Voice of Factory: In-Memory and Big Data Applica5ons For Yield and Quality Management

Voice
of Factory
In-Memory and Big Data applica5ons

for Yield and Quality Management

Abhay Satpute
Senior Director
Usha Arora
Vice President
E-business Suite Manufacturing ApplicaKons

October 28, 2015
Copyright 2015, Oracle and/or its aliates. All rights reserved. |
Safe Harbor Statement

The following is intended to outline our general product direcKon. It is intended for
informaKon purposes only, and may not be incorporated into any contract. It is not a
commitment to deliver any material, code, or funcKonality, and should not be relied upon
in making purchasing decisions. The development, release, and Kming of any features or
funcKonality described for Oracles products remains at the sole discreKon of Oracle.
Agenda
1
Industry and Technology Drivers
SoluKon Overview
Yield and Quality Insights
PaVerns and PredicKve AnalyKcs
Architecture
Q&A
Agenda
1
SoluKon Overview
Architecture
Q&A

Disrup5ve Changes Transforming Manufacturing

Industry 4.0
Industry 4.0
Internet of Things
Smart Factory
Big Data
Factory of the Future and the Internet of Things (IoT)
Sensor enabled
device
Interconnected
devices
form a digital line
Factory of the Future :

Mul5ple Digital Lines
And Network of factories

Digital Products
form the Internet of Things
PerspecKve on IOT, Big Data
50 B
2 min.
10%, 1%
Connected World
Networked Society
Internet Of Everything
Machine to Machine
Smarter Planet
Industrial Internet
The Data Explosion

Manufacturing Big Data Analysis is Hard
Work
InstrucKon
High Volume machine data
NonConforman
ces
Rou5ng
High Variety structured & unstructured

Velocity real Kme process monitoring
Bill of
Material
Genealogy
Manufacturing
Resides in Departmental and system Silos

Dicult to synthesize
CollecKon, storage and aggregaKon
Specialized skills
Security and governance
Many technologies, lack of good tools

Big Data
Parts &
Opera5ons
Assembly
Serials and
Lots
Equipment
Product
Quality
TradiKonal Analysis is not enough

Need for a new approach to Analysis
Voice of Factory
CorrelaKon between machine parameters and product quality test results ?
What are the most inuenKal factors that aect product yield and/or quality?
Can I predict product characterisKcs from the tesKng at early step ?
Are there paVerns of behavior of machine ?
Previous Work Order during which we saw the same behavior ?
What lot were processed when machine had certain variaKon of a parameter ?
If yield changes by x% in upstream what would it do to total output ?
Agenda
1
SoluKon Overview
Architecture
Q&A
10
Oracle Voice of the Factory soluKon

IOT and Big Data Applica5ons for Yield and Quality Management
ConsolidaKon and contextualizaKon of
informaKon from mulKple sources
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Yield and Quality Dashboards

Insights from historical data
Real Kme predicKve analyKcs
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End-to-end visibility of manufacturing

process
Designed for business users
An Oracle SAAS on PAAS oering
SoluKons for Discrete and Process Industries

11
Voice Of Factory ApplicaKons

Technology Enablers
Oracle big data
connectors
Oracle BDD
Oracle NoSQL
Database
Advanced AnalyKcs
Big Data Technologies

Cloud CompuKng

Data VisualizaKon
12
Manufacturing Yield and Quality Management

Factors Inuencing Yield and Quality
Man
Poor Operator Skills/Lack of Training,
DeviaKon from SOP
Machine
Wrong calibraKon
over usage
Method
Incorrect tool specicaKon
No documented procedure
Materials
Supplier quality issue
Incorrect ingredient used
Management
Lack of standardized processes
Manual and oine tasks
Man
Machine
Method
CAUSE
Materials
Management
The 5Ms
Early Visibility and ResoluKon is Key.

