2024 PLM Europe

Subba Rao
Manufacturing Operations Management
Production Operations Excellence for A&D

Tier Suppliers
http://www.siemens.com/mom
Agenda:
Operational Excellence for A&D manufacturers
Myth vs Reality
How to get there? Dilemma!
Solution @Work
Efficiency, Effectiveness
and Excellence
In the context of manufacturing organization ….
Efficiency Effectiveness
… is the degree to which objectives are achieved … … is determined without reference to costs …
means DOING THE THING RIGHT means DOING THE RIGHT THINGS
Measurable concept (time, effort, cost) Not really measurable

Preserve resources Main aim is to achieve goal
FOLLOW PROCESSES CONSIDER LONG TERM STRATEGY
OPERATIONAL EXCELLENCE = EFFICIENCY x EFFECTIVENESS
Unrestricted © Siemens AG 2017

Page 4 2017.09.25 Siemens PLM Software
Aerospace & Defense Market Space
Complexity & Volume Drive Manufacturing Processes
Key processes & skills capacity
Depot repairs performed within factory
Variability in factory routings

Volume
• Low Touch Labor Multiple variants of a configuration
High
• Factory Automation
Mixed BOM’s with conditions of supply
Yield impact analysis on factory flow

A&D
Design to cost & recurring unit cost
Tier 3
A&D Tier 2
A&D
High Touch Labor Tier 1
Hand Tooling
Manual to Semi-Automated Tests
Note: CAGR is based on 2015 numbers
Low
Low High

Typical inefficiencies in production floor
One reason: lack of synchronized processes and harmonized systems
Typical shop-floor IT environment

Lack of tools to design for manufacturing during
detailed design & push to production
Disparate systems & paper travelers for production

process orchestration
Complexity in design change introductions

Timing to effect work in process rework
Scheduling to optimize resources
? Efficiency
First Time Through Test Yield (FTTTY) driving
rework & factory efficiencies
Alignment of as-designed with as-built for

Effectiveness
compliance
What is the complexity of reaching production ready state
Upstream processes have to be streamlined for accurate downstream information flow

……. to bring efficiencies and effectiveness for operational excellence

PLM ERP MES
Even with all accurate upstream validation
Execution in shop-floor has its own complexity for information needs
Corporate (IT, Business, Engineering ..)
Schedulers
Mfg / Ind. Engineers Production Control
• Constraint based
Plant Operations Management
• BOM, BoP, changes Detailed Scheduling • Part, Kit & Tool

• WI, DCD • What-if scenarios / Movements &
• Sketches/Drawings/ schedule repairs • location tracking
Supply Chain Quality
• Inbound Mtl inspection
Models • Point of use triggers
• Quality Plans
Excellence in
•
& Audit
Supplier collaboration
• Measurement & Data
Collections, FAI, buyoff operations mean
streamlined
• Shipping / delivery • NCR’s & resolutions
Plant IT
synchronization
• Data Synchronization
•
•
Data Integrity
KPIs, Reporting
and coordination
across these
Supervisors CAM/Eqp Engr.
disciplines for an
• Machine Data
•
•
Resource plans
Operator Time tracking
•
Programs (DNC)
Machine perf.
effective &
efficient business
• Buy-off’s
• Overrides, escalations Monitoring
• Plant coordination
Operators Maintenance – financially &
Machines
competitively
• Order Execution • Preventative
• WI adherence • Auto. Data Collection • Reactive
• Data Collections • Product & Process • Predictive
• Self buy-off’s Tracking • Prescriptive
• Perf. monitoring
Broader spectrum of Manufacturing Execution capabilities
Siemens solution addresses Business Problems from tactical to strategic needs
Teamcenter Manufacturing ERP Integration
S Order Status Supervisor

Order
Engineering /
Execution Operation
I & Life cycles Detailed Prod. dashboard & Manufacturing As-Built Data
Management Reports, KPIs
M with WIP Scheduling res. loading Change Collection
(Serialized / and Analytics
visibility per schedules Incorporation
A Batch)
T Certification / Work Order /

Process Product / End Data
skills & Buyoff Instruction Operation Tool Track &
I Adherence &
Management Delivery Hold/Release
Item Track &
Trace
Collections &
Orchestration Trace (WIP) SPC
C & adherence Management Management
Non-
Tool life and Internal Shop- First Article
I DNC conformances Travel Work Order
floor
Machine (Line) Inspection
T Integration / redline Management Maintenance
Monitoring Logistics* Execution *
management
Automation Integration

Page 9 2017.09.25 * In roadmap Siemens PLM Software
Operational Excellence
through Siemens portfolio
Harmonize & synchronize business

processes across Engineering,
Manufacturing Planning, production & quality
Teamcenter ERP SIMATIC IT

Myths vs Reality
Myth 1: Our current processes and cross-department
collaboration is working but lacks discipline
Reality:
Disparate Point to point or Cumbersome

systems in shop- no integrations collaboration methods
floor across systems across teams

