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Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.
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Rockwell Automation’s Connected Enterprise RA’s Modernization journey
Mick Mancuso Director of Manufacturing Operations April, 2017
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Agenda
Results
IT & OT Convergence
Operations’ Priorities
About Rockwell Automation
Lessons Learned
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Leading global provider of industrial power, control and information solutions
at A GLANCE
AUTOMATION SOLUTIONS for a broad range of industries
80+ COUNTRIES
22,000 EMPLOYEES
$5.9B
Technology innovation Domain expertise Culture of integrity &
corporate responsibility
SERVING CUSTOMERS FOR
113 YRS
FISCAL 2016 SALES
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Rockwell Automation Products
Connection Devices
Components Control & Visualization Platforms
Solutions / ETO
Push Button & Signaling Devices
Sensors & Switches
Small Controllers
Smart Motor Controllers
Logix Family
Performance & Visualization
Variable Frequency Drives
Custom OEM Panels
LV Control Centers
MV Control Centers
PRODUCT COMPLEXITY & LEAD TIME
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About Rockwell Automation Operations
The Connected Enterprise Implementation & Transformation
387, 000 SKUS
20 YEARS AVG PRODUCT
LIFE
PRODUCT TYPES • Stock + Configure to Order • Engineered to Order
UP TO 200 SKUs PER ORDER
15 PLANTS
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RA Manufacturing Objectives
In every Rockwell Automation manufacturing plant, our core objectives are clear and they are standardized:
Safety & Security
Quality
Service
Productivity
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The Connected Enterprise
Time and Attendance
(Kronos)
Automation (ControlLogix)
Torque Control (Atlas Copco) Testers
(HP 3070)
Product Marking (Global Product Marking - GPM)
Automated Optical Inspection (Koh
Young)
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Process Example
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Process 1 Process 2 Process 3
Operator 1 Operator 2 Operator 3
7 Mins 5 Mins 4 Mins
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Process Example
9
Process 1 Process 2 Process 3
Operator 1 Operator 2 Operator 3
4.5 Mins 4.5 Mins 4.5 Mins
When Process is Optimized, the next level of Productivity lies in: • Adherence to Process & Standards • Reducing Downtime • Making Decisions Quicker - Real-Time Data Matters • Eliminating Defects
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IT & OT Convergence
Production Floor
REPORTING EXECUTION APPLICATION INTEGRATION
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Reporting
Standard Reporting Data Exports • Labor Variance • Down time • Defects • Production Status • Order History • Thru put
• Indirect/Direct Labor • Order Complexity/Variance • Defects analysis • Engineering Change analysis • Work Cell Efficiency • Training – Worker Flexibility
Shop Floor Performance Management - Dept Performance - Performance Mgmt - Engineering Quality - Root Cause Analysis
- Quick Problem Solving
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Execution
Production Cell Performance Displays – Actionable Information
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Remote Dashboard Monitoring
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Printed Circuit Board Assembly Example
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PowerFlex Drive Assembly Example
Quality & Productivity Improvement – Closed Loop, Guided Manufacturing with Integrated Smart Assets
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VantagePoint Event Tracking
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Application Integration
• Engineering Changes • MIR / OCN changes SharePoint
• Labor Reporting • Kronos
• Continuous Improvement • FileMaker Training Documents
• Quality • Global Product Marking linkage
• DC Electric Tools
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Our Situation Now
We have clearer visibility into every plant’s operation
Best practices are more accurately identified and proliferated using consolidated analytics
Using real-time data, more profitable decisions are easier to make
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Safety & Security Access points and control MES vs. ad-hoc Excel solutions
Quality
Defect detection & containment Training documented & controls to stop Operator
Delivery
Fast-track process for expedites Continue to run Operation while doing ERP system
maintenance
Improvements in Objectives
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Inventory
120 days to 82 days
CapEx 30% per year in
capital avoidance Productivity ► 4% to 5% yearly productivity*
Delivery
Mid-80s to 96%
Lead Times Reduced 50%
Time to Want
82% to 98%
Quality 50% reduction in
PPM
Rockwell Automation Journey Video
THE CONNECTED ENTERPRISE Rockwell Automation Transformation
* Productivity gains offset inflation and fund investments
OES’s Vision for Our Connected Enterprise
- The Connected Supply Chain -
Analytics: The discovery and communication of meaningful patterns in data
Some Key Takeaways
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• Senior Management Sponsorship Required • Strong IT and OT Collaboration is Essential • Don’t Underestimate the Culture Change Required • Create a “Win” … Others Will Follow • Must be Tied to Business Strategy … Not a Stand Alone Initiative • Focus on Critical KPIs … Versus Data • Never Ending Journey … Close Monitoring Required
Faster Time to Market
Improved Asset Utilization $ Lower Total Cost
of Ownership Enterprise Risk Management
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