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TEKsystems Global Services® helps clients implement an innovative Big Data for Manufacturing solution that provides a 360-degree view of shop floor performance, allowing for real-time corrective actions to improve efficiencies and reduce costs.
TEKsystems has worked with a diverse group of manufacturing clients across a wide variety of industries, including oil and gas, automobile, and consumer packaged goods, to implement our Big Data for Manufacturing solution.
Manufacturing organizations are constantly searching for new ways to deliver high-quality products while keeping production costs low. Recent developments in technology and advances in shop floor automation throughout the 20th century have driven the manufacturing industry to become more intelligent. Ensuring that shop floor equipment and the technologies that power them run smoothly is now more critical than ever to meeting organizations’ business goals and making sure the pace of production meets demand levels.
Since shop floor equipment plays such a vital role in production today, businesses must scrupulously monitor the equipment’s performance and understand its unique components to ensure that optimal efficiencies and the desired rate of production are being achieved. These machines are often outfitted with a wide assortment of industrial controllers that generate copious amounts of data specific to that controller’s unique function, and in different output formats and attributes (e.g., temperature, pressure, RPMs) depending on the sensors’ functionalities. Because of the variety of equipment manufacturers, sensors and last mile connectivity, organizations face huge challenges in collecting data and making sense out of it. With so many shop floor machines generating data in varying formats, it is difficult for most organizations to report on and aggregate the data into actionable insight they can derive real value from.
Additionally, many organizations do not have an analytics software solution that supports data collection, evaluation and summarization, so any subsequent reporting and analysis is often done manually, if at all. Manual data analysis is time consuming, can contain errors and is reactive rather than proactive because it cannot be done in real time. As a result, businesses struggle to understand how to improve upon the data they gather and have a minimal understanding of where trends in performance and data occur or why shortcomings in production are present.
Big Data solutions provide companies with the opportunity to better understand disparate data sources and formats across their shop floors, allowing business owners to pinpoint areas for cost savings, real-time corrections and analysis, and overall improved efficiency. Managing and understanding output data can be extremely powerful; proactive steps can be taken to address underperforming machines or machine components and more predictive equipment maintenance can be achieved. Organizations that leverage this insight can make more informed business decisions, such as when new parts need to be ordered and why some machines are outperforming others in terms of quality and speed. Overall, organizations are better positioned to accurately predict end-of-day production numbers needed to maintain revenue streams and meet consumer demand.
TEKsystems Global Services® offers manufacturing clients a Big Data solution that provides greater insight into shop floor performance. Our customized solution provides visibility into large amounts of data being reported by various pieces of shop floor equipment in different formats. Understanding this data, and being able to process it in real time, allows plant managers to quickly take corrective actions as needed to improve overall performance, create higher quality products and yield greater efficiencies.
Leveraging Oracle Manufacturing Operations Center (MOC), Oracle Manufacturing Analytics, Oracle Big Data Appliance, Oracle Big Data Discovery and Cloudera CDH, TEKsystems’ solution allows for the exchange of information between the Big Data solution and multiple manufacturers’ industrial controllers. This enhanced ability to communicate allows for the compilation and analysis of disparate data, made available in comprehensive reports displayed on analytical applications. These dashboard reports allow plant managers to view shop floor data in real time and understand performance metrics for each individual shop floor asset. These dashboard views also allow managers to harness data from various sources and remediate issues immediately if a machine or controller is underperforming or malfunctioning.
Oracle BI Applications (OBIA), Oracle Business Intelligence Enterprise Edition (OBIEE), Oracle Manufacturing Operations Center (MOC), Oracle Big Data Appliance (BDA), Oracle Big Data Discovery (BDD) and JD Edwards, Cloudera CDH
Our customized solution provides visibility into large amounts of data being reported by various pieces of shop floor equipment in different formats.
The client, one of the world’s largest manufacturers, had multiple production lines in their plant, each producing a different appliance. Each line was made up of multiple machines that performed unique functions as part of the overall appliance assembly process. The machines were automated with various sensors to record performance data, such as temperature, speed and quality parameters. Even though data was collected by the machines, there was no single platform or view of the operational data displaying day-to-day enterprise data collected by enterprise resource planning systems. This meant that the day-end performance report only showed a high-level view of the shop floor’s performance and that it was only as strong as the weakest machine on the line, since individual machine performance and quality could not be viewed.
