Achieving Breakthrough Performance

Achieving Breakthrough Performance

Achieving Breakthrough Performance

1 ILS Technology White Paper July 2014 Seamlessly connect your assets with your enterprise systems and databases ILS Technology White Paper July 2014 Seamlessly connect your assets with your enterprise systems and databases Achieving Breakthrough Performance Honda North America Improves Resource U!liza!on, Reduces Complexity and Improves Data Quality with the deviceWISE Industrial Automa!on Pla+orm

2 ILS Technology White Paper July 2014 Seamlessly connect your assets with your enterprise systems and databases “The device Wise Plax1aorm allowed us to support growth in business and equip- ment data, maintain our staff size, reduc- ing complexity of PLC configura&on, and improve the quality of equipment data.” Andre Swain Plant Floor IT Manager Honda Improves Resource U&liza&on, Reduces Complexity and Improves Data Quality with ILS Technology’s deviceWISE Industrial Automa&on Plax1aorm Summary Honda Manufacturing of Alabama, which began produc$on Novem- ber 14, 2001, maintains a 3.7 million square foot plant facility on 1,350 acres.

The plant is Honda’s largest light truck produc$on facility in the world and the sole manufacturer of the Odyssey minivan, Pilot sport u$lity vehicle, Ridgeline pickup truck, the Acura MDX and the V-6 engines that power them. Opera$ons performed include steel and aluminum blanking, stamping, welding, pain$ng, plas$c injec$on molding, aluminum cas$ng, aluminum machining, ferrous machining, vehicle sub-assembly and assembly, engine assembly, vehicle tes$ng and quality as- surance. At capacity, the plant produces about 360,000 vehicles and engines per year.

Plant floor IT managers across Honda automo$ve facili$es in North America were challenged with integra$ng disparate PLCs from Om- ron, Rockwell, Mitsubishi and others with proprietary (MES) appli- ca$ons and widely used DB2, MSSQL and Ac$vplant. They were tasked with improving IT resource u$liza$on with simple common tools, increasing commonality between tools and plants, and im- proving data quality. By implemen$ng the deviceWISE solu$on, Honda has been able to support a growth in business and equip- ment data while maintaining IT staff size, improve ease and speed of upgrades, reduce PLC configura$on complexity and improve data quality.

ILS Technology White Paper July 2014 Seamlessly connect your assets with your enterprise systems and databases

3 ILS Technology White Paper July 2014 Seamlessly connect your assets with your enterprise systems and databases Original Implementa!on: Heavy Customiza!on, Difficult to Maintain The plant floor IT manager at Honda is responsible for running produc$on equipment and IT applica$ons. PLC programming primarily consists of Omron, Rockwell, Mitsubishi but includes many other diverse products as well that require support. Applica$ons include a proprietary manufacturing execu$on system (MES) developed by Honda, IBM’s DB2 database soCware, MicrosoC’s SQL and Hollis Technologies’ Ac$vplant for data analy$cs.

The original 2001 IT implementa$on included a large JAVA- based MES tracking applica$on on a large UNIX plaEorm that Honda used to manufacture a product inside the plant. It was a custom-developed equipment interface wriFen in house to meet business needs. The solu$on worked well but was difficult to maintain; addi$onal customiza$on was required each $me a new device was introduced. Facts Honda Manufacturing of Alabama www.hondaalabama.com PLCs: Omron Rockwell Mitsubishi Applica!ons: MES (proprietary) DB2 MSSQL Ac$vplant

4 ILS Technology White Paper July 2014 Seamlessly connect your assets with your enterprise systems and databases Challenges: Improve Resource U!liza!on and Data Quality, Increase Commonality An increase in emerging technologies and smarter devices on the plant floor since the original implementa$on has resulted in a greater IT focus with IT embedded in plant equipment. Honda needed to find a way to improve IT resources with simple com- mon tools. Given the robust manufacturing environment, Honda also needed the ability to ramp up or ramp down produc$on based on market demands while keeping their staff size the same.

