Global Strategy

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Global Strategy Scalable Architectures

• Jerry Yen
• Principal Engineer
• General Motors Corporation
• Controls, Conveyors, Robotics, Welding Group

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Agenda

• Introduction
• Think Global
• Think Scalable
• Summary

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Introduction - OMAC Definitions
Open Allows integration of COTS hardware and software components into a de facto standard environment
Modular Permits plug and play of hardware and software components
Scalable Enables easy and efficient reconfiguration to meet specific application needs across a broad spectrum of different size implementations
Economical Achieves low life cycle cost
Reliable Maintainable Supports robust plant floor operation (maximum uptime), expeditious repair (minimal downtime), and ease of maintainability
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Introduction Presentation Topics

• Application of OMAC best Practices/Guidelines
• Think Global Globalization and Standardization
• Best practices / Lessons learned in Manufacturing
• Think Scalable Scalable Systems

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Functional Areas CCRW Supports
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CCRW Processes
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Think Global!!
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CCRW Global Business Strategy

• Common
• Drive common architecture, designs,
  specifications, work practices and training.
• Open
• Utilize open standards that enable competitive
  sourcing, driving down cost.
• Volume
• Strategically utilize globally capable suppliers,
  giving them long term contracts and global GM
  volume.

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CCRW Globalization Priorities

• Globalize All CCRW Standards and Specifications
• Deploy scalable solutions
• Deploy Global Common Components and Bundled
  Commodity Sourcing
• Develop and Implement a Global CCRW Resource Plan
• Develop and Implement a Comprehensive training
  Plan for All Regions
• Review Vehicle Program Plans to Ensure Compliance
  with Global CCRW Architecture

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Globalize CCRW Standards and Specifications

• Common Software (single family of PLCs).
• Common Hardware (standard panels)
• Standard open communication networks.
• Maximum reuse of validated designs.
• Auto generated software and hardware designs.
• Stabilized design environment.

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Globalize CCRW Standards and Specifications

• Certified capability of design engineers
• Provide skilled trades training materials to
  successfully maintain CCRW related equipment in
  their plants
• Scalable robust controls architecture
• Key to driving common in the world
• Solutions must be scalable to varying operating
  environments
• Leverages the power of common without arrogance

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Deploy Global Common Components and Bundled
Commodity Sourcing

• Enables execution of the Global Bill of Equipment
  (BOE)
• Maximizes global asset re-use and re-cycle
• Enables resource and workload sharing
• Fast program execution across regions
• Re-use of engineering
• Cost saving benefits from global volumes of
  components and equipment
• Continuous improvement of standards and technical
  specifications based on global lessons learned
• Common designs enables use of advanced tools for
  simulation and automated engineering

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Global Common Components Lessons Learned

• Supplier relationship expectations are different
  in other countries/regions
• Legal requirements may require changes to
  existing policies
• Forecasting becomes even more critical
• Freight Logistics
• Cultural implications
• Very few truly global suppliers

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Winning Strategies for Globalization

• Common Technology Components is Only a Start
• Dont underestimate the people aspect
• Multi-Language
• Seek to Understand
• Cultural implications
• Vendor relationships
• Training
• Face to-Face interactions
• Cant over-communicate

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Think Scalable !!
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Keys to Scalability

• Common Network Architecture
• Consistent features in automation products to
  support all automation levels
• Challenge Third party support in products,
  including safety
• Reuse of Software in all levels of architecture
• Object Oriented Design as potential enabler
• Challenge Reuse software in the low automation
  level
• IP67 Components
• Move to more safe products
• Challenge lack of defined connector standards
• Scalable Safety
• Smaller and cheaper Safe IO modules (2I/2O)
• Smaller safety PLC that is integrated with a
  smaller standard PLC,
• Need same programming environment

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Process Driven Scalable Controls Architecture

• Select architecture based on tool process
• Manual Process with 2 Hand Control
• Manual Process with Safety Device
• Hard Auto Weld Tool
• Robot Cell
• Multiple architecture levels used in a plant

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Example - Scalable Andon Goals

• Create scalable systems for all GM facilities
• Address Global Manufacturing System core
  requirements
• Define levels of functionality based on
  requirements, automation level, labor rate, etc.
• Design systems to be modular
• Minimize/eliminate rework to elevate functional
  level
• Reduce life cycle costs of plant floor systems
  including
• Hardware software
• Design deployment
• Maintenance and ongoing changes

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Benefits

• Savings
• Deployment (hardware/software)
• Operations support
• Properly leverage and fully utilize
• Labor
• Plant floor device capability
• Global common controls standard
• Controls engineers capability to deploy
• Common

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Lessons Learned

• Back to Basics core business requirements
  absolute first step
• Scalable solutions can be applied anywhere even
  in North America
• Global partners outside North America are
  valuable sources for lean approaches to plant
  floor systems

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Summary

• OMAC concept works
• Not just for components and systems
• Enabling globalization, standardization, and
  scalability
• Progression from company specific to industry
  specific to cross industries
• Working together has always been an OMAC trade
  mark