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Dell Manufacturing & .NET

Dell Manufacturing & .NET. FOR INTERNAL AND EXTERNAL USE. Kim Hammonds October, 2007. Agenda. Dell Portfolio and Supply Chain Dell’s Global Presence Managing the Dell IT Environment Factory and Supply Chain Processes Toolset to Manage Development Process Architecture

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Dell Manufacturing & .NET

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  1. Dell Manufacturing & .NET

    FOR INTERNAL AND EXTERNAL USE Kim Hammonds October, 2007 DELL CONFIDENTIAL
  2. Agenda Dell Portfolio and Supply Chain Dell’s Global Presence Managing the Dell IT Environment Factory and Supply Chain Processes Toolset to Manage Development Process Architecture Real Time Tracking & Visibility Flashboard DELL CONFIDENTIAL
  3. Dell Product Portfolio PowerEdge Servers PowerVault Storage PowerApp Server Appliances XPS Notebooks OptiPlex Desktops Software & Accessories XPS Desktops Precision Workstations Latitude Notebooks VOSTRO
  4. The Direct Model Dell Supply Chain Suppliers DELL Customers Product Quality and Reliability Service and Support Price for Performance Customization Latest Technology Best Customer Experience Highest Quality Low Cost Efficiency Partnering/Virtual Integration Continuity of Supply E-Business Collaboration Low-Cost Manufacturers Technology Leaders Dell Confidential
  5. Supply Chain & Factory Planning “push” “pull” Buy-to-Plan Build-to-Order Dell facilities act as manufacturing centers, not warehouses – only inventory needed for next 2 hours of orders is on site Provides direct signal of Dell customer demand for suppliers Dell’s performance to customer orders is directly linked to our suppliers’ level of support Material requested to build customer orders Dell Manufacturing SLC Suppliers Materials delivered in time to meet up with customer order Dell Confidential
  6. Where We Are Today Revenue of $57.4B last four quarters #25 on the Fortune 500 Fortune “Most Admired” Top 10 – 1999, 2000, 2001, 2003, 2004, 2006 and #1 in 2005 CIO 100 – 10 of last 13 years, including 2000, 2002, 2003, 2004, 2006, 2007 InformationWeek 500 Top 50 – 2006 Dell IT in more than 34 countries Manufacturing (9) Contact Center (41) Fulfillment (6) Dell Confidential
  7. Managing a Global Environment Hardware ~ 110,000+ client systems ~ 20,000+ Dell servers 18,000 Mobile Devices Networks 107 Dell global WAN sites 39 locations 307 WAN links 420 metro Dell-managed fiber paths 855 wireless access points 177 dedicated extranet partner links Total SAN Storage 5.8+ Petabytes Second-largest storage areanetwork in US, Top 5 globally.* Dell Confidential * Source: Brocade Communications Systems Inc.
  8. IT By the Numbers: We Are the Scalable Enterprise Data and Networks: What is the total size of the Dell Data Warehouse? 330 Terabytes on 84 nodesAnd we run 16,000 reports each day How many emails do our servers handle each day? 1.8 million outbound40 million inbound (94% of these are spam!) How many voice calls do we handle each month? 16.5 million inbound toll-free calls3 million outbound calls How many suspicious data packets do our firewalls reject each day? About 400 million per day (or 4,000 suspicious data packets every second!) Dell Confidential
  9. IT By the Numbers: We Are the Scalable Enterprise Dell.com: How many Dell.com page requests last quarter? 3.8 billion How many systems are configured each week on Dell.com? ~1 million — and 1 million per day in peak holiday season How many visits to Dell.com last quarter? 400 million How many unique visitors to Dell.com last quarter? 133 million What is the highest number of pages ever requested in one minute? 64,584 (and we handle all that traffic on only 28 Dell PE6650 servers!) Dell Confidential
  10. IT By the Numbers: We Are the Scalable Enterprise Complexity: How many Contact Centers, Manufacturing, & Distribution sites? 41 contact centers, 15 manufacturing/distribution How many changes in the environment do we handle each year? About 15,000 In how many countries, languages & currencies does Dell do business? 81 countries, 24 languages, and 26 currencies How much cabling is needed for a typical factory? 166 miles of cabling & 10,000 LAN drops in a typical factory How may security patches do we implement per year? 7.5 Million security patches/year How many systems are running on our network? 20,000 Servers 110,000 Clients 18,000 Mobile Devices Dell Confidential
  11. Show Dell / Microsoft Video DELL CONFIDENTIAL
