MW Smart FactoryInformation Technology Integration with Manufacturing

Objectives:Inform about current trends in IT technology that impacts ManufacturingShow the various levels of integration with IT in Manufacturing and show potential opportunities

Agenda:• Review of industry trends impacting IT and Manufacturing

• “Internet of Things”• RFID• Advanced Analytics

• How these trends impact Maxion Wheels• Integrating IT with Manufacturing• Where are we today and how is technology creating opportunities• What specific opportunities exist in Limeira

Objectives and Agenda

IT Integration with Manufacturing

Current Technology Trends

Current Trends

Mobile

Integration

RFID

Everything CONNECTED

IT Integration with Manufacturing

IoT

Internet of Things

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The MEGA Trend Matrix – Global 2025IoT

Connectivity and Convergence

Network of Physical “things” around us that are connected

IoT - Example

The Nest thermostat. Wi-Fi-connected thermostat allows you to remotely adjust the temperature via your mobile device and also learns your behavioral patterns to create a temperature-setting schedule.

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Examples of IoT

IoT – WhyValue proposition: Greater value and service will be achieved by exchanging data with other connected devices or the user / operator

IoT enables:• Better management of assets• Efficient consumption of resources• Eliminate human error• Higher efficiency and convenience for the user

IoT – Future is Now

Evolving Technologies:• Facial recognition•Retinal scanning•Gesture recognition•Wearable technology•Wireless power•RFID

How long before our entire environment is connected?Connected home Connected car

IoT – Impact to Maxion Wheels• Customer – Connected car is evolving very quickly – a

connected or smart wheel would be a great innovation• Growing pains just like the Smartphone market 5 years ago

• Manufacturing – opportunities are HUGE

• Information Technology• Being pushed to allow consumer technology at work• Need better and faster networks• Need to help leverage this to provide more value to plants

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IoT Gateways

IoT Gateway• Rugged design• Newest technology

• WiFi, Bluetooth, WWAN (3g or LTE)• Support for legacy devices

• Serial interfaces: RS-232, RS-485, RS-422/485

Designed to aggregate, secure and relay data from sensors and equipment from a plant floor.

IT Integration with Manufacturing

Predictive Maintenance

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Predictive Maintenance

Maintenance System - Opportunity

Reactive / Breakdown

Orders

Preventive

Schedules

Reliability & TPM

Predictive Schedules

PM/TPMOrders

Planned Corrective,Safety-Proactive,

General, …

Predictive OrdersUsage

Equi

pmen

t –

Tool

s –

Mol

ds –

Reg

ulat

ory

– Fa

cilit

ies

MES

Requestors

ReportingSystem

Inspections

Down TimeReason Codes

Plant Floor Data

Collection

Only Change Oil When Breaks

Change Oil Every 3 Months

Reliability

Analysis

Safety-Reactive Orders

Manual Entry

Manual Entry

Plan

t St

ruct

ure Change Oil

Every 6000 km

Integration

Moving to Predictive Maintenance

Reactive - Breakdown Only

Preventive

Predictive

Reliability

Analysis

33%

50%

66%

+Productivity

+Uptime

PotentialMaintenance

Savings

Maintenance Maturity Level

Plant Maint

BudgetR$

7.5M/Yr

Est. Maint.

SavingsR$

2.2M/Yr29%

*Banff-Dupont study, Reliability Analysis, 2002

IT Integration with Manufacturing

RFID

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• Hand Written Manual• Manual Entry Manual• Barcode Scanning Manual / Automatic

• Machine Integration / Sensors Automatic• RFID Scanning Automatic

History of Data Collection and EntryRFID

Reduce laborReduce errors

Real-time

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RFID TagsRFID is a type of automatic identification technology that transmits data in the form of a unique serial number wirelessly.

RFID is being implemented in manufacturing worldwide to act as an intelligent monitoring system that can provide track and trace functionality throughout all levels of the supply chain.

RFID

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RFID (Radio Frequency Identification)

RFID Wireless Receiver

RFID Tag

Receiver

Receiver

RFID Attached to PalletsTrack Movement

Track Location

Track wheel shipments

• Real Time Inventory• Automated Scanning• Location Tracking• Production Confirmation• Data Integrity• Warranty

RFID

IT Integration with Manufacturing

Advanced AnalyticsDeep Learning

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• Complex analysis of data• Correlating inputs to outcomesWhich inputs result in the best outcome

• When to use:• In highly complex activities• Where there are many variables• Where it is difficult to correlate inputs to

outcomes

• A form of Artificial Intelligence• Goal: Create smart machines or operators

What is Deep Learning

Automate Complex Activities – Preserve Knowledge – Improve – Replicate

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Everyday Uses

Automate Complex Activities – Preserve Knowledge – Improve – Replicate

Apple Siri

IT Integration with Manufacturing

Value to Maxion Wheels

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IT Integration with Manufacturing Landscape