To address this challenge they reorganized to bring IT and plant floor opera$ons into one department for a central focus on produc$on. Their goal was to improve produc$on, efficiency and overall quality of the systems.

From a manufacturing perspec$ve, Honda had to be lean, agile and flexible while maximizing capability and capacity. They need to be able to take advantage of higher sales volumes when they occurred by maximizing produc$on. To meet this challenge, Hon- da needed to be able to increase commonality between tools and plants. Another challenge Honda faced was improving data quality. More advanced tools meant larger data sets to store and more analy$cs to collect, resul$ng in slower speeds. Honda needed to improve integra$on speed and ease.

Challenges: > Improve resource u$liza$on with simple common tools > Increase commonality between tools and plants > Improve product quality ILS Technology White Paper July 2014 Seamlessly connect your assets with your enterprise systems and databases

5 ILS Technology White Paper July 2014 Seamlessly connect your assets with your enterprise systems and databases Objec!ves To achieve Honda’s goal to improve resource u$liza$on and data quality, plant floor IT managers needed a flexible system to suit the architecture of each plant. They needed to drive decision making by staying flexible within all layers of the applica$on ar- chitecture: not from just inside their apps but from the factory floor side as well. Honda needed a solu$on that was: > Scalable: Scalability meant suppor$ng large factory implementa$ons with large UNIX systems as well as small factory implementa- $ons with medium Linux systems.

Smaller factories needed the func$onality provided by the plaEorm for larger factories but at a lower cost and with a smaller footprint to accommo- date smaller data centers. Scalability also meant suppor$ng special situa$ons, e.g., satellite opera$ons, with unique equipment or suppliers.

> High Performance: The new solu$on had to meet or exceed current plant perfor- mance. It needed to be able to handle the data rates of the different plants. > Flexible: Plant floor IT managers needed the ability to pick and choose which part of the enterprise architecture they wanted to use. ILS Technology White Paper July 2014 Seamlessly connect your assets with your enterprise systems and databases Requirements: > Flexibility > Scalability > High Performance

6 ILS Technology White Paper July 2014 Seamlessly connect your assets with your enterprise systems and databases Ini!al Approaches Fell Short of Goals Honda’s first step towards improving resource u$liza$on was to reduce custom code.

Everything that was ver$cally integrated inside the MES tracking applica$on stack – from the device drivers connec$ng out to the factory floor, the program logic, configura$on, and applica$on interface – was custom developed. Customiza$on was required each $me a new device was introduced, slowing down the process. Honda first took certain modules from the applica$on stack and looked at the equipment interface to begin migra$ng to a single vendor provided OPC-based solu$on. The goal was to reduce the $me required to write drivers to connect to equipment every $me a new device was added to the plant floor, typically six weeks.

From a soCware perspec$ve, Hon- da wanted to be able to just buy connec$ons. Unfortunately, the OPC-based solu$on s$ll required a lot of heavy custom code to integrate manufacturing systems. It also fell short of delivering the desired improvements in resource u$liza$on. The logic and applica$on integra$on was s$ll wriFen by Honda, the response $me was slow, there was data buildup in transit, and the team s$ll had to deal with configura$on issues.

Customiza!on versus Simplified Architecture Goal: Integrate manufacturing systems quickly without wri$ng custom drivers each $me new equipment was introduced. ILS Technology White Paper July 2014 Seamlessly connect your assets with your enterprise systems and databases

7 ILS Technology White Paper July 2014 Seamlessly connect your assets with your enterprise systems and databases Achieving Breakthrough Performance with the deviceWISE Industrial Automa!on Pla+orm To simplify this architecture and bring everything into one com- mon, simple interface from the factory floor, Honda deployed the deviceWISE industrial automa$on plaEorm.