The client was looking for a way to better understand the operations and performance metrics for each unique machine and machine sensor so they could understand when and how individual machines were underperforming and pinpoint areas for improvement. Having a means to view more sophisticated operational analytics would allow plant managers to proactively tweak any performance issues on the floor as they occurred. It would also help plant managers identify patterns in equipment usage or equipment performance as they pertained to production speed, quality or errors. This increased insight would help improve overall production line performance, better ensure daily production goals were met, and provide a greater understanding for when and why new components needed to be ordered for an individual machine.
Having previously partnered with TEKsystems for enabling shop floor visibility, amongst other engagements, the client asked us to assist them with implementation of Oracle MOC 12.1.3, a sophisticated Big Data solution that allowed for reporting of granular data specific to each individual machine on the shop floor. Specifically, the software would provide plant managers with dashboards and reports to show resource productivity and machine metrics to take corrective actions in real time. This increased level of insight would allow for higher-quality products to be produced and improve overall productivity of various production lines.
Over the course of about one year, TEKsystems provided a team of technical and functional consultants to do the entire implementation. We used iterative implementation methodology, taking approximately 12 to 13 weeks to complete every line. The client now has greater visibility into their shop floor and can view performance metrics generated from each machine at any given time, allowing for immediate remediation steps when needed. The client has also gained a more in-depth look into their shop floor performance, which has led to lower maintenance costs, extended asset life, higher production volume and lower operational costs, as floor managers can now keep a pulse on every facet of their production lines.
Below is a sampling of two additional client success stories.
The client, a global medical device manufacturer, sought TEKsystems’ help in implementing Oracle MOC and OBIA Manufacturing Analytics so they could better understand and track when various medical devices were being manufactured and what specific components were going into each product, which would help ensure compliance with device standards. By implementing MOC and OBIA, the client realized increased insight into the various machines producing medical devices within their plants. The client also gained the ability to easily track and record relevant data for each machine on comprehensive dashboards.
The client, a leading multimaterial product developer, was using Oracle’s JD Edwards 9.0 to monitor and track internal machines producing rubber-based cushions. While useful for providing collaboration within the client’s network, the machines lacked a way to communicate with Oracle MOC 12.2.2, which would provide more comprehensive and in-depth reports of the various machines’ components and performance metrics. The client first partnered with two outside vendors that attempted to directly install MOC, but due to a lack of knowledge about the intricacies of integrating the two systems, both vendors were unable to deliver the Big Data solution the client sought. Aware of our success implementing our Big Data for Manufacturing solution at a number of other manufacturers, the client reached out to TEKsystems for assistance in getting their MOC solution up and running.
TEKsystems customized MOC to source data from JD Edwards software. The enhanced communication and customized Big Data solution allowed the client to view real-time BI reports on four separate reporting dashboards that showcase contextualized data collected from shop floor devices. This improved visibility established a greater understanding of production and individual machine metrics and performance, which has helped the client decrease machine downtime and improve overall operational efficiency.
By implementing MOC and OBIA, the client realized increased insight into the various machines producing medical devices within their plants.
As an Oracle Platinum Partner and an Oracle BI Co-development Partner, TEKsystems has extensive knowledge of Oracle’s expansive catalogue of BI, enterprise project management and Big Data solutions. Having helped clients across all industries implement complex solutions across the full spectrum of Oracle products, we have a unique understanding of best practices for implementing integrated Oracle solutions.
Connected solutions are increasing in popularity for many organizations due to the highly versatile, mobile and intelligent nature of the capabilities and information they provide. TEKsystems is at the forefront of understanding the best way to integrate connected solutions into an organization to build upon existing technology and advance enterprise business operations.
TEKsystems works with a multitude of manufacturers across many industries, each facing their own unique set of operational challenges, compliance mandates and business goals. Our experience spans a wide variety of services, including technology deployment, analytics, Big Data, enterprise applications, middleware and integration, QA and testing, and custom application development. Completing these diverse engagements uniquely positions us to understand the problems faced by manufacturers, including shop floor logistics, as well as these organizations’ technical environments and overall business objectives.