Kevin: e-Manufacturing is the realization of the benefits from the truly
connected manufacturing enterprise. Many MRP/ERP systems were installed with
promises that never materialized because of the way they were disconnected from
the realities of the plant floor. With e-manufacturing, information is shared
freely between business and plant floor applications, allowing organizations to
better plan, execute, and deliver to meet customer needs. The goal for today’s
manufacturers is to produce the right product, on predictable and repeatable
schedules, all with exceptional quality. e-Manufacturing ties systems together
and enables real-time decision making across the enterprise.
e-brief: Is the drive toward lean manufacturing spurring interest in
e-manufacturing?
Kevin: The drive toward lean manufacturing is definitely one of the key
drivers toward e-manufacturing. The challenge of lean manufacturing is not only
removing any excess costs but also increasing the capability of the next
generation of systems. Many of our customers are actively working to drive out
costs from their manufacturing processes. GE Fanuc, using Six Sigma methods and
drawing on the collective experience of GE’s own manufacturing plants, can
help take them to the next level.
Leading manufacturers are streamlining processes, driving responsibility back
to suppliers, designing rather than testing in quality, and managing the entire
product lifecycle through repairs and returns.
e-Manufacturing provides the enabling
collaborative technologies to see this next great productivity realization.
e-brief: So, what are the major challenges in the move toward
e-manufacturing?
Kevin: The biggest challenges are formulating the vision and
understanding the ROI. Companies need to have a vision of what their
e-manufacturing solution needs to be prior to any implementation. If you are
simply taking the same mechanical processes and digitizing, you may not be fully
leveraging the potential of e-manufacturing. Manufacturers should be driving out
the non-value added manual touch points, eliminating the need to expedite
material and driving a decision making process based on real time data. Gone are
the days when managers suggest changes with the monthly report. Business leaders
today need to know where they are every single day and must have a system in
place where they can affect change to meet the business objectives in real time.
As a manufacturing leader, you must set your vision for the future and drive the
systems required to meet this vision through your own facility and those of your
partners and suppliers.
e-brief: It sounds like implementing e-manufacturing takes some time.
Kevin: Not really. Many companies don’t have a vision for their
manufacturing future, and that’s where we can help. At GE, we know where we’re
going and can help others get there, too. We have looked beyond the traditional
automation components and instead draw upon the great manufacturing experience
of GE. GE has a vast knowledge base not only of manufacturing excellence but
also digitization, productivity and profitability. We have implemented these
solutions at some of our own plants – throughout the world – and can bring
this experience to our customers. Multi-year programs are no longer required to
achieve measurable benefits. With today’s newer systems, we often start to see
benefits in months.
e-brief: Doesn’t connectivity present a challenge, too?
Kevin: Connectivity can be a challenge at any plant. At GE, we have
overcome connectivity issues in several ways. On the device level, we have
standardized on Ethernet for easier, open communication. Additionally, we are
offering retrofit and upgrade programs to help manufacturers take the next step
toward e-manufacturing and Ethernet-enable hardware such as PLCs. Our sister
company, GE Cisco Industrial Networks, also helps in the area of connectivity by
assessing and implementing an industrial network infrastructure to provide a
communications backbone. Our broad software offerings connect users via web
technologies that leverage next generation portable devices, which are quickly
being integrated into modern manufacturing plants. Our consulting services
organization has excellent domain knowledge and is helping companies worldwide
achieve their e-manufacturing goals.
e-brief: You mentioned the web. How are manufacturers coordinating
traditional operations with those that are intranet and internet managed?
Kevin: Traditional operations must be viewed as part of an overall
solution, integrated with Intranet and Internet technologies. These are not
separate parts of a company, but rather tools to be used to improve the
traditional operations, driving out costs and increasing productivity. There are
no limits to using these tools, and almost every traditional operation can
benefit from web-based technologies. Our digitization efforts are aimed at
eliminating paper from the process and delivering specific information directly
to people at all levels who can make the best use of it.
e-brief: Where are you seeing e-manufacturing?
Kevin: We’ve seen great interest in e-manufacturing, spanning many
industries. And, each industry has different reasons for implementing
e-manufacturing. For example, the automotive industry has a tremendous need to
speed production, seamlessly integrate suppliers, improve quality and reduce
costs. The pharmaceutical industry, on the other hand, has a very specific need
to comply with FDA 21 CFR, Part 11. Fortunately, the breadth of GE gives us
wide-ranging experience and the ability to deliver e-manufacturing solutions
across many industries.
e-brief: So, what’s in the crystal ball?
Kevin: You will see great innovation as GE Fanuc continues to rapidly
evolve its solutions through the plant and into the supply chain. We are
developing technologies with superior functionality -- the latest that support
our overall e-manufacturing solutions for companies. We’re looking to our GE
heritage, finding answers for ourselves and our customers. It’s time for the
next realization in productivity.
More questions? Contact Kevin Roach at kevin.roach@gefanuc.com.