Exponen5al Increases in Warranty Costs by Lifecycle Phase*
The Rule of 10s
Initial Design
$1X
Simulation Testing
$10X
Prototype Testing
$100X
Initial Production
$1,000X
Warranty Repair
$10,000X
Recall
$100,000X
Early Visibility
Minimizes Units
in Field!
*Source: Warranty Week
SoluKon components
IOT and Big Data Applica5ons for Yield and Quality Management
Yield and Quality Dashboards
PaVerns and CorrelaKon Analysis
PredicKve Analysis
StaKsKcal Analysis
Genealogy Analysis
Traceability and Impact Analysis
15
Oracle Voice of the Factory SoluKon

Big Data Analysis of 5M Man, Machine, Method, Materials, Management
Key ApplicaKon Features:
Yield and Quality analysis Real-Kme monitoring and data analysis of Yield DeviaKon and all contribuKng factors
(within 5M) to improving Yield & Cycle Times
Genealogy Analysis Comprehensive analysis of As Designed, As Built, As Serviced products Analysis to
support Product Call Backs, Enhanced Sourcing etc. (Manufacturers spend millions each year on product Re-call
Analysis, Example: Auto Industry)
Traceability Analysis Real-Kme analysis to trace usage and cause due to man, material, method across
Manufacturing & Supply Chain
Sta5s5cal Analysis Track manufacturing and supplier defects, Yield analysis leveraging histograms, control
charts, Pareto and cause-eect analysis
Paeerns & Correla5on Analysis - IdenKfy correlaKons between component quality, quanKty, equipment/test
staKon parameters and nished product characterisKcs, Yield, Scrap, and Defects with both current and
historical data (Fully leverages 12c PaVern matching algorithms, SAX, Machine learning, and Data Mining
techniques)
Predic5ve Analysis With Time Series, PaVerns, and CorrelaKons Predict with predened set of parameters to
factors spanning product, manufacturing process, and equipment (DownKmes, Maintenance, OEE)
Agenda
1
SoluKon Overview
Architecture
Q&A
17
Voice of Factory
What and Why
Key Business Metrics
The What Analysis
The WHY Analysis
Yield
89% ($750M)
InnovaKve metrics on
key numbers on status
Related indicators for
reasons behind the
status
CorrelaKons and
paVerns generated by
library of algorithms

Defec5ve Products
7% ($459K)
Book to Ship Cycle Time
393 days Key Business Metrics
The WHY Analysis

The What Analysis
The WHY Analysis
Ship to Delivery Cycle Time

Yield
744 days
89% ($750M)
Scrapped Inventory
Defec5ve Products
820 units ($3.6M)
7% ($459K)
Excess Inventory
Book to Ship Cycle Time
25 units ($250K)
393 days
Unan5cipated Down5me
Ship to Delivery Cycle Time
763 hours ($576k)
744 days
Unavailable Workforce
Scrapped Inventory
7 hours ($65k)
820 units ($3.6M)
Excess Inventory
25 units ($250K)
Unan5cipated Down5me
763 hours ($576k)
Unavailable Workforce
7 hours ($65k)
Yield Insights
What, Where, When, How much .
Yields computed across
Product families
Departments
Manufacturing faciliKes
Over Kme
Industry specic aggregaKons e.g. Heat
Simplied scrap monitoring
Industry leading visualizaKons
Easy drill downs and data access
19
Real-Kme Yield SimulaKon and Impact Analysis

Simulate changes in the yield of a producKon
batch
Rollup Costs of enKre batch genealogy as per
planned requirements, actuals and simulaKon
Assess impact on product Costs & yield, plant,
producKvity, margins & prots
Real-Kme access to yield analysis of producKon
batches.
Respond to producKon shortages or surplus
eecKvely
Drill through producKon history and discover the
root causes of low yield
20
Quality Insights
What, Where, When, How much .
Product defects across
Product families
Departments
Manufacturing faciliKes
Over Kme
Scrap, Reject, Rework
Test failure stats and trends
Non-conformances
Root cause clusters
21
Genealogy and Traceability