  12. Factory Process Supply Chain - Dell’s World Class Supply Chain Allows for Just in Time Inventory Factory Planning - Orders Organized and Prioritized by Factory – in 2 hour blocks. Kitting - Parts are picked and placed on the tote, alongside the chassis. Build - Computer is put together with all the parts from the tote added to the chassis. Burn- Operating System and other customer selected software is ‘burned’ onto the hard drive. Extended Test is also performed. Boxing- Computer is placed in a box, and remaining materials such as documentation, keyboard and mouse are placed inside box. Shipping / Distribution - Box receives shipping label and is routed via shipping and distribution system directly to the back of the truck. Dell Confidential
  13. Message P2M ACF_READ Stop Station Go Display Picks Done BGLJ961 Factory Automation Demo Basic Process Flow P2M Server ACF_WRITE ACF_WRITE .NET Software CIMPLICITY Server P2M Display Controller Physical Wiring 1.Trigger 3. Stop 2. To P2M 4.Done 5. Go 6.Release
  14. Developing the I/T Systems Key Tenants for Development & Testing Source Control Check-In Policies (i.e. Testing) Custom Policies (i.e. Code Review) Work Items (i.e. Tasks, Defects) Reporting (Canned Reports) BVT (Automated Build, Test, Deployment) Code Coverage Analysis Continuous Integration Testing Performance & Load Testing Resource Planning& Chartering Developing Stabilizing Envisioning Planning Horizon Process
  15. Integration Architecture
  16. Integration Architecture Technology Running Dell’s Manufacturing Integration Layer Visual Studio 2005 Visual Studio Team System NET 3.0 WCF Enterprise Library 3.0 Windows 2003 & IIS 6.0 Site Info.NET (Custom to Dell) SQL Server 2005 MOM
  17. Plug-in Instrumen-tation Config Helpers & Design ObjectBuilder Enterprise Library 3.0 Data Access Logging Caching Core Cryptography Exception Handling Data Access – provides and easy transparent way to connect to databases Logging – standard way to log information that is critical to run Dell’s business Security Policy Injection Exception Handling – gives Dell developers a standard way to handle exceptions Security – caches authentication data Validation Dell Uses the Enterprise Library for Standardization and Re-Useable Components
  18. SiteInfo.NET Dell’s Internal Solution to Handle “Configuration Settings Management” for .NET applications Technology: ASP.NET UI and SQL Server 2005 Backend Easily Manage Multiple Configuration Files Centrally stored applications settings Ability to remotely manage changes to several application servers at once Encryption of connection strings or sensitive data Role based security for administration Auditing of settings changes Client access to settings restricted by host Environment and region layers to differentiate settings
  19. Real Time Tracking & Visibility
  20. Real Time Tracking & Visibility Replay Events and System Flow
  21. Metrics Turns the logged data into useful information in the form of reports for engineers, production staff, maintenance and management. First implementation of the industry standard S-95 model which consist of a plant model and standard relational database tables models. First implementation of providing industry standard OEE for measuring equipment effectiveness. Application is plug and play in all factories with minimal configuration changes. Capabilities Hourly Reports Track Code Genealogy Block Starved WIP Cycle Time OOE & Equipment Scanners MTBF Ad-Hoc Reporting Much More …
  22. FlashBoard Description Flashboard (Factory Logging And Services Health Dash Board), displays real time data to assist in troubleshooting the Cimplicity Integrated Services Layer. Technology NET 3.0 WCF ASP.NET Windows 2003 IIS 6.0 SQL Server 2005 MOM Information Provided Average IIS Round Trip Average IT Call Round Trip Errors In a ROW Last IT Call with Errors Last Good IT Call Successful IT Calls (1 hour) Bad IT Calls (1 hour) Total IT Calls (1 hour Server IT Call Utilization
  23. FlashBoard
  24. Back Up DELL CONFIDENTIAL
  25. Real Time Tracking & Visibility
  26. Real Time Locator
  27. ION Case Study The Microsoft and Dell teams worked together to create load harnesses for each application. Determine the realistic Load for an application. Multiply that load by at least 10x (in most cases more) Load Test Utilize CLR Profiler to gather metrics on memory allocation/release under load. Increase the load approximately 10 fold and run again (3 cycles) Performance Test Utilize Windows Performance Monitor to gather counter metrics under load. Increase the load approximately 10 fold and run again (3 cycles) The Microsoft Team collected over 7 Gig of metric data during this process.
  28. Boxing Ship Burn Build Kitting Factory Layout Factory Process
  29. Manufacturing Systems DOMS WIPS OFS PLC Scanners Order Induction P2M Conveyors Kitting GPCS Lifts/ Tapers Build Lifts/ Tapers IBMS Burn Other.. ADS Boxing Printers MIAS Shipping ION Laser Etcher, etc CIMPLICITY FACTORY HARDWARE
  30. Global View
  31. Real Time Tracking & Visibility
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