The Digital Factory in Can-making using MESMartyn Gill – Business Development Director, EMEA
Agenda
Who is Lighthouse?
The Journey to the Digital Factory with MES using the S95 standard
The significance of Connected Processes
Digital Transformation
Shopfloor-Online (the heart of the Digital Factory)
MES is all we do…We build MES solutions that are fully integrated with the customer business processes and systems
Our Product is called Shopfloor-Online
It is running in hundreds of factories
We take along term partnership approach with our customers
We have 30 years experience of IT in manufacturing
We build MES solutions for the manufacturing industry
Shopfloor-
Online
Product
Integration
Services
MES
Solution+ =
Sales
14%
Implementation &
Support
52%
Admin
16%
Development
18%
People Resources
Our Organisation
Lighthouse Systems
LSL (EUR)
Sales
Implementation & Support
Admin
Development LSF (France)
Sales
Implementation & Support
LSN (Nordic)
Sales
Implementation & Support
LSCE (Central Europe)
Sales
LSG (Germany)
Sales
LSI (USA)
Sales
Implementation & Support
Admin
LSA (Asia)
Sales
Implementation & Support
Our Worldwide Network
Nordic
Sweden
Middle
East
Dubai
France
Paris
Central
Europe
Poland
UK
Crawley
USA
New York
Canada
South
Africa
PE
Israel
Ireland
Cork
Belgium
Aalter
Nether
-lands
Veghal
Thailand
Asia
Singapore
Germany
Koblenz
• SI Partners
• Regional
• Or Industry Specialists
• LZ Lifescience
• Stolle Machinery
• Partner Capabilities
• Have relevant experience in MES
• Complementary solutions (automation)
• Have dedicated Shopfloor-Online resources
• Have been extensively trained
• Can build and support their own solutions
Italy
Genoa
Brazil
Sao
Paolo
BLUE: LH Offices
ORANGE: Partners
Our End Users in the Can and Ends Industry, Worldwide
Shopfloor-Online MES: The heart of the Digital Factory
2 Piece Can
3 Piece Can
Ends
Aerosol / Bottle
160+ Can and End Manufacturing Plants globally using Lighthouse’s Shopfloor-Online MES Software suite!
Today’s manufacturing typically has low levels of Integration between IT and OT
9
Today’s manufacturing typically has low levels of Integration between IT and OT
Convergence of IT and OT will allow decision makers to drive
inefficiencies out of the manufacturing operations.
Information Technology (IT)
Office Information Technology
Operations Technology (OT)
Automation Systems on the factory floor
MES provides the method of convergence
10
Plant Equipment
(Automation & PLCs)
Layers 0,1,2
Finance, Inventory and Core
business functions
Operators, Supervisors,
Process Engineers and
Continuous Improvement &
Operations Managers
Manufacturing in real-time
Production Counts, Detect
Counts, Downtime, Process
Parameters, Quality, Gauging
and Vision Systems
ERP
Layer 4Days, Months,
Quarters & Years
Machines, Logic, Lines,
Sensors
Plant Operations
Layer 3 – MES
Days, Shifts, Hours, Minutes, Seconds
Purchasing and Supply
Chain, Customers,
Sales Order
Management
What is S95 and where does MES fit?
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Plant Equipment
(Automation & PLCs)
Layers 0,1,2
ERP
Layer 4Days, Months,
Quarters & Years
Plant Operations
Layer 3 – MES
Days, Shifts, Hours, Minutes, Seconds
What is S95?
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Plant Equipment
(Automation & PLCs)
Layers 0,1,2
ERP
Layer 4Days, Months,
Quarters & Years
Plant Operations
Layer 3 – MES
Days, Shifts, Hours, Minutes, Seconds
• ERP is the BUSINESS system
• It has the BIG picture
• Used by OFFICE workers
• MES is the MANUFACTURING system
• It has DETAILED manufacturing
information
• Used by FACTORY workers
• User friendly, fast, with much automation
What is S95?
Where does Shopfloor-Online MES fit within S95?