Trace Material, Work and Resource

Material Flow Network
ProducKon Order Timeline

22
Material Flow Network

As Built Genealogy
Complete Traceability
Inbound Material
Material Inside manufacturing plant
Outbound material
InteracKve and IntuiKve UI

Zoom and Pan
Right click for more informaKon
Expand / collapse
Track lots and Serials

InteracKve User interface
23
InteracKve ExploraKon
24
Timeline
Work and Resource Time Line
Work Timeline
Batch / Job Start and End Kme
Step / operaKon start and End Kme
Ingredient / Material issue
ExcepKons
Resource Time line
Machine status
Process parameter ExcepKons
QuanKty completed
Single view of data from ERP,MES, Machines, Quality

25
StaKsKcal Quality Analysis

Monitor Processes and Quality
Large library of AVribute and Variable
process control charts
Decision rules (Western Electric, Nelson)
to detect out of control condiKons
MulK-dimensional data analysis
Any relaKonal data source
InteracKve, Congurable dashboard
Prebuilt adaptors
Oracle Discrete Manufacturing
Oracle Process manufacturing Quality
User congurable Tool board for StaKsKcal Analysis

26
Variable control charts
Run Chart
XmR chart
X bar R and Process Capability charts
27
MulKdimensional Analysis
Bar Charts
Pareto Charts
Single and
Multiline Trend
Charts
Scatter Pairs
28 28
CorrelaKons VisualizaKon
StaKsKcal correlaKon
visualizaKon to show the
relaKonships between
dierent test results

Oracle CondenKal
29
Agenda
1
SoluKon Overview
Architecture
Q&A
30
PaVern Matching
Insights From Big Data
Analyze manufacturing big data from
mulKple sources to detect paVerns
Supervised and unsupervised data mining
funcKons to idenKfy :
Top factors aecKng yield or quality
AssociaKons and co-relaKons among
inuencing factors
Impact of process variaKons on quality
Core determinants of process performance
Co-relaKon between ingredient quality and
test results
Analyze paVerns in Kme series machine data
31
PaVern Matching
Transform Data to Ac5onable Insights
PaVerns & CorrelaKons / Machine Learning
Time series machine data analysis

32
PredicKve AnalyKcs
Real Time Data Analysis
Analyze real Kme data to
Assess downstream risks
Minimize defects, maximize yields
Take correcKve acKons
PredicKons based on historical insights
Role based User interfaces
Dashboard for business users
Tool board for data scienKsts
Drill downs to supporKng data
Leveraging Insights from Historical data
33
Agenda
1
SoluKon Overview
Architecture
Q&A
34
Oracle IOT Apps Cloud Voice of the Factory ApplicaKons

Oracle Cloud Services
ORACLE CLOUD SERVICES
ON-PREMISE APPLICATIONS
DATA FLOW
Oracle Big Data / IoT Apps Cloud

Voice of Factory
ERP ApplicaKons
Voice of Customer
Yield/Quality Analysis
StaKsKcal Analysis
Explore & Discover
ERP
Reference
Data

Sensors

MES

Factories /
Equipments
External
Sources
PredicKve Analysis
Voice of Product
Data, AcKons
and Events for
ERP/Other Apps
Genealogy & Traceability

PaVerns & CorrelaKons
Oracle Cloud Playorms (PaaS)

Oracle BI
Cloud Service
Oracle Mobile
Cloud Service
Storage and Persistence
Oracle Java
Cloud Service
Oracle Big Data

Discovery CS
Oracle
Integra5on CS
Federated
Queries
WAN
Oracle Database
Cloud Service
Quality
/Test
Data
Oracle IoT Analy5cs

Cloud Service
Oracle Big Data

Cloud Service
PLC /
SCADA

Copyright 2015, Oracle and/or its affiliates. All rights reserved.

