How Orbital ATK is Leveraging the IIoT and Visual Factory Technology to Drive Continuous Improvements

PRESENTERS:

Paul Hardy Application Architect at Orbital ATK Aerospace Structures

John MaherVice President of Product Strategy at Synchrono®

Presentation Overview

1. IIoT – Connecting Orbital ATK

2. Enabling the Visual Factory

3. Metrics for the Factory of the Future

Quick Facts:

• $4.5 Billion Global Aerospace and Defense Systems Company

• Innovative, Affordable Products for Government and Commercial Customers

• 12,000 Employees, Including over 4,000 Engineers and Scientists

• Over 19 Million Square Feet of R&D and Production Facilities in 18 States

Commerical • Rolls-Royce Aft Fan Case• GE Engine Cases• Airframe Structures• 767 Composite Door Springs• A350 Fuselage Stringers • A350 Fuselage Frames• 787 Primary Stiffening Structures• A400M Wing T-Stringers

Aerospace Structures Division (ASD)A leader in composite automation innovation

Military • F-22 Fiber Placed Pivot Shafts• F-35 Wing Skins• F-35 Fixed Skins• Nacelles• C-17 Counter Balance Assembly• Apertures / Radomes / Antennas • Survivable Structures• Performance Verification• Sensor Technology• Low Observable Technology• F-18 Next Generation Jammer

Launch • Atlas & Delta Launch Structures• Rocket Motor Cases • Composite Overwrapped Pressure

Vessels

Part 1:

IIoT - Creating a Connected

Environment at Orbital ATK

• Increase rate from 4x to 12x in 24 months

• Become more competitive and increase market share

• Improve communication, collaboration and decision-making by connecting all layers of manufacturing and the extended supply chain

Business strategy

How Orbital ATK is Leveraging the IIoT and Visual Factory Technology to Drive Continuous Performance Improvements

“Start with the end in mind”

– Stephen Covey

“Quick access to data we can take action on to improve”

- Orbital ATK ASD

1. Implement a connectivity Platform – and continually build upon it

2. Provide fast, easy access to actionable data (NOT another data warehouse)

3. Enable more focused continuous improvement

Business strategy

How Orbital ATK is Leveraging the IIoT and Visual Factory Technology to Drive Continuous Performance Improvements

• Enterprise visibility and communications• Instant manufacturing intelligence• Flexible, scalable architecture for today – and

tomorrow

Factory of the Future

How Orbital ATK is Leveraging the IIoT and Visual Factory Technology to Drive Continuous Performance Improvements

Gateway

E n t e r p r i s e S e r v i c e B u s : W e b S p h e r e

L o c a l S e r v i c e B u s : S y n c O p e r a t i o n s

Costpoint Crane 3PL SABA Cost View ePic Teamcenter UA PeopleSoft CIMS Maximo Timecard

Material Prep Machine

Linear Forming Machine

EMS Wonderware HMI Autoclave AUIS Machining

Center

Kanban for Costpoint

Sync Manufacturing TipQA

SyncAlert SyncExecution TC Mapping

Solumina AssetSmart

InfinityQS Historian RFID

Parts Attributes

1 2 3 4 5 6 7 8 9 10

A

B

11 13 15

23

14 16

2218 20

17 19 21

24 25 26 27 28 29

12

Data Exchanged: Item, Work Centers, Work Orders, Process Data, Bill of Materials, Tools, Schedules, Event/Alerts/Alarms

Data Exchanged: Item, Purchase Orders, Projects, Inventory, labor, Budget, MBOM, EBOM, Tools, Human Resources

Data Exchanged: Item, Purchase Orders, Work Centers, Projects, Inventory, Process Data, Budget, Receipts, MBOM, Tools, Suppliers, Event/Alerts/Alarms

1. Understand your data – and what will translate into meaningful information

2. Constantly refine your focus

3. Identify categories of data and what they mean

Examples: Quality, Availability, OEE

Getting started

How Orbital ATK is Leveraging the IIoT and Visual Factory Technology to Drive Continuous Performance Improvements

Part 2:

Enabling the Visual Factory with SyncView

EXAMPLES

Converting data into meaningful information through visualizations

How Orbital ATK is Leveraging the IIoT and Visual Factory Technology to Drive Continuous Performance Improvements

Gemba walkReal-time visibility of current priorities, KPIs and metrics.

• Single version of the truth• Clear priorities• Actionable metrics

How Orbital ATK is Leveraging the IIoT and Visual Factory Technology to Drive Continuous Performance Improvements

(NEW – Ticket A000134) Call M. Smith at 801-555-6565.  Machine C3 has a status of Machine is Down.  Drill head needs replacement.

< Messages SyncAlert Contact

Saturday 10:13 AM

SyncManufacturing Planning, Scheduling & Execution

Safety AppMES

SyncOperations – fault detection, SyncAlert – alert

notification, Asset Management

Quality SoftwareSyncView, via Operator Input

SyncManufacturing

SyncOperations – machine connectivity

Database

HMI

Single view; multiple data sources

How Orbital ATK is Leveraging the IIoT and Visual Factory Technology to Drive Continuous Performance Improvements

Equipment Status and OEE

Drill-down to determine root-cause of issues

• Minimize downtime• Direct preventative

maintenance

How Orbital ATK is Leveraging the IIoT and Visual Factory Technology to Drive Continuous Performance Improvements

(NEW – Ticket A000134) Call M. Smith at 801-555-6565.  Machine C3 has a status of Machine is Down.  Drill head needs replacement.

< Messages SyncAlert Contact

Saturday 10:13 AM

Sample Work Cell Dashboard

Access to actionable information

Single version of the truth

Enterprise-wide communication

Focus continuous improvement

Outcomes

Increased Throughput

Increased rate by 400%

Reduced downtime

New business growth = Increased market share

Business results

Part 3:

Metrics for the Factory of the Future

Wealth of Data

CI!

Actionable Information

Metrics that you can take action on to improve operations

“To measure everything is to measure nothing.”

Simple set of operations metrics that drive action

Monitor these metrics to:• Improve flow• Manage constraints• Direct Continuous Improvement

http://www.synchrono.com/resources/metrics-for-action/

Metric for Action: Perfect Order Percentage

Metric for Action: Queue Turns

Metric for Action: On-Time Delivery

Metric for Action: Stock Buffer Health

Metrics for Action: Schedule Adherence and Queue Turns

Questions & Answers

Download the white paper:

Demand-Driven Manufacturing Metrics that Drive Action

How Orbital ATK is Leveraging the IIoT and

Visual Factory Technology to Drive Continuous

Improvements