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Machine Builders in my Factory?

As you know there are many changes in manufacturing operations today. These certainly relate to Operations Excellence, Continuous Innovation, Energy Management, even the Supply Chain and Customer Service world. There are technology changes and personnel changes. There are Global impacts as manufacturing companies compete in new regions and those same new regions sprout new manufacturers. And at the end of the day (or maybe the beginning?) there is a need for someone to build a specialized machine.

We have already seen the power of a converged (technologically) network. Ethernet/IP helps the controls world provide information to the IT world. We see this every day, where older proprietary networks are replaced by standard Ethernet. Here are some thoughts as they relate to specialized machine builders:

So, we have this technology that can unify us, Ethernet. Who knew that years ago I sold against Ethernet? But that was a different version. Today is new, with managed switches, managed services, and tomorrow is your new today.

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Tracking Assets: RFID Meets Industrial Wi-Fi – Industrial Ethernet Book Part 1

October 27, 2011 at 12:07 pm PST

I had the pleasure of meeting up with both Leo Ploner, Publishing Director, Industrial Ethernet Book (IEB) and Tom McNulty from the Chicago, US office recently here in Silicon Valley recently. I was pleased to see that Cisco had contributed to an article in the 65 / 35 Issue of the Industrial Ethernet Book around the topic of RFID and industrial WiFi – a topic close to my own heart in terms of previous blogs of mine (Intro to RFID, Continental Tire, Boeing, and John Deere).

The first Industrial Ethernet Book was published in 1999.  Since then it become an excellent  information source for industrial networking and communication technology, and aims to provide unbiased editorial views focused on both process and discrete manufacturing industries. The editorial content is aimed at end users, system integrators and vendors within factory automation and process automation.

The article starts with the recognition that “Increasingly ‘smart’ devices, which include radio frequency identification (RFID) tags and sensors that have advanced diagnostics, are contributing to the billions of devices now connected to IP networks. This proliferation of smart devices is referred to by some as the ‘Internet of Things’, and it is projected to grow to trillions of devices that will be connected using the emerging IPv6 protocol (ref1). For manufacturers, a growing number of connected smart devices promises to revolutionise portability, mobility, context-aware condition and use of critical assets.” Read More »

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John Deere avoids cost with Cisco Wireless Architecture

September 29, 2011 at 11:40 am PST

Maybe you’ve seen the recent article in RFID Journal: John Deere Planter Factory Gains Efficiency.

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.

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Boeing Delivers First 787 Dreamliner. Cisco Delivers Solutions to Boeing. Congratulations Both!

September 26, 2011 at 5:56 pm PST

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!

Jim does talk about the delays -- but it was such a vast undertaking -- and in the ‘old days’ it would have taken a lot longer! There are plenty of Manufacturing improvements that have taken place over the decades that have helped speed things up. Here are three Cisco Solution areas where Cisco and its partners made a difference: Cisco WebEx, Cisco MMVC (Manufacturing Mobile Video Collaboration) Solution, and Cisco Context aware, many using Cisco Unified Industrial Architectures. It’s as easy as 1, 2, 3 for any manufacturer who wants to know the secrets. Here’s how, and with customer comments to boot

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Cisco and Partners add Business Value for Continental Tire

September 1, 2011 at 10:53 am PST

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.

But now back to the customer… Read More »

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