Agenda
1
SoluKon Overview
Architecture
Q&A
36
Keep Learning with Oracle University
Classroom Training
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Learning SubscripKon
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Live Virtual Class
ApplicaKons
Training On Demand
Industries
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37
Related Sessions
Thursday, October 29, 2015
CON8153 Gain Supply chain Visibility with Oracle Outsourced Manufacturing
Solu5on
12:00 p.m. Anand Gangal, Oracle PracKce foundaKon leader, Cummins Inc
Nikhil Tungare, Senior Manager, Oracle

Muralidharredy Venkatasesha, Director, Product Management, Oracle
2:30 p.m.
CON8149 - Oracle E-Business Suite Manufacturing Applica5ons: Customer Success

Stories
Gurpreet Kaur, Senior Director, LifeCell IT
Leela Krishna, Principal product manager, Oracle
Moscone
West3012
Moscone
West3011
38
Manufacturing Demo Grounds

Industry 4.0/Factory of the Future: Internet of Things (IoT), In-Memory
and Big Data Applica5ons
Moscone West, Level 1

WorkstaKon ID: WSC-021
Oracle E-Business Suite Process Manufacturing Solu5ons


Oracle E-Business Suite Discrete Manufacturing Solu5ons

Oracle - Stratasys 3D Printer Demo

Moscone South
39
Manufacturing Demo grounds

Industry 4.0/Factory of the Future: Internet of Things (IoT), In-Memory and
Big Data ApplicaKons

WorkstaKon ID: WSC-021 Venue: Moscone West, Level 1 SCM Showcase
Oracle E-Business Suite Process Manufacturing SoluKons

Oracle E-Business Suite Discrete Manufacturing SoluKons

Oracle - Stratasys 3D Printer Demo

WorkstaKon ID: XXXX Venue: Moscone South

Voice of Factory: In-Memory and Big Data Applica5ons For Yield and Quality Management

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Voice

In-Memory and Big Data applica5ons

E-business Suite Manufacturing ApplicaKons

Copyright 2015, Oracle and/or its aliates. All rights reserved. |

Safe Harbor Statement

Copyright 2015, Oracle and/or its aliates. All rights reserved. |

Industry and Technology Drivers

Yield and Quality Insights

PaVerns and PredicKve AnalyKcs

Industry and Technology Drivers

Yield and Quality Insights

PaVerns and PredicKve AnalyKcs

Industry and Technology Drivers

Factory of the Future and the Internet of Things (IoT)

Factory of the Future :

Copyright 2015, Oracle and/or its aliates. All rights reserved. |

PerspecKve on IOT, Big Data

The Data Explosion

High Volume machine data

High Variety structured & unstructured

Resides in Departmental and system Silos

TradiKonal Analysis is not enough

Need for a new approach to Analysis

Industry and Technology Drivers

Yield and Quality Insights

PaVerns and PredicKve AnalyKcs

Oracle Voice of the Factory soluKon

Yield and Quality Dashboards

End-to-end visibility of manufacturing

SoluKons for Discrete and Process Industries

Voice Of Factory ApplicaKons

Big Data Technologies

Manufacturing Yield and Quality Management

Early Visibility and ResoluKon is Key.

The Rule of 10s

*Source: Warranty Week

Copyright 2015, Oracle and/or its aliates. All rights reserved. |

Yield and Quality Dashboards

PaVerns and CorrelaKon Analysis

Traceability and Impact Analysis

Copyright 2015, Oracle and/or its aliates. All rights reserved. |

Oracle Voice of the Factory SoluKon

Industry and Technology Drivers

Yield and Quality Insights

PaVerns and PredicKve AnalyKcs

The What Analysis

The WHY Analysis

The WHY Analysis

The WHY Analysis

Ship to Delivery Cycle Time

Copyright 2015, Oracle and/or its aliates. All rights reserved. |

Real-Kme Yield SimulaKon and Impact Analysis

Copyright 2015, Oracle and/or its aliates. All rights reserved. |

Genealogy and Traceability

Material Flow Network

ProducKon Order Timeline

Material Flow Network

InteracKve and IntuiKve UI

Track lots and Serials

Copyright 2015, Oracle and/or its aliates. All rights reserved. |

Single view of data from ERP,MES, Machines, Quality

Copyright 2015, Oracle and/or its aliates. All rights reserved. |