John Deere, working with integration and technology partners Prime Technologies (now Kubica) and AeroScout, used the existing Cisco Wi-Fi networking nodes that it had already installed throughout the facility to avoid the expense of installing RFID readers for a new manufacturing solution.
John Deere MaxEmergeXP
Here’s the story: John Deere’s Seeding Group factory in Moline, Ill. was seeking an automated solution to improve on its manual work in process manufacturing system. It wanted to increase efficiency in the way it replenished welding material as well as improve the way it carried out processes at its assembly stations at the plant. The factory in question assembles John Deere’s row-crop planter machines -- the MaxEmerge XP range - that are used by farmers to deposit a variety of seed in soils and seedbeds.
The new system uses a wireless back-haul to a Cisco infrastructure that enables the SAP, reporting and programmable logic controller (PLC) systems to communicate live. It’s intended to improve material replenishment and reduce delays caused by waiting for materials in its welding areas. It allows the equipment manufacturer’s kitting staff to boost material replenishment speed, and allows assembly workers to prepare for specific equipment as it approaches their assembly stations. The RFID Journal Story goes into excellent detail on the wip process and the process improvement, but I did want to reiterate some of the key business metrics:
“Our goal was to improve Takt time *,” says Shay O’Neal, John Deere Seeding Group’s project manager, who expects the reduction to increase from what he estimates may be about 5 percent improvement in Takt time thus far. He reckons there has been a 40 percent reduction in cycle time because of the improvement in replenishment. He has also seen a decrease in overtime work undertaken by kitting staff at the welding station. “I was pleasantly surprised to see how well the system met our needs,” O’Neal said in the RFID Journal article.
John Deere has seen a 40 percent increase in efficiency in welding due to improvements in material replenishment and fewer delays caused by waiting for materials in its welding areas.
On the assembly line, the system provides a view into the work in process (WIP), which thus far has reduced the cycle time (Takt) it takes to assemble a single product by about 5 percent.
Since existing Cisco Wi-Fi nodes read the RFID tag of each seeder as it passes from one assembly station to another, indicating where it has been and what its next assembly location will be, John Deere avoided the expense of installing RFID readers.
In my most recent blog “U.S. manufacturing: is it sustainable?“, I referenced an article about how U.S. manufacturing has been leading the economy out of the depths of the Great Recession. The authors put forward a thesis with supporting data that suggest Americans believe the manufacturing industry is the basis for wealth creation and is fundamental to a sustained and successful U.S. economy.
The rub is that only 30% of Americans said they have or would encourage their children to pursue a manufacturing career.
Why such a discrepancy? An answer to this question is not simple. However, I do believe we must seek that answer and address the gap, if the U.S. is to remain competitive in the global marketplace. Being an engineer myself--a manufacturing and controls engineer no less--I know the first and most essential step to a solution is making sure we’ve defined the problem well.
According to the survey, the top three reasons why kids aren’t interested in engineering:
Kids don’t know much about engineering (44 percent).
Kids prefer a more exciting career than engineering (30 percent).
They don’t feel confident enough in their math or science skills (21 percent) to be good at it. This is despite the fact that the largest number of kids ranked math (22 percent) and science (17 percent) as their favorite subjects.
Survey findings on the adult side:
Only 20 percent of parents have encouraged or will encourage their child(ren) to consider an engineering career.
The vast majority of parents (97 percent) believe that knowledge of math and science will help their children have a successful career.
So, while American children and adults both feel that math and science are important (even enjoyable), there is an ironic disconnect (cognitive dissociation?) between recognizing the importance and committing to pursue a career in engineering and manufacturing.
Congratulations to Boeing on shipping it’s first 787 Dreamliner to ANA (All Nippon Airways). The world has been waiting and US Manufacturing has delivered. But it’s not just US Manufacturing -- suppliers as far away as Australia, Italy, Japan and Russia, to name but a few countries have been working with Boeing Engineers to bring the airplane to market -- and using Cisco or Cisco Partner technologies to do so!
The video, courtesy Associated Press’ YouTube Channel, shows the first Boeing 787 Dreamliner Airplane being handed over by Jim Albaugh, President and CEO, Boeing Commercial Airplanes, to ANA’s President and CEO - with a large key!
There’s been a lot of buzz on the Internet about the way Continental Tire of the Americas has vastly improved its manufacturing process. They adopted an innovative solution based on a Cisco architectural networking approach provided by Cisco Partner Applied Group combined with AeroScout’s asset tracking solution and a inventory management system from Global Data Sciences enabling their manufacturing facility achieve a 20 percent reduction in component tire losses. Now that’s significant!
Chet Namboodri interviews Peter Granger about the benefits Continental Tire is achieving from the Cisco Unified Wireless based manufacturing/wip solution
It was a real pleasure for me to take part in the Customer case study event organized by Cisco, AeroScout and Global Data Sciences for me to speak about the Cisco contribution. The video gives a short summary as Chet Namboodri, Cisco Industry Blogger-in-Chief and Global Managing Director of Cisco’s Manufacturing Industry Marketing interviews me about what was said, and the benefits Continental expects.
That event is where I met up with folks from Continental, AeroScout and Global Sciences to hear from the customer first hand how the solution is increasing production and efficiency in its North America manufacturing plant. That plant is located in Mount Vernon, Illinois, and it produces more than 1,000 different tire SKU’s in its 60-acre (2.6 million square-foot) facility.
The implemented solution leverages Continental Tire’s Cisco Unified Wireless Network to add a Real-Time Location System (RTLS) and automated Work-in-Process (WIP) tracking without having to install a proprietary network of readers and sensors. That’s key. Cisco provides standards-based solutions that work well with a customers backhaul, which, for most customers is also Cisco. Cisco’s Architectural approach means networking elements and processes work well together with ‘compatibility’ tested solutions such as those from AeroScout.
Cisco Live’s first ever “Industrial Intelligence Day” focusing on manufacturing and industrial customer needs was judged a great success according to the feedback given at the sessions in Las Vegas this week. In an action packed day attendees heard about trends in network convergence between business IT and Industrial plant networks, and how standard Ethernet IP protocols were becoming prevalent in industrial and control networks.
As Master of Ceremonies, I had the pleasure of introducing Alan Cohen, Vice President, Global Public Sector & Industry Solutions. Alan kicked off the day talking about the care-abouts of executives in Manufacturers and how Cisco is addressing them. He used real-life customer examples such as Coca-Cola, General Motors, GE, Continental Tire and Anglo Platinum. Alan expressed how Cisco was helping these customers address the challenges of Growth, Market Transitions, Innovation, Risk and Goverance. This set up a good interactive environment for Bryce Barnes and John Parello to introduce Energy and Sustainability for the manufacturing sector. Bryce pointed out that 35% of all energy usage in the world is consumed by manufacturing industry and we added that that figure goes over 50% if you include the transportation and distribution of those manufactured goods and materials.
After watching John Chamber’s Insightful Keynote, delegates returned to hear Paul Didier and Chris Haley (both Cisco) and Gregory Wilcox (Rockwell Automation) talk about the status and trends for wired LANs including resilience and security with a fascinating presentation on Motion from Gregory. That was followed by wireless strategies from David Wolf and Scott Friberg from Cisco talking about wireless innovations and real-world testing where wireless is now deemed appropriate for time critical applications. Then delegates went to the main tent for a thought-provoking session. Read More »