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World Class Technologies for World Class Technologies for ManufacturingManufacturing
Patrick J. Delaney, CFPIM, CIRM, CPM
World Class Technologies for Manufacturing
World Class Technologies for Manufacturing
National Manufacturing WeekNational Manufacturing Week
ChicagoChicago
McCormick PlaceMcCormick Place
February 23-26, 2004February 23-26, 2004 Manufacturing Enterprise AutomationManufacturing Enterprise Automation Manufacturing Process AutomationManufacturing Process Automation Product Design AutomationProduct Design Automation Facility Security & AutomationFacility Security & Automation Data Capture and Data Tracking AutomationData Capture and Data Tracking Automation
World Class Technologies for Manufacturing
Computer-Integrated Computer-Integrated ManufacturingManufacturing
Purdue University Purdue University 30 Engineering 30 Engineering SchoolsSchools
Manufacturing Manufacturing Technology Technology ProgramProgram
Rehg & Kraebber, Prentice Hall, 3rd Ed. 2004
World Class Technologies for Manufacturing
World Class World Class TechnologiesTechnologies
for for ManufacturinManufacturin
gg
Electronic Commerce [www.com+EDI]Electronic Commerce [www.com+EDI] Internet Supply Chain Systems SuiteInternet Supply Chain Systems Suite Enterprise Resource Planning SystemsEnterprise Resource Planning Systems Advanced Planning & Scheduling SystemsAdvanced Planning & Scheduling Systems Integrated ERP/CRM/SRM Integrated ERP/CRM/SRM Wireless WANs [over 30 miles]Wireless WANs [over 30 miles] RFID Tracking TechnologyRFID Tracking Technology Global Tracking SystemsGlobal Tracking Systems Internet B2B Server ApplicationsInternet B2B Server Applications Sales & Field Force Automation [SFA]Sales & Field Force Automation [SFA] Mobile Connectivity [MC]Mobile Connectivity [MC] Computer Aided Design CAD/PLMComputer Aided Design CAD/PLM Computer Aided Manufacturing [CAM]Computer Aided Manufacturing [CAM] Manufacturing Automation ControllersManufacturing Automation Controllers Device and cell controllersDevice and cell controllers
World Class Technologies for Manufacturing
DuPont InnovationDuPont Innovation
Automotive Coatings Automotive Coatings TechnologyTechnology
Wet on Wet Paint SystemsWet on Wet Paint Systems Rust coatingRust coating Primer coatPrimer coat Color coatColor coat Clear coatClear coat
Final stage oven dryFinal stage oven dry
World Class Technologies for Manufacturing
Robotic Robotic EvolutionEvolution Hydraulic in early 1980sHydraulic in early 1980s
Electric/electronic todayElectric/electronic today Newer vision systemsNewer vision systems Higher accuracy & repeatabilityHigher accuracy & repeatability Proprietary controllers Proprietary controllers
[Motorola][Motorola] Advanced CAD/CAMAdvanced CAD/CAM SimulationSimulation Greater path accuracy [0.05mm]Greater path accuracy [0.05mm] Dual robotic cellsDual robotic cells Jig-less manufacturingJig-less manufacturing
Betty Boop
World Class Technologies for Manufacturing
Manufacturing Manufacturing Software Software Development PathDevelopment Path APS
ERP/ERO
SCM
MES
SFC
MRP IIMRPInventory
control
Forecasting DRP
Order Entry CRMSFA
World Class Technologies for Manufacturing
S upply Chain Suite
Order Management Sys tems
OMS
Enterprise Resource P lanning
ERP
Warehouse Management Sys tem
WMS
Advanced P lanning & Scheduling
AP S
T ransportation Management Sys tem
TMS
Supplier Relationship Management
SRM/SCOR
Des ign Engineering/ CAD
G2G
Elec tronic Commerce Suite
B2B
Customer Relationship Management
CRM
World Class Technologies for Manufacturing
Supply Chain Event Supply Chain Event Managers [SCEM]Managers [SCEM]
Monitor all E-commerce Monitor all E-commerce transactionstransactions
Business rule basedBusiness rule based Create action messages Create action messages
and flagsand flags Check each event for Check each event for
validity and accuracyvalidity and accuracy Accommodates all trading Accommodates all trading
partnerspartners Order status, shipping, Order status, shipping,
inventory, billing, etc.inventory, billing, etc.