Myth 2: Our engineering and business systems can provide all
required information to shop-floor and “niche” point solutions are
good
Reality:
Advanced mfg. Increased Tedious engineering

technologies customizations in and / or manufacturing
needing richer data engineering and/or change incorporation
from engineering business systems
systems
Myth 3: Our shop-floor infrastructure is archaic and we cannot
collect required data from machines or people (in right way)
Reality:
Sensors and Point of use Automation of

advanced information can human machine
technologies can enable timely human processes is reality
make machines – machine data and key for agility
smart collections
Myth 4: We collect all sorts of data, all we need is a data
warehouse and analytics tool
Reality:
Data redundancies Data with process Need to blend IT and

are not taken away improvement tools is OT data for
for educated key for mfg. flexibility streamlined process
decision making and effectiveness improvements

Holistic approach is key strategic lever
to overcome myths and achieve operational excellence
Teamcenter
Visualization/Graphics Bus (JT + Atlas + Augmented Reality)
Product Lifecycle Manufacturing Operations Management

Management
Design Engineering
Production Execution
Automation
Teamcenter
Simulation & Test
Run-Time Manufacturing Operations Service Bus

Manufacturing
Engineering
Lifecycle Analytics
Manufacturing Quality Advanced Enterprise SCADA

Execution Execution Planning & Manufacturing
System System Scheduling Intelligence
SLM
Unrestricted © Siemens AG 2017 ERP

Harmonize business process flows / steps across value chain
(Happy Path Example)
Plant asset
Manufacturing Assign named Execute Initiate Machine Collect data:
association, Preview Order /
Process (BOP) Update Schedule users to Order/OP, cert. Program Serial numbers,
durations & Generate Order
Configuration & & Dispatch Order scheduled jobs checks, review download (if tool-id,
release (with ERP data)
detailed planning for the shift WI, shop notes automated) inspection data
configured Plan
Manage holds /
Inspection Calls
Inspect, review
release of op, Schedule
Disassemble PLM MOM
and perform SN#, reopen Manage as-built
for buyoff process updates, updates / repairs
buyoff
order splits
operations ERP
Increase operator efficiency by providing order / operation / machine context specific information at point of use
Solution Enabler
Business Value
• Real-time error proofing - certifications
checks, data collection deviations
• Single operator screen to navigate work,
collect reqd. data and complete the task at
hand with engineering authorized information
• Real-time visual indications of events &
issues and accurate track of all actions
• Near real-time information availability to other
teams within shop-floor
Harmonize business process flows / steps across value chain
(More common Unhappy Path Example)
Quality Review
Defect Order As-Built /
Initiate Defect & Discrepancy Release Hold
Resolution Path Execution Genealogy
Documentation
Review
Release rework Execute rework
authorized
order order
rework
Initiate order
Add context to Apply changes
specific
changes to order
changes
Define Release Re- Accept / apply

Escalate to Review Change
Disposition Re-plan plan (rework changes to
Engineering Problem Report Workflow
Steps order) order
Initiate MCN, ECN

PLM MOM
and Corrective
ERP actions
How to get there? Dilemma!
Tactical vs strategic “needs”
dilemma in starting the journey
Short- Long-
term term
Demands Goals
Solve immediate problems at hand Take right steps that aligns with strategy &
also solves immediate problems at hand

Stages to achieve the holistic vision of digital enterprise…
Each manufacturer is at a different starting position
ERP
3D model based Product
PLM Engineering
and mainly 2D model based Product- and Industrial- Product- and Industrial
Industrial Engineering on Engineering collaborate on a Engineering manages
independent data bases shared and consistent data concurrently the
model for production planning comprehensive Enterprise Bill
of Process
Operations Management
shares the planning data
model and connects
MES/MOM Various, heterogeneous, One Solution to connect the planning in real time to the Increased
mostly homegrown Shop Floor field level and consolidate and shop floor Digital Enterprise
IT Systems managed on plant integrate the Shop Floor IT • Maximum flexibility
level components • Improved “Design for Implementation
Manufacturability”
• Optimal balance between
planning and autonomy
TIA Portal to manage Smart connected devices

automation engineering - full deliver continuously real-time
TIA integration of field level into data to various application to
Mix from old and new
Operations Management optimize shop floor
machines with different level of
platform creates transparency productivity
automation, sensoric and
connectivity to Shop Floor IT of operations
Model-based simulation – Virtual and real production increasingly merge –

As each manufacturer has different starting point
1. Journey & duration towards digitalization for operational excellence varies

BUT with same end goal in mind
2. MES/MOM is one of the core elements of that journey
3. Some implementation examples of SIMATIC IT deployments in aerospace

companies … towards this journey

Solution @Work: Aero Engines Manufacturer
“Simplification the processes: 100’s of

custom systems & interfaces, reduce
waste, move to paperless, reuse, refine
& re-purpose”
Current /
Emerging
State
 Reduce non-conformances, modifications,

development cost and time to manufacturing
 Roll out at other plants in UK, USA, Asia, … +
other programs

