e-Manufacturing; before and after
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The document discusses the implementation of e-manufacturing by ACS Corp. in Korea, highlighting the challenges faced in traditional manufacturing and the advantages of real-time data integration. It details the deployment of various technologies, such as IoT and automated information systems, which have led to significant improvements in production efficiency, cost reduction, and customer satisfaction. Key findings emphasize the need for accurate data, a supportive organizational structure, and collaboration with global vendors for successful manufacturing innovations.
e-Manufacturing; before and after
- 1. Antonio Suk Keun Cha Cofounder/CTO ACS Corp. in Korea December 2nd, 2014
- 4. I. Before: Scoping of e-Manufacturing Manufacturing is the production of merchandise for use or sale using labor and machines, tools, chemical and biological processing, or formulation based on provides flexible for increasing quality, reducing cost and shorten delivery for manufacturing processes. – Source:Wikipedia Q C D F Quality Cost Delivery Flexible Manufacturing business opportunities in El Salvador Mission for CEOs
- 5. I. Before: Scoping of e-Manufacturing “What are your biggest problems with manufacturin”g? (multiple responses accepted) Poor visibility into plant operations Inaccurate demand forecasting Poor communication Supply shortfalls Poor customer satisfaction Don’t know Percent of 100 manufacturing companies responding 38% 36% 24% 18% 8% 8% Forrester Research, July 2000
- 6. Enterprises must insure that data is accurate and timely, to support collaborative initiatives Data Latency and Inaccuracy Six common practices that will cause ERP II failure: Manual adjustments to inventory Relying on annual physical inventory Delaying material receipts and issues Ignoring rescheduling and exception messages Production reporting only at the end of the line Using “dummy” sales and/or purchase orders Fall Conference 2001 Direct, Automated Information Feeds Enterprise Applications e-Manufacturing with Real Time Enterprise I. Before: Scoping of e-Manufacturing
- 7. I. Before: Scoping of e-Manufacturing Real time collection of 4M1E (Man,Machine,Material,Method,Energ) and providing real time performance measurement for internal optimal decision based on production current status, product promised date for customer satisfaction in every type of manufacturing enterprises. You cannot manage what you can not measure!!! Before Customer information Deliver information 군산생산감시시스템 (화성) BUMPER I/P Monitoring/Analysis Information Decision making Information Real time 4M1E data Integration After 4M1E
- 8. I. Before: Scoping of e-Manufacturing The Methods of 4M1E integration in real time with International standard -Wired sensor networks : Communication Protocols, Process I/O, Sensor I/O -Wireless sensor networks: Internet of Things/Machine to Machine(IoT/M2M), RFID/Bar Source Items Method Std. OP Lot No. Traceability … Machine Counter Run time Failure reason Material Location Specification WIP level … Man Start/End Failure code Not run Reasons … Energy Voltage, current, flow, Pressure … 4M1E Device Controllers Wired Sensor Networks RFID PLC Machine e-Manufacturing Software (POP/MES/ERP) Protocols Process I/O Sensor I/O PDA Mobiles Office PCs RFID/USN Touch Screen Mobiles Wireless Sensor Networks Wired IoT/M2M Devices Sensors Relays Access Point Bar code Reader Touch Terminals ISO 22400 ISO JTC 1 Wireless Sensor Network IoT/M2M Device Gateway code, Touch screen, Mobile devices Wired IoT/M2M Device Production floor (POP: Point of Production, MES: Manufacturing Execution System ERP: Enterprise Resource Planning)
- 9. 9 • Wired IoT/M2M devices - Open embedded Linux based low power consumption intelligent devices I. Before: Scoping of e-Manufacturing • Wireless IoT/M2M devices - Low power and small size of IP based wireless sensor network Installed Installed
- 10. • Touch Screen Terminals - No IT resource in terminal - Low power, good for harsh environment - No issue of hacking and IT security - Easy to use manual data entry by workers 10 : Display big characters & touch I. Before: Scoping of e-Manufacturing • Managing by moving - mobile for production and maintenance - PDA and smart phone integration
- 12. II. e-Manufacturing deployed by ACS • 1,000+ Real time production management system in world wide since 1988 • International Standard based COTS(Commercial Off The Shelf) approach Name ACS(Advanced Consulting Services Co.) Business consulting service, solution developing manufacturing ICT convergence Employees 95 R&D budget 8% of Annual Revenues (as of 2013) Core Technology e-Mfg®, u-Mfg® Auto-configuration® real time event driven, M2M/IoT Qualified Product DABOMⓇ-series Central managing by DABOM globally distributed manufacturing enterprises DABOM® means “see-all” in Korean word and a trademark of ACS
- 13. II. e-Manufacturing deployed by ACS Industrial Template functions Real time event based Middleware (DABOM-Middleware) Manufacturing International standard application (ISA S-95 MESA-11) DABOM-MES Industrial specific application Wired and wireless sensor Devices (DABOM-Device: iTOUCH, iDCU)
