Cisco Covacsis Solution Overview

Intelligent Plant Framework

Make the shift from automation based production to knowledge based production
EXECUTIVE SUMMARY
IPF

Manufacturing companies across sectors are bound to witness an

inevitable shift in the mid- to long term. Cisco Covacsis solution
understands this need of the production floor, and provides the

500 BN (DATA POINTS ANALYZED)

25 K (DEVICES CONNECTED)
1000 % (CUMULATIVE RETURNS)
15 + (CLIENTS WITH BN $ REVENUE)
McKinsey & Co. has featured IPF at the
Global Practice Olympics

manufacturing sector with IPF a unique product that helps

realize better Return on Investment for plants and machinery.

Basic Premise of Intelligent Plant Framework IPF

1.

What immediate systemic intervention is needed to further

improve conversion economics (conversion cost, quality and
utilization of machines) of the floor?

2.

How can an organization create value differentiation at the production floor itself?

3.

How can production departments prepare for inevitable challenges related to knowledge centric
production?

How Does IPF Work?

A.

Provides a cost-effective technology to acquire data

straight from disparate machines in real-time

B.

Converts acquired data into actionable impact in real-time

by translating contribution of floor events to top-line and
bottom-line

Benefits to Production Department

Visibility of exact root causes behind deficiencies
Cost and profit drivers to optimize conversion economics (Cost, Quality, Efficiency)
Significant increase in first pass yield
Substantial improvement in utilities saving
Improvement in OEE
Error free decision making tool by encompassing most granular and precise information

Cisco Covacsis Solution

Our solution IPF is one-of-its-kind and no other off-the-shelf solution provides such comprehensive and
complete understanding of micro level production and cost parameters in such a cost effective manner.

We deploy our solution on each machine and gather all data points every second. Data from all machines
is consolidated at one place and displayed on a single screen at any standard desktop / tablet anywhere.

Our solution can communicate and gather data from any make and model of machines of a PLC.
Absolutely zero dependency on machine or PLC manufacturers.

2015 Cisco and/or its affiliates. All rights reserved. This document is Cisco Public.

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Implementation across the process floor is extremely simple as we dont need to halt production. Our
solution can be installed on a running production line. This also eliminates the hidden cost otherwise
incurred by the organization.

Our solution uses standard off-the-shelf hardware hence provides complete liberty to the organization
over a longer period of time.What immediate systemic intervention is needed to further improve
conversion economics (conversion cost, quality and utilization of machines) of the floor?

Benefits to Production Department

Highlights inconsistencies in production parameters for a given quality of product produced at different point
of time under different operating conditions Analysis over historical data
Helps understanding unwanted incidents during the production process in real time and respond in a
predictive manner
Sets up evolutionary knowledge based manufacturing platform

High Level Features of IPF

1.

Provide unified diagnostics of all micro level process parameters across all equipments or machines in
real time on remote desktops without any human intervention
o

Production team will have complete and comprehensive view of all process parameters across
all machines on a single screen. Any deviation or aberration in any parameter will be notified in
real time.

2.

No manual data entry as all data are being captured straight from the machines every second

Parameters can be viewed from any remote system and one need not to come to the machine

Conduct insightful analysis and identify underlying trends related to production cost, quality, process or
patterns for a given time period
o

Each and every unit of the produce is monitored in real time and

Precise cost of per unit of production on a given machine can be calculated and benchmarked.
For example:

3.

Cost of chemicals consumed by a particular batch / lot

Reprocessing cost for a given measure of quality across time

Utilities cost per unit of production per day or per shift etc.

Productivity and efficiency for a particular shift over a period of time

Create actionable reports by translating all incidents into cost and revenue
For example:
o

Most frequent reasons of stoppages on the floor over a period of time

Cost drivers for per unit of fabric produced over a given period of time and their contribution in
overall cost.

2015 Cisco and/or its affiliates. All rights reserved. This document is Cisco Public.

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Functional Blocks of IPF

Asset Performance
Plant Efficiency
Floor Economic Index
Capacity Utilization & hidden capacity

Cost Performance
Utilities consumption for a machine/batch/shift in real
time
Cost due to rejections/waste etc.
Cost of operational inefficiencies
Diagnostics tool
Financially most inefficient stage

Operational Performance
OEE
Yield/Productivity
Bottleneck in real time
Utilities consumption

Quality Performance
Real time quality index based on online process
monitoring
Quality report of every batch individually
Quality diagnostics tool

Consistency measurement of process/machine/batch

Stoppage/Breakdown/Slowdown analysis
Diagnostics

Batch Analysis
P&L of batch in real time
Batch cycle time tracking
WIP inventory contribution for every individual batch
Batch efficiency
Various process parameters in batch across all stages
Changeover analysis

Benchmarking
Analysis of not adhering to benchmarks
Benchmarking of various parameters like time, cost,
process parameters
Utilities consumption benchmarking for every SKUmachine combination

Maintenance
ABC analysis of various breakdown reasons across
locations/ plants/ sections/ machines
Performance measurement of an action
Machine OEE in real time with historical data

For More Information

Read more about the Cisco Covacsis Solution, or contact your local account representative.

2015 Cisco and/or its affiliates. All rights reserved. This document is Cisco Public.

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