Solution @Work: Aircraft engine components
manufacturer
“Streamlining the business processes

through connectivity between MES and
PLM”
 Process and Work instructions from PLM to MES

 Feedback from production to PLM
 Digitally driven best practices to reduce time to
manufacturing

Solution @Work: Aerospace OEM
“Harmonize methods and processes to

reduce data duplication for asset
performances and material tracking”
 Standardization of asset monitoring and KPI /

performances across sites
 Composite material tracking

Solution @Work: Defense Contractor - USA
“Provide Safe Passage signals to the

Automated Guided Vehicle (AGV) control
system. Monitor Safe Passage signals from
OEM Systems and Work Cells
Collect, archive, trend and analyze key
performance data”
http://www.assemblymag.com/articles/
 Real-time data collections

 Asset performances, KPIs & safe passage
permissive’s

Solution @Work: Aerospace OEM
“Orchestrate automated cell processes

for task accomplishments, status and
KPI visibility across automated assets
capturing & reacting to human –
machine events”
 Data collection and orchestration from a flexible

automated cell
 Monitor & execute each equipment and process
step based on release machine programs

Path forward to change the status quo and achieve
operational excellence in shop-floor
Standardize business processes with modular deployment of MES/MOM, as an

enabler for digital enterprise realization towards operational excellence
Typical current state Recommended state Enabler of collaboration

PLM
Product- and Industrial
Engineering manages
concurrently the
comprehensive Enterprise Bill
of Process
One Solution (incremental &

Various, heterogeneous, modular way) to connect the Operations Management shares Increased
mostly homegrown Shop Floor field level, engineering / the planning data model and Digital Enterprise
IT Systems managed on plant business level and connects planning in real time
level consolidate and integrate the to the shop floor Implementation
Shop Floor IT components
MES/MOM Smart connected devices

deliver continuously real-time
data to various application to TIA
optimize shop floor
productivity

Subba Rao
Lead Strategic Engagements / Industry Management
Manufacturing Operations Management
Email: subba.rao@siemens.com
Phone: +1 (248) 514.8466
www.siemens.com/mom
Thank You

2024 PLM Europe

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Subba Rao

Manufacturing Operations Management

Production Operations Excellence for A&D

Measurable concept (time, effort, cost) Not really measurable

FOLLOW PROCESSES CONSIDER LONG TERM STRATEGY

OPERATIONAL EXCELLENCE = EFFICIENCY x EFFECTIVENESS

Unrestricted © Siemens AG 2017

Depot repairs performed within factory

Variability in factory routings

Yield impact analysis on factory flow

Unrestricted © Siemens AG 2017

Typical shop-floor IT environment

Disparate systems & paper travelers for production

Complexity in design change introductions

Alignment of as-designed with as-built for

Upstream processes have to be streamlined for accurate downstream information flow

Unrestricted © Siemens AG 2017

• BOM, BoP, changes Detailed Scheduling • Part, Kit & Tool

Teamcenter Manufacturing ERP Integration

S Order Status Supervisor

T Certification / Work Order /

Unrestricted © Siemens AG 2017

Harmonize & synchronize business

Teamcenter ERP SIMATIC IT

Unrestricted © Siemens AG 2017

Disparate Point to point or Cumbersome

Unrestricted © Siemens AG 2017

Advanced mfg. Increased Tedious engineering

Sensors and Point of use Automation of

Data redundancies Data with process Need to blend IT and

Unrestricted © Siemens AG 2017

Product Lifecycle Manufacturing Operations Management

Simulation & Test

Run-Time Manufacturing Operations Service Bus

Manufacturing Quality Advanced Enterprise SCADA

Unrestricted © Siemens AG 2017 ERP

Define Release Re- Accept / apply

Initiate MCN, ECN

Unrestricted © Siemens AG 2017

TIA Portal to manage Smart connected devices

Model-based simulation – Virtual and real production increasingly merge –

Unrestricted © Siemens AG 2017

1. Journey & duration towards digitalization for operational excellence varies

2. MES/MOM is one of the core elements of that journey

3. Some implementation examples of SIMATIC IT deployments in aerospace

Unrestricted © Siemens AG 2017

“Simplification the processes: 100’s of

 Reduce non-conformances, modifications,

Unrestricted © Siemens AG 2017

“Streamlining the business processes

 Process and Work instructions from PLM to MES

Unrestricted © Siemens AG 2017

“Harmonize methods and processes to

 Standardization of asset monitoring and KPI /

Unrestricted © Siemens AG 2017

“Provide Safe Passage signals to the

 Real-time data collections

Unrestricted © Siemens AG 2017

“Orchestrate automated cell processes

 Data collection and orchestration from a flexible

Unrestricted © Siemens AG 2017

Standardize business processes with modular deployment of MES/MOM, as an

Typical current state Recommended state Enabler of collaboration

One Solution (incremental &