Developed to operate within the “four walls” of the enterprise, deviceWISE connects and integrates produc$on machines and processes with exis$ng enterprise resource planning (ERP) and manufac- turing resource planning (MRP) systems and SCADA applica- $ons. DeviceWISE runs on mul$ple plaEorms (Windows, Linux, AIX, etc.), uses simple configura$on logic and is fully-featured for advanced industrial automa$on. By adding deviceWISE, Hon- da was able to bring their blended system – the custom and the OPC package – into one common, simple interface. The deviceWISE solu$on met Honda’s requirement for a flexible and scalable system to suit the architecture of each plant.

For large plants, deviceWISE provided centralized control with op- $ons for satellite systems for localized logic and data reduc$on. Honda could run deviceWISE locally or communicate back up to the enterprise inside their data center and back to the factory floor. They could collect data downstream and have nested in- forma$on or nested devices below that, thereby crea$ng a small, common architecture and then feeding the data up to the enterprise into the large systems such as the ERP system or MES systems.

ILS Technology White Paper July 2014 Seamlessly connect your assets with your enterprise systems and databases Solu!on: deviceWISE Industrial Automa!on Pla+orm

8 ILS Technology White Paper July 2014 Seamlessly connect your assets with your enterprise systems and databases The deviceWISE plaEorm also met Honda’s high performance requirements. The original plant tools couldn’t handle the larger data sets sent from newer, more intelligent produc- $on devices with faster scan rate capability. For example, the history of a part serial num- ber had to be retained in the PLCS.

Adding more data to the PLCS slowed the overall scan $mes, which could lead to missing data. Implemen$ng the deviceWISE solu$on enabled Honda to: simplify the plant device configura$on, make the complex business logic that was buried in the applica$on available to the plant device, remove complex ladder logic, and u$lize a cheaper plaEorm to write logic. It also meant using the enterprise to store and search the larger data set while not impac$ng the PLC scan rate and improving perfor- mance.

ILS Technology White Paper July 2014 Seamlessly connect your assets with your enterprise systems and databases

9 ILS Technology White Paper July 2014 Seamlessly connect your assets with your enterprise systems and databases deviceWISE Return on Investment Honda Manufacturing began installing the deviceWISE plaEorm early 2013. This plaEorm enabled Honda to meet the following business objec$ves: > Support Growth in Business and Equipment Data Informa$on driven produc$on means larger data sets and more analy$cs. Honda has been able to manage that growth with the deviceWISE plaEorm.

> Maintain Staff Size Since implemen$ng the deviceWISE solu$on, Honda’s plant floor IT department has not increased staff even though they increased the number of systems they manage. They achieved their goal to stay lean while maximizing and im- proving capacity.

> Reduce complexity The simple configura$on provided by the deviceWISE plaEorm means more people can support it, allowing Honda to maximize staff resources. ILS Technology White Paper July 2014 Seamlessly connect your assets with your enterprise systems and databases Benefits of the deviceWISE solu!on > Support growth > Maintain staff size > Reduce complexity > Improve data quality > Improve delivery speed

10 ILS Technology White Paper July 2014 Seamlessly connect your assets with your enterprise systems and databases > Improve Quality of Equipment Data The deviceWISE plaEorm enabled the plant floor IT de- partment to offer their internal customers on the factory floor beFer data, empowering them with more decision making capability.

> Improve Delivery Speeds Plant floor IT managers have able to speed up the deci- sion making processes by providing more decision- making capabili$es at the machine level. Conclusion By installing the deviceWISE plaEorm, Honda has been able to support a growth in business and equipment data while maintaining IT staff size, improve ease and speed of up- grades, reduce PLC configura$on complexity and improve data quality.

ILS Technology www.ilstechnology.com 5300 Broken Sound Blvd. Suite 150 Boca Raton, FL 33487 Product & Sales Inquiries: +1 (561) 982-9898 x107 sales@ilstechnology.com Media and Analysts: +1 (561) 982-9898 x133 pr@ilstechnology.com @deviceWISEm2M +ILSTechnology illstechnology ILS Technology White Paper July 2014 Seamlessly connect your assets with your enterprise systems and databases

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