during the planning of the transformation instead of during deployment phase in the traditional approach.
Global roll out to over 100 plants can be managed and deployed with in-depth risk management, fast tracking of parallel roll outs and cost reduction.
More specifically:
These models are maintained during the complete life cycle of the transformation. Lessons learned can be captured and used at any time, deviations from the planning can be represented in the model and the model can be used to identify other parts effected by these changes. This impact analysis will directly point at conflicts with the design of other groups of people and enables efficient communication of changes and their effect.
The figure below shows how the different constituents and dimensions described in the different documents are modelled using the Smart Industrial approach to create a dynamical MES template.
In the Smart Industrial Transformation Approach models are used in a specific way:
• Scenarios are modelled from different point of views like e.g. for a manufacturing process: the physical object view, the machine view, the operator view and the process engineer view. These four views together describe the actual process best.
• Scenarios are modelled in the most detailed way and semi-automatically derive higher level views, thus views with lesser detail. These different views with varying level of detail are required for different groups of people. A manager just wants to see the high level picture, while a process engineer wants to see all details. By deriving the higher level views we ensure that the different levels of details are consistent with each other.
Now it is possible to visualize and have interactive stakeholder involvement providing right level of information at the right time.
Stakeholders are able to visualize the ‘As-Is’ and the ‘To-Be’ situation, and do scenario play and impact analysis to manage process and application migration.
Benefits
Risk management of project ≥ 90%
Faster End to End program delivery up to 50%
Cost reduction ≥ 30 %
Insight visualization for the different type of stakeholders
Decrease global support cost with up to 50%
Our Services
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Our assessment framework is uniquely tailored for Industry 4.0, Industrial Internet of Things, and Digital transformation. It is supported by a Smart Industrial Transformation approach, based on holistic modelling.
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By using our unique Smart Industrial Transformation deployment framework we make sure that your deployment will be better, smarter and faster.
It is the only solution that is able to integrate and digitize the different dimensions of, Users, Suppliers and Customers, Processes, Applications, Physical assets, Infrastructures and Data, needed for best in class transformation deployments.
The basis is the ability to create digitized templates, which brings your templates alive and enables you to constantly control, manage the uncertainty and have maximal agility during your deployment journey.
The digitized transformation template is typically used to manage the deployment of:
- Global (MES) applications;
- IT-OT architecture in general as well as more specifically RAMI 4.0 (Reference Architecture Model Industrie 4.0);
- Digitized System Architecture Transformation – Architecture and application deployment of OEM machines;
- Horizontal and Vertical integrated value chains.
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Our Smart Industrial Transformation based roadmap framework is a holistic model based framework uniquely tailored for Industry 4.0, Industrial Internet of Things and Digital transformation.
It is the only solution that brings alive your strategy, by digitizing it. This is a key advantage as strategy is a constant iteration, while communication and execution are key.
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Our Smart Industrial Transformation based roadmap framework is a holistic modelled framework uniquely tailored for Industry 4.0, Industrial Internet of Things and Digital transformation.
It is the only solution that brings alive your roadmap by digitizing it. With this you are in constant control, able to manage the uncertainty and have maximal agility during the journey.
The roadmap framework is typically used to get insight and input:
• To align Users, Suppliers and Customers, Processes, Applications, Physical assets, Infrastructures and Data dimensions;
• To understand the impact and execution of your roadmap items;
• for insight on impacts of roadmap items;
• for your IT-OT (Information Technology – Operational Technology) Architecture;
• for roadmap agility;
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By using our unique Smart Industrial Transformation architecture framework we make sure that your architecture will be at the life cycle management level to meet Industry 4.0. IIoT (Industrial Internet of Things) and Digital transformation requirements
It is the only solution that is able to integrate and digitize the different dimensions of, Users, Suppliers and Customers, Processes, Applications, Physical assets, Infrastructures and Data, needed for Industry 4.0 architecture. This brings your architecture alive, enabling you to constantly control, manage the uncertainty and have maximal agility during your transformation journey.
The architecture framework is typically used to design and manage:
- IT-OT architecture in general, incl. impact analysis;
- Specific RAMI 4.0 (Reference Architecture Model Industrie 4.0);
- Digitized System Architecture Transformation – Architecture and application redesign of OEM machines;
- Smart Manufacturing (data) architecture with advanced analytics capabilities;
- And deployment of IT-OT architecture.
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Our training courses:
2 day – Basic modelling training (include 1 year free private subscription), attendant will learn:
- What ArchiMate models are
- How to use the Models4Insight models
- Build basic models
- Manage basic models
- Basic queries
4 day – Advanced modelling training (include 1 year free private subscription), attendants will learn:
- To integrate ArchiMate, BPMN, ERD, UML models
- How to use the Models4Insight models
- Build advanced models
- Manage advanced models
- Analytics capabilities
- Advanced query of models
5 day
Combine basic and advanced modelling training (include 1 year free private subscription). This training can be given in two periods (one of 2 days and one of 3 days) :
2 day
Basic analytics training for connected assets, connected operations and manufacturing improvement. Attendants will learn:
4 day
Advanced analytics training for connected assets, connected operations and manufacturing improvement. Attendants will learn:
5 day
basic and advanced analytics training for connected assets, connected operations and manufacturing improvement. This training can be given in two periods (one of 2 days and one of 3 days)
Customized Training
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We offer modelling services to be able to create digital formal models (digital twins) for Industry 4.0, II0T and Digital transformation. Those models are digital representations covering processes, applications, infrastructures, physical assets and contextualized data.
The modelling is based on de ArchiMate architecture language using our Models4Insight™, IP based Modelling & Insight solution platform, It enables you to design, create, enhance, manage, store and retrieve digitized integrated models giving a formal digital representation making you in control of your Industry 4.0, IIoT and Digital Transformation journey. It is offered as a free public version or private subscription based service.
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