Heat Treat Lean Cell

1. Heat Treat Lean Cell Optimizing Maintenance Processes Tony Haynes – Program Manager

2. Preface • Unique depot manufacturing environment • Low volume, high mix with frequent priority interruptions • Focused on repair rather than new parts manufacturing • Factory equipment networks usually “islands” disconnected from factory Intranet • Few depots implement formal manufacturing execution systems – Commercial Technologies for Maintenance Activities

3. Lean Transformation • Lean tenets focus on removing everything that does not add value to the product • Minimize material handling • Reduce manufacturing process footprint • Physical arrangements that minimize WIP movement • Synchronize operations • Use WIP buffers to compensate • Eliminate process redundancy • All depots are undergoing Lean Transformation – Commercial Technologies for Maintenance Activities

4. OOPS! So what do you do when your equipment footprint is large, when equipment reliability is uncertain, when incoming workload is largely unpredictable, and the only way you can gather data is by dispatching an engineer to collect it? In short – the normal situation for depot manufacturing. – Commercial Technologies for Maintenance Activities

5. The Problem Areas • Heat treat, thermal spray, and metal removal • Large footprint • Difficult to forecast daily work load • Frequent priority jobs • Complex machines – significant down time • Little or no automated data collection from depot equipment or processes • Down time often seems excessive but data is of questionable reliability – Commercial Technologies for Maintenance Activities

6. Focus – “Islands” of Factory Networks • Two drivers • Fear of infection by malicious software • Very real need to separate factory floor networks from office IT systems • Solutions exist that can isolate factory nets but still make historian data available • The Smart Machines Pilot Project, Phase II, is interested in piloting a solution • Example architecture from Canadian National Infrastructure Security Coordination Centre • Additional information available from NIST’s Process Control Security Requirements Forum, ISA’s SP99 committee, and from www.pcsf.org – Commercial Technologies for Maintenance Activities

7. Securing Plant Control Networks – Commercial Technologies for Maintenance Activities

8. Focus –Data Collection • Large amounts of useful data exist in equipment control systems but is transient • Process health and effectiveness usually requires the addition of sensors that have nothing to do with control • Data historians collect and store data from both • Any process data that requires human entry is of questionable reliability • The Smart Machines Pilot Project is focused on exactly this domain – Commercial Technologies for Maintenance Activities

9. First 24 Hours on the Mold 5 Machine View shows steam heat applied to upper and lower platens, and temperature rise of the mold cavity in between.

10. A Part Cycle Without Faults on Monday Dec. 27th Time line data is masked here. Production cycle time is CAT confidential.

11. The Next Part Cycle With Faults on Monday Dec. 27th Time line data is masked here. Production cycle time is CAT confidential.

12. Typical results from Thursday April 7th. Note similarity of the vibration signatures during multiple runs.

13. Focus – Unpredictable Workload • Traditional scheduling systems don’t work well in environments such as depots • But optimizing equipment loading could have major beneficial effect on energy costs • The emergent behavior property of agent-based systems was long ago shown to be effective (NCMS’ Shop Floor Agents project) – Commercial Technologies for Maintenance Activities

14. Focus - Footprint • No solution identified – Commercial Technologies for Maintenance Activities

15. Summary • Issues with installations such as these are pervasive • Common root problems appear • No single solution but elements of the common issues can be addressed – Commercial Technologies for Maintenance Activities

16. Questions? Tony Haynes 734-995-4930 tonyh@ncms.org