Computer Associates BizWorks
i2 Global Logistics Monitor
World Class Technologies for Manufacturing
Ford CaseFord Case
E-commerce graphics E-commerce graphics applicationapplication
Internet transfer of Internet transfer of engineering documents & engineering documents & graphicsgraphics
Utilizing a translation software Utilizing a translation software to interface with incompatible to interface with incompatible supplier applicationssupplier applications
Internet CAD
World Class Technologies for Manufacturing
Daimler-Chrysler CaseDaimler-Chrysler Case Laser based 100% inspectionLaser based 100% inspection Automatic collection of SPC Automatic collection of SPC
datadata Line stopping feedbackLine stopping feedback Machine analysis and Machine analysis and
preventive maintenance preventive maintenance warningswarnings
Bi-lingual inspection Bi-lingual inspection instructionsinstructions
Automated display of ISO Automated display of ISO 9000 procedures9000 procedures
Intranet sharing of QA data Intranet sharing of QA data across plant sitesacross plant sites
World Class Technologies for Manufacturing
Honda SupplierHonda Supplier
Inbound items are bar-codedInbound items are bar-coded Outbound items are bar-codedOutbound items are bar-coded WIP isn’t bar-coded WIP isn’t bar-coded Warehouse isn’t bar-codedWarehouse isn’t bar-coded Cycle counts dailyCycle counts daily Physical inventory every 30 Physical inventory every 30
daysdays
World Class Technologies for Manufacturing
Old Rand-McNally Publishing Co. Old Rand-McNally Publishing Co. CaseCase
Cycle Counting Cycle Counting ApproachApproach
Largest printing plant in the U. S.Largest printing plant in the U. S. Very large warehousesVery large warehouses F.G. Four racks highF.G. Four racks high Lose signaturesLose signatures Cycle countersCycle counters
FlashlightsFlashlights BinocularsBinoculars Computer print outComputer print out
World Class Technologies for Manufacturing
Data Capture Data Capture DevicesDevices Hand held devicesHand held devices
Pen based devicesPen based devices Scanner/data input devicesScanner/data input devices RFID trackingRFID tracking ERP integratedERP integrated Windows CE - OSWindows CE - OS Finger size point & scanFinger size point & scan Micro-chip theft controlMicro-chip theft control Electronic asset tracking [EAT]Electronic asset tracking [EAT] RackrunnersRackrunners MicroStamp RFID TechnologyMicroStamp RFID Technology
World Class Technologies for Manufacturing
Voice Recognition TechnologyVoice Recognition Technology
InfoWorld 100 InfoWorld 100
Technology Winner 2003Technology Winner 2003 Warehouse picking applicationWarehouse picking application Headset communicationsHeadset communications Belt clip display systemBelt clip display system Two-way communicationsTwo-way communications Improved pick accuracy to one error Improved pick accuracy to one error
in 3,000 picksin 3,000 picks
World Class Technologies for Manufacturing
Technology Assessment TeamTechnology Assessment Team
Technology AssessmentTechnology Assessment Investment prioritiesInvestment priorities Integration issuesIntegration issues Benchmarking studyBenchmarking study New employee profilesNew employee profiles Technology trainingTechnology training Payback measurementsPayback measurements University relationshipsUniversity relationships Technology VisionTechnology Vision
World Class Technologies for Manufacturing
Today’s Typical Systems Environment
Most technologies are only partially Most technologies are only partially implemented or interfacedimplemented or interfaced
Budget constraints constantly cut back Budget constraints constantly cut back deploymentsdeployments
Acquisitions & divestments force major steps Acquisitions & divestments force major steps backwardbackward
E-commerce skill sets are weakE-commerce skill sets are weak Short term needs interfere with obtaining Short term needs interfere with obtaining
quality deliverablesquality deliverables End to end supply chain initiatives have End to end supply chain initiatives have
overwhelmed the development queueoverwhelmed the development queue Outsourcing has built more islands of Outsourcing has built more islands of
automation automation
World Class Technologies for Manufacturing
World Class Technologies World Class Technologies AssessmentAssessment
INTEGRATION
SO
PH
ISTIC
ATIO
N
World Class Technologies for Manufacturing
Today’s Purdue GraduatesToday’s Purdue Graduates Database structuring and administration [Quick BASIC, C+]Database structuring and administration [Quick BASIC, C+] Design techniques of Expert Systems [PC Easy & EXSYS]Design techniques of Expert Systems [PC Easy & EXSYS] PC based ERPPC based ERP Distributed system design & networkingDistributed system design & networking Hands-on PLC programming [programmable controllers]Hands-on PLC programming [programmable controllers] Apply CAD and CAE software toolsApply CAD and CAE software tools Work in a $10 million CIM laboratoryWork in a $10 million CIM laboratory
CIM softwareCIM software CNC workstationsCNC workstations automated materials handling with robotsautomated materials handling with robots automated data capture [RFID]automated data capture [RFID] vision systemsvision systems
World Class Technologies for Manufacturing
PPR HubPPR Hub
Product
Process
Resource
HUB
Production System
Process Planning
Robotics
Factory Flow Simulation
Scheduling & Control
Efficiency
Cost Analysis
QA
Ergonomics
System Integrators: Rockwell/ IBM/ Dassault/ ABB/ EDS/ MIT
World Class Technologies for Manufacturing
National Manufacturing WeekNational Manufacturing Week
Chicago McCormick PlaceChicago McCormick Place
February 23-26, 2004February 23-26, 2004
www.manufacturingweek.comwww.manufacturingweek.com
What industries are using your product?What industries are using your product? What new features have been added to your product since What new features have been added to your product since
last year?last year? What are the integration features of your product?What are the integration features of your product?
World Class Technologies for Manufacturing
Speaker Contact Speaker Contact DataData
Patrick J. DelaneyPatrick J. Delaney
NWU Research ParkNWU Research Park E:mail: E:mail:
[email protected]@aol.com Phone:Phone:
1-800-806-51771-800-806-5177