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Plant Equipment
(Automation & PLCs)
Layers 0,1,2
ERP
Layer 4Days, Months,
Quarters & Years
Plant Operations
Layer 3 – MES
Days, Shifts, Hours, Minutes, Seconds
Production
Operations
Maintenance
Operations
Inventory
Operations
Quality
Operations
Shopfloor-Online: Functional Modules
Inventory Operations
Inventory
Label Printing
Traceability –Consumption
Build Traceability
Warehousing/ Logistics
Quality Operations
Quality Checks
SPC
Process Monitoring
Links to Documents
Concerns/CAPA
Supplier Complaints
Customer Complaints
Maintenance Operations
Asset Register
Maintenance Management
Repairs
Tool Management
Energy
Production Operations
Scheduling
Job Tracking
Downtime
Production Counting
Waste
Line Log Book
OEE
Labour
Shopfloor-Online: Functional Modules
Inventory Operations
Inventory
Label Printing
Traceability –Consumption
Build Traceability
Warehousing/ Logistics
Quality Operations
Quality Checks
SPC
Process Monitoring
Links to Documents
Concerns/CAPA
Supplier Complaints
Customer Complaints
Maintenance Operations
Asset Register
Maintenance Management
Repairs
Tool Management
Energy
Production Operations
Scheduling
Job Tracking
Downtime
Production Counting
Waste
Line Log Book
OEE
Labour
The Significance of the ‘Connected’ factory
Manufacturing Operations
Inven
tory
Pro
du
ctio
nQ
uality
Main
ten
an
ce/
En
gin
eeri
ng
InboundDeliveries
WarehouseMove
InventoryConsumeInventory
LocalStorage
IsolationsCreate
InventoryScrap
Print LabelMove
InventoryWarehouse
OutboundShipping
PlannedProduction
Orders
SetupInstructions /
Docs /Recipes
ManpowerPlan
ManpowerTracking
Execution
ProductionsCounts
Waste
DowntimeEvents
Inbound QC
ProcessParameters
In-Line QC
Lab Checks
Concerns/CAPA
MaintenancePlan
PlannedMaintenance
Activity
ToolManagement
UnplannedMaintenance
Activity(Repairs)
Energy Usage
ERP PLCs
The ‘Disconnected’ factory
Manufacturing Operations
Inven
tory
Pro
du
ctio
nQ
uality
Main
ten
an
ce/
En
gin
eeri
ng
InboundDeliveries
WarehouseMove
InventoryConsumeInventory
LocalStorage
IsolationsCreate
InventoryScrap
Print LabelMove
InventoryWarehouse
OutboundShipping
PlannedProduction
Orders
SetupInstructions /
Docs /Recipes
ManpowerPlan
ManpowerTracking
Execution
ProductionsCounts
Waste
DowntimeEvents
Inbound QC
ProcessParameters
In-Line QC
Lab Checks
Concerns/CAPA
MaintenancePlan
PlannedMaintenance
Activity
ToolManagement
UnplannedMaintenance
Activity(Repairs)
Energy Usage
ERP PLCs
The Significance of the Connected Factory using a single MES Solution
The Digital Factory has all the measurement systems, line sensors and computer systems joined up in a completely seamless manner…
The data from the measurement systems, sensors and computer systems would be available to each other… and talk to each other!
Predictive Analysis could determine when tool changes or maintenance is really required
These technologies & capabilities could dramatically change manufacturing operations
Spoilage rates could be cut, HFI could be eliminated, Line Availability
(Uptime) could be increased, non value-added manpower could be a thing
of the past
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The Digital Transformation – Quality Data
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ManufacturingExecution System
Dome Depth
Rim Varnish
Film Weights
Decoration Defects
Top WallMid WallBottom Wall
Lacquer Weights
Axial Load
Dome Reversal
Pin Holes
Trim HeightColour
Flange Diameter
Lube Weight
Oven Temps
pHFlouride
Dome Reversal
The Digital Transformation – Production Data
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Cupper Counts
Bodymaker Counts
pH
Oven zone temperatures
Label Changes
Pressure
Downtime
Cupper Sprayer NeckerBodymaker DecoratorWasher Oven
ManufacturingExecution System
Short Cans
Trimmer FaultsDowntime
Downtime
Inks
Varnish
Energy Downtime
ProductionCounts
Downtime
Lacquer
Tooling
Fluoride
ProductionCounts
The Digital Transformation – Inventory and Asset Data
Press Tools
Pallets of Bright CansRaw Materials
Complex Tool PacksCoil Changes
Tool Assignments
Tool Repairs
Maintenance Schedules
Punches
Rings
Pallets of Finished GoodsPallet Labels
HFI
Manufacturing Execution System
Shopfloor-Online MES: The heart of the Digital Factory
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ArchitectureOne database = one system
Browser based
No Client Installation
For UsersAccess from anywhere
Easy to use
Easy for training
For ITCloud or On-Premise
Scalable (single factory / multi factories)
Easy deployment
Standard IT infrastructure
Classic Can-Making Process Dashboard
Floor 1
Real-time visualisation – Screen Configurability
Shopfloor-Online: Production Scheduling
Shopfloor-Online: Plant Overview Dashboard
Operator User Interface
Quality Control – Real-time monitoring
Mobile Data Collection
MES – The ‘Real’ Benefits
All factory (Operations Technology) data will go into one place
All users will be able to access it from wherever they are
No data will be recorded on paper
No reports manipulated in Excel
Information will be immediate, live, accurate, correct
Data will be transformed into actionable items
Performance, status, problems will be instantly visible to all
Users will be alerted to problems (SMS, email)
Users will be guided through business processes
MES – The ‘Added Value’ Testimonial
• Less time spent entering data
manually
• Downtime now automatic
• Label Changes
• Data Entry page configuration
• Quality data improvement and
alignment
• Standardised Part Variants between
European and all American sites
• Potential to utilise cross-functionality
• Local System
• Saving on hosting costs
• System will suffer less delay from local
servers
• No dependency on a wide area network
• Data accuracy
• Interfaces mitigate human error
• Allow better business decisions
• HTML5: Latest web-browser
technology
• Faster updates
• Less error prone
• No restriction on IE
• Browser independent
• Ergonomic User Interface
• Searchable content
• Favourites
• Visual appeal feeds in to user buy in
• More control by super users
The Journey to Digital Transformation
Smart Manufacturing…. It’s a journey
It might be a long journey!
It’s a journey that can only be made with incremental steps
You don’t have to get travel sickness!
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Start with a DIGITAL TRANSFORMATION strategy
Connect your measurement systems and Quality Data to a centralised MES
Connect your machines, sensors and PLC’s to a centralised MES
Tag your critical Assets and track their use in a centralised MES
All plants can be Smarter even with existing systems…
Start your Digital Transformation journey nowwww.LighthouseSystems.com