verticale

Brilliant Factory: la fabbrica diventa digitale. GE Oil&Gas - un caso concreto

(in lingua inglese)

Digital Fundamentals
• Quality Management
• Data Collection & Acquisition
• Product Tracking & Genealogy
• Performance Analysis
• Dispatching & Scheduling
• MFG Execution
• Completion & Validation
• Performance Monitoring & Analysis
• Resource Management
• Asset Management & Awareness
• Tool Management & Awareness
• Maintenance Management
• Manufacturing MbE

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Atti di convegni o presentazioni contenenti case history
SAVE Milano aprile 2017 L’Asset Management nel Manifatturiero Intelligente

Pubblicato
da Alessia De Giosa
SAVE Milano 2017Segui aziendaSegui




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Estratto del testo
Gli atti dei convegni e pi di 8.000 contenuti su www.verticale.net Milano Smart Operational
Excellence:
Brilliant Factory Sharing Session ANIPLA
April 19, 2017 Donatella Banchi ' GE Oil & Gas
Corrado Giussani ' GE Digital
Antonio Ziliani - Capgemini 2016 General Electric Company - All rights reserved 2017 General Electric Company - All rights reserved Leading the manufacturing revolution THE ORIGINAL INDUSTRIAL REVOLUTION [PAVING THE WAY] FORD ASSEMBLY LINE ELECTRICITY + MASS PRODUCTION TOYOTA PRODUCTION SYSTEM THE AGE OF DIGITAL ELECTRONICS GE BRILLIANT FACTORY THE INTERNET OF THINGS + ARTIFICIAL INTELLIGENCE 1900 1985 2025+ 1918 GE BRILLIANT FACTORY Driving digital maturity, built on lean foundation, with continuous improvement 2017 General Electric Company - All rights reserved 2 2017 General Electric Company - All rights reserved Customer
Focus
(L1)
Engaged &
Committed (L2)
Scientificall
y Improving
(L3)
Inventing
New Levels
of Success
(L4)
Seeking
Perfection
(L5)
Lean Fundamentals ' S5
' Standard Work
' Value Stream Mapping (VMS) ' Total Productive Maintenance (TPM) ' SMED (Single Minute Exchange of Die) ' Lean Product and Process Design LEAN FACTORY MATURITY FRAMEWORK Lean
getting
started Vision + structure established Improvements
starting to have
an impact Continuous improvement a way of life Mature in all
regards ' on road to world
class
performance 3 Living Lean: On the shop floor 2017 General Electric Company - All rights reserved Manual
(L1)
Data
Access
(L2)
Real-
time
visibility
(L3)
Data &
Process
Analytics
(L4)
Optimized &
Controlled
(L5)
Machine productivity visibility,
ERP integration at set-up &
completion, automated data
collection Digital Fundamentals ' Quality Management
' Data Collection & Acquisition
' Product Tracking & Genealogy ' Performance Analysis
' Dispatching & Scheduling
' MFG Execution
' Completion & Validation
' Performance Monitoring & Analysis ' Resource Management
' Asset Management & Awareness ' Tool Management & Awareness ' Maintenance Management
' Manufacturing MbE DIGITAL MATURITY FRAMEWORK Paper-based operations with no data collection and basic metrics Inventory integration & visibility, fully-automated machine data, As-built BOM costing & yield analysis, integrated quality management Real-time product
tracking & location,
with 3D models
integrated with
machines, and
complete product
genealogy 4 Living Digital: On the shop floor Manual data collection, with metrics based on paper records 2017 General Electric Company - All rights reserved W HY W HA T Cycle Cost VCP Downtime OTD Cycle Bridge information gap between engineering & manufacturing via digital tools Enable higher uptime & quality at each individual manufacturing machine tool Increase throughput & inventory turns by enhancing data visibility at factory level VIRTUAL MANUFACTURING SENSOR ENABLED FACTORY + SUPPLY CHAIN OPTIMIZATION The digital revolution ' MBE 'Bill of Process & Part
Program in PLM/MES ' Electronic Work Instruction ' Connect shop machines ' KPI Metrics & Analytics ' Condition Based Maintenance ' Smart Facility Solutions ' Quality management: Statistical
Process Control & Digital Gauges ' Scheduling ' Manufacturing Execution System 5 2017 General Electric Company - All rights reserved One Cloud Platform to Bridge the 'OT / IT Gap' PLC SCADA OT GATEW AY CRM IT ERP SUPPLY CHAIN Predix' 6 2017 General Electric Company - All rights reserved Scalable from machines to cloud Orchestrates data, controls, and analytics for effective interoperation Enables quick response to customer requirements Accelerates the industrial app economy through a services catalog Ingests and processes data faster Analyzes data using industrial and material science Securely connects all operating assets Built around an ecosystem of companies and developers Predix is a Platform for Developing, Deploying, And Monetizing Industrial Internet Applications 7 2017 General Electric Company - All rights reserved Brilliant Factory Experience Facts & Figures Visualization examples Used to view alerts &
actions to reduce
downtime and
MTBF/MTTR Machine Monitoring 1 | Facility Monitoring 2 | Used to view
machine deviation
from standard
performance to reduce
number of failures Condition Based Maintenance 3 | Date Machine Trigger Problem Description Status Note Actual Cost (') Production