- 14. Company facts - Annual Rev : 10 Million USD - No. of Employees : 104 peoples - Type of Manufacturing : Electronics Part - Type of Products : AC IN/OUT LET , PIN JACK Reasons for deployment II. e-Manufacturing deployed by ACS - Can not see what is current status of production line - Impossible to productivity analysis and quality, equipment down history due to manual reporting - No way to make a decision for delivery due date - No way to estimating accuracy production planning User Benefits - More than 25% increased quality control level - Quickly respond for production issue - At least 30% reduction cost of record and analysis works - Increased customer satisfaction - More than 20% increased run time of equipment
- 15. Hardware & Network Configuration - ERP access - ACS DABOM-MES access Office PC ERP Server (H.Q) ACS DABOM-MES Extrusion machines (27 Unit) Device Interface (4 Unit) Press Line Device Interface (6 Unit) …… Press (12 unit) 8 Machines Manages by PDA …… 21machines manages by PDA Extrusion Line Touch Screen Assembly line Internet II. e-Manufacturing deployed by ACS
- 16. Reasons for deployment User Benefits - Reduced 30% of labor cost - 25% of reduced capital investment - 10% of increased profit of company II. e-Manufacturing deployed by ACS Company facts - Jeju Local Government operation - Annual Rev : 170Million USD (23.1% Market) - Type of Manufacturing : Process industry - Type of Products : Drink waters - Image making Jeju Local Government as clear and trust - Needs real time tracking of drink waters - Impossible to tracking of labor and production cost
- 17. POP/MES Server ERP Server Wireless Access Point Touch Screen Terminals Bar code Printer Large LCD Display PDAs PLCs II. e-Manufacturing deployed by ACS
- 18. Work order plan Quality Trend II. e-Manufacturing deployed by ACS
- 19. II. e-Manufacturing deployed by ACS Before After Result 68% Reduced 32% WIP 100% 65% Reduced 35% 240 Min./ Month 120 Min./Month Reduced 50% Item Inventory Time for Inv. Level 100% Leadtime 1.95 Min. 1.05 Min. Reduced 46% Inventory accuracy 60% 97% Enhanced 57% Short STOP Time 120.85/Month 24.96/Month Reduced 79%
- 21. 21 III. After: Smart Factory and Vision • USA: Focused on Global Coordination with 3 D printing • Germany: CPPS: Cyber Physical Production System for smart Factory • Korea: Smart Factory using ICT • 제조, ICT, 서비스 산업의 융합에 따라 제조업의 비중이 다시 높아짐 Manufacturing 2.0 Industry 4.0 Manufacturing Innovation 3.0
- 22. 22 III. After: Smart Factory and Vision • Vertical Top down -> Horizontal Internet driven • One way -> Bi-direction • Wired networks -> Wireless Sensor Network • SMART(Seamless, Mobility, Autonomous Configuration, Real-time, Traceability)
- 23. ③ Chungnam Techno Park SaaS based e-Manufacturing Services ② ② ① ① Green IT 23 III. After: Smart Factory and Vision
- 24. POP Application Dabom®-middleware POP Server Line 1 Remarks Bar code reader Sensors Touch Panel IDCU Hard Wire Wireless AP 100Mbps Fast Ethernet Production Status Display Production Status Display Line 2 Line 3 Line 4 Line 5 Line 6 Line 7 Line 8 Line 9 Line 10 Line 11 Line 12 Warehouse MES Server & Dabom®-MES Application Wireless M2M Device Wireless bar code reader Thin client Touch Terminal 24 Implementing production line at Yong-san plant III. After: Smart Factory and Vision
- 25. User benefits III. After: Smart Factory and Vision Index Detailed index Y Co. Current Target Time for Work order Delivery time for work order 1H 15M 3M Time for daily inventory audit Time for inventory status 5H Real time Real Time Time for inventory status Report 5H 10M 5M Time for daily work report generation Time for work order 3H 15M 5M Time for summary 2H 15M 5M Total 16H 55M 18M Index Detailed index K Co. Current Target Time for daily inventory status Time for inventory status 3H Real time Real time Time for daily sales summary Time for sales summary Real time Real time Real time Time for report 1H Real time Real time Audit time Closing for logistic 15H 10M 5M Time for financial report (5H) - Real time Monthly average closing time 10Days 5Days 3일 Total 10Days 19 hours 5Days 10 Min 3 days 5M
- 27. IV. Lessons learned and recommendation For Executives of Manufacturing SMEs - Mindset of what really means by real time for production resources(4M1E) : Bar coder reader can not cover every issues in production - Think about TCO (Total cost of ownership) : Development cost of 30% and maintenance cost of 70% - Think about bottom-up approach with step by step deployment No Top-Down For Executives of ICT vendors - Need a skill set of 4M1E integration in real time for global consulting services - Need Real time event driven middleware functional support for local maintenance - Need to train ICT peoples
- 28. To El Salvador IV. Lessons learned and recommendation - Must establish a support organization dedicated for the Government control : Look at the case in Korean case (Dr. Kim will help you!) and the Smart Factory program - Collaboration with global vendors as Korea : Development cost of 30% and maintenance cost of 70% - Bench-making of global success cases like the SaaS model for Cloud computing : Chungnam Techno Park in Korea to be an excellent reference site
- 29. Gracias ! 29
Editor's Notes
- #13: 우선 시작하기 전에 저희 회사에 대하여 설명 드리겠습니다.. 1988년에 설립하였으니 올해 26년 되는 기업이구요.. 설립 후 현재까지 제조업에 필요한 실시간 생산정보화 즉, 전세게 산재된 공장을 실시간으로 운전상황을 눈으로 볼 수 있도록 하는 솔루션 DABOM을 공급하고 있으면 현재까지 1,000 프로젝트를 성공적으로 수행하였습니다. DABOM은 대표 솔루션으로 다보여준다는 순수한 우리말을 의미하며 상표 등록했습니다..본 제품은 국제 표준기반으로 상용화된 정보기술을 열악한 환경에 사용할 수 있는 상용화 기성품 COTS (Commercial Off The Shelf) 기술을 적용한 기업이죠.. 매출의 8% 이상을 연구개발 분야에 투자하고 있으며, 산업부 및 미래부 등 정부기관으로부터 신기술, 신제품, 세계일류상품, 굿 소프트웨어 및 산업용 소프트웨어 품질 인증을 국내 최초를 받기도 했습니다.