Standard

MW Maturity Level

Market Trends

CloudSaaS

Data & Analytics

EmergingHigh Demand

Basic

Predictive MaintRealtime Inventory

Prod PlanningRFID

Network / WiFiConnected

SensorAI /Deep Learning

• PLC• Machine Integration• Sensors

(ERP)

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Where we are today

Advanced (ERP)

CloudSaaS

Data & Analytics

Emerging

Basic

Predictive MaintRealtime Inventory

Predictive MaintRealtime Inventory

Prod PlanningRFID / PFDCRFID / PFDCNetwork / WiFiConnected

SensorAI /Deep Learning

• PLC• Machine Integration• Sensors

PLC Networks

Plant Floor WiFi

Vision Systems

Andon’s

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Where we are today

Advanced (ERP)

CloudSaaS

Data & Analytics

Emerging

Basic

Predictive MaintRealtime Inventory

Prod PlanningRFID

AI /Deep LearningNetwork / Wifi

Sense / Monitoring

PLC

• PLC• Machine Integration• Sensors

Plant Floor Data Collection (PFDC): Inventory Management, production

reporting

(Czech, Turkey, Dello, GUA/SAN)

Plant Maintenance-mostly break/fixProduction Planning-Turkey

ERP Integration-Scanners, Data collection systems.

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Integration Cycle – Technology Impact

Collect

Sense

Analyze

Act

Become awareMachine cycled, temp higher

Communicate and store dataCasting database

What does this mean?Ask questions, draw conclusions

Take action to improve / correctChange casting settings

Network capable sensorsWiFi, RFID, PLC Integration

ConnectivityWiFi, Bluetooth, Gateway

Data Warehouse

Predictive Analytics, Deep Learning

Technology

Collect

Sense

Analyze

Alerting, Mobile, Displays

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Integration Cycle – Apply to Manufacturing Processes

Collect

Sense

Analyze

Act

Network capable sensorsWIFI, RFID, PLC Integration

ConnectivityWIFI, Bluetooth, Gateway

Data Warehouse

Predictive Analytics, Deep Learning

Technology

Collect

Sense

Analyze

Alerting, Mobile, Display

Preventative MaintenancePredictive Maintenance

Control complex process with large amount of variables (Casting)

Automate Inventory Management and

production reporting

Use Cases

Opportunities for Limeira?

IT Integration with Manufacturing

Discussion

Discussion

Mobile

Integration

RFID

IT Integration with Manufacturing

Thank you!

“Bad news — the scale is threatening to cut off our

access to the fridge…’

The evolution of electronics“These “smart, connected products”—made possible by vast

improvements in processing power and device miniaturization and by the network benefits of ubiquitous wireless connectivity—have

unleashed a new era of competition.”

Cloud ComputingConnectivity Big Data & AnalyticsSensors & Actuators

Internet of Things1933

First room thermostat introduced

1971AlohaNet is first public wireless packet data network

1998John Masey, Chief Scientist at SGI presents a paper titled “Big Data…and the Next Wave of Infrastress”

1999Cloud computing is introduced to the enterprise

2010The IoT and interconnectivity create novel possibilities for electronics

Internet of Things in ManufacturingGLOBAL OPERATIONS

I can see my production line status and recommend adjustments to better manage operational cost.

I know when to deploy the right resources for predictive maintenance.

I gain insight into usage patterns from multiple customers and track equipment deterioration.

MANUFACTURING PLANT

Identify and correct quality issues. Inventory Management

Remotely Manage Equipment

Monitor production flow in near-real time

GLOBAL FACILITY INSIGHT

Condition-based maintenance. Predictive maintenance

THIRD-PARTY LOGISTICS

Provide cross-channel visibility into inventories.

CUSTOMER SITE

Transmits operational information to the partner (e.g. OEM) and to field service engineers

Managers

R&D

Plant Floor

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Where Do We See Advance integration or automation Delivering Value?

• Lower Cost Data Collection• Real-time Monitoring, Alerting and Control• Machine status and parameters• Product specifications• Inventory Tracking

• Predictive Maintenance – condition, cycle, • Lower Maintenance Cost (10%-50%)• Higher Uptime

• Deep Learning for Manufacturing• Making better wheels more consistently

Where do we see value? Where do you see value?

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Where Do We See Advance integration or automation Delivering Value?

• Process Understanding and Optimization• Failure Reduction, Quality Improvement• Supply or Demand Chain Optimization• Productivity or Resource Optimization• Increased Predictability of Supply Chains and Customer

Demand• Automated Maintenance• Other?

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0s

Smart Bullets

“Tests suggest that increasing a target's distance actually improves the the projectile's accuracy by giving it more time to adjust its flight path”

More Data = Better Results