time saved (h) 5/25/2016 10_182A Rule35 [P2] Tool changer rotation not
complete IN PROGRESS Checking
Alignment 5/21/2016 10_186A Rule14 [P15] Torque Overload TEST Chip conveior
Motor damaged 250 4 5/21/2016 10_181A Rule2 [P1] Tool not loaded properly TEST Checking
automatic tools
change 66 2 5/21/2016 10_181A Rule14 [P15] Torque Overload TEST Too many chips 33 4 5/21/2016 10_176B Rule20 [P19] Abnormal Cooling System TEST Foam inside the
tools coolant 100 4 5/13/2016 10_186B Rule2 [P1] Tool not loaded properly TEST Tool loaded in the
wrong position by
operator 66 2 5/13/2016 10_181A Rule2 [P1] Tool not loaded properly TEST Tool change test 66 2 5/13/2016 10_176B Rule20 [P19] Abnormal Cooling System TEST Level cleaning 66 4 5/13/2016 10_176A Rule20 [P19] Abnormal Cooling System TEST Level cleaning 66 2 Used to view alerts &
actions to supervise
systems remotely &
increase VCP 6 Connected Plants 6 Water Meters 9 Ovens 4 Test Benches 26 Gas Tanks 3K Tags Configured Basic Infrastructure recovery (Scada, Predix Machines, Predix
environment)
Mon-Sat: 8 '20pm (CET) On line and email support & Data Quality Analysis
Mon-Fri: 9 '18pm (CET) 24/7 Automatic Mail dispatcher to Ops Leader and IT Support Predix App Support DevOps team
Mon-Fri: 9 '18pm (CET) Infrastructure Tech Service ' Configurations, Deploy & Field Services
Mon-Fri: 9 '18pm (CET) Weekly review to collect insights, requirements & bugs 4.5M Records Stored daily 171 Machine Tools 35+ Users Connected daily 8 2017 General Electric Company - All rights reserved High Level Architecture Visualization/Functionality ' Synoptic view to monitor machine status, MTBF, MTTR, Downtime ' Production monitoring providing Real Time machining data per
personas Machine monitoring 1 | Shop line visualizations 2 | Admin & Diagnostic 3 | Smart Shop Solutions, powered by Predix' ' Smart Shop Admin ' work calendar & shift management ' Diagnostic in place ... System info, data diagnostic & data
storage diagnostic ' KPIs ' OEE, Availability, Data History, Machine uptime Dashboard & Analytics to optimize machining and productivity
(per plan/line/machine tools) Historical data
we store all data collected enabling Data Scientist and machine
learning tools to perform further analysis to optimize machining
operations 9 GE for Customers GE for GE GE for World GE Strategy: Becoming a Digital Industrial Company Productivity ' Digital thread ' Predix + data analytics ' Digital twin/1st principle model ' Services Transformation Apps ' Outcomes for customers ' Optimize GE equipment ' Industrial apps portfolio, micro
services ' Digital extensions Operating System ' Enable industrial companies ' Predix industrial operating system ' Industrial-focused security Supplier Customer One goal in sight ' Drive Productivity and Increase Relevance in the World 2017 General Electric Company - All rights reserved 10 11 Copyright Capgemini 2017. All Rights Reserved Capgemini | February 2017 About Capgemini First European System
Integrator
in the world with
presence in more than 40
countries. Third consecutive year, named
"one of the most ethical
companies in the world
" by
the Institute Ethisphere. Listed to the 'Paris Stock
exchange
' since 1985. Our vision: the value of
technology becomes real
thanks to the people. 12,5M' of revenues, 287M' in Italy
+12.7% YoY, 2009-2015 Italy doubles
Digital + 30% of revenues, 29% growth YoY 3500+ expert in Italy with 9 sites Free cash flow of 1071 M' 11.5% Operating Margin ' 1.55 dividend
buy-back program: 36% of net profit + 180,000 Worldwide resources (98 430 working offshore) North
America
Latin
America
Europe Middle-East & Africa Asia-
Pacific
16 034 9 363 62 301 1 407 91 504 12 Copyright Capgemini 2017. All Rights Reserved Capgemini | February 2017 Capgemini Digital Transformation End to End Capabilities Expertise ' Deep Business Knowledge
' Customer Business Knowledge ' High Skills in code development
' Expertise in development of user interface Delivery Capability ' Drive business change
' Define KPIs
' Support Technology Transition ' Analyze technology
' Find innovative solutions
' Drive Technology
' Enable system pro-activity ' Back End Software development
' Predix OS expertise
' Front End Software User Interface development Role Business Expert Solution Architect / Technologist Software Engineer /
Developer
' High Competencies in Data Science
' Machine Learning Specialist
' Robotics and AI background IoT Architect / IoT Engineer ' Machine Knowledge
' Hardware and Software Expert ' Enable connection between machine and central system
' Enable data collection
' Enable machine communication 4 different roles to ensure skills coverage and high quality performance BACKUP Digital Industrial Revolution in Full Force 152M Cars connect to the internet'6 fold increase 100M Internet connected light bulbs +1B Growth in the installed Base of Smart Meters 10 Petabytes generated by GE machines each day By 2020 2017 General Electric Company - All rights reserved 14 15 Predix Architecture 2017 General Electric Company - All rights reserved 15


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