Bosch Splunk Roundtable: Bosch atmo Performance Center
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This document provides an overview of Bosch's manufacturing solutions performance center project. The project aimed to connect key manufacturing processes at Bosch's Bamberg plant to provide improved data-based analysis and reduce analysis time from 15 minutes to under 90 seconds. The first phase connected three core processes comprising over 100 machines and generating millions of measurements daily. Challenges included preprocessing large amounts of raw data and correlating data across different files and time stamps. The second phase expanded the connectivity to additional processes. The performance center project improved transparency, reduced analysis time significantly, and enabled over 80 customer-implemented alerts.
Bosch Splunk Roundtable: Bosch atmo Performance Center
- 1. BOSCH MANUFACTURING SOLUTIONS | SERVICES PERFORMANCE CENTER C. GIEHL | ATMO-1DE/SGS | 06.2020
- 2. 460 regional subsidiaries in 60 countries ca. 410,000 associates ca. 270 manufacturing sites 130 engineering locations Bosch – Corporate presentation A global network1 3 Four business sectors 1) As of 12.2018 Industrial Technology Energy & Building Technology Consumer GoodsMobility Solutions
- 3. 2018 market and figures1 Bosch – Corporate presentation 78.5 billion euros in sales ca. 270 manufacturing sites Bosch Group ca. 410,000 associates Europe 150 249,964 53% Asia Pacific2 77 114,825 30% Americas 41 45,092 17% 4 1) As of 12.2018 2) Including other countries Figures adjusted for extraordinary effects resulting from changes in the consolidated group and methodological changes and depreciation and amortization resulting from purchase price allocation. Manufacturing sitesAssociatesShare of sales
- 4. Bosch – Business Sectors Four business sectors Mobility Solutions Industrial Technology Energy & Building Technology Consumer Goods 5
- 5. Industrial Technology Bosch – Business Sectors 6 Mobility Solutions Industrial Technology Energy & Building Technology Consumer Goods
- 6. Overview Bosch Manufacturing Solutions (ATMO) 8 ATMO-1DE FEUERBACH, GERMANY ATMO-9DE HOMBURG, GERMANY ATMO-2ES MADRID, SPAIN ATMO-4NA CHARLESTON, USA ATMO-7MX TOLUCA, MEXICO ATMO-3CN SUZHOU, CHINA ATMO-5CN CHANGSHA, CHINA ATMO-8TR BURSA, TURKEY ATMO-6IN BENGALURU, INDIA TNS* (EUR m) 570 Locations 9 Employees approx. 2000 * CF09.2019
- 7. ATMO PERFORMANCE CENTER Internal | ATMO-1DE/SGS | 2018-10 © Robert Bosch Manufacturing Solutions GmbH 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. 2 Introduction CUSTOMER BENEFITS Low initial invest implicating low risk Improved analysis results due to greater data base From data to improvement – ATMO as single-source provider OUR MOTIVATION Performance Center for Digital Excellence in manufacturing to increase online and digital transparency Enabling remote 1st level support in order to become a proactive Services Provider (incl. rollout within own Services organization) Generating new business models for Remote and Condition Based Services PERFORMANCE CENTER One-tool solution for data-based standard/customized reports and services, including connectivity by machine connection and remote access
- 8. Bamberg plant – Sensor element Project description Target: Connect all machines of sensor element value stream 28 Process steps (from mixture of components to final testing an packaging) 138 machines with data 28 different data formats Lead time: 2 – 3 weeks (worst case: >8 weeks) Output: 125.000 elements per day (2019: 45m elements) Internal | ATMO-1DE/SGS | 2018-10 © Robert Bosch Manufacturing Solutions GmbH 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. 5
- 9. Bamberg plant – Sensor element Project phase 1 – Connection of key processes Internal | ATMO-1DE/SGS | 2018-10 © Robert Bosch Manufacturing Solutions GmbH 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. 5 EKRA (18 printing lines) 40 – 60 printing steps for 76 or 152 elements per foil (depending on produced type) Appr. 100 process values (measurements) per printing step Appr. 60.000 events per day with 100 values each SPL (4 visual testing lines) Up to 160 measurements per part produced (depending on type produced) Appr. 120.000 events per day with 100 fields each KPL (4 final testing lines) 11 stations per line (single machines) In total 150 different measurements 40 – 80 measurements per part produced (depending on type produced) Appr. 7.5 Mio measurements (events) per day with 1 value each
- 10. Bamberg plant – Sensor element Customer expectation – Correlation of data Internal | ATMO-1DE/SGS | 2018-10 © Robert Bosch Manufacturing Solutions GmbH 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. 5 Challenge: Lead time of up to 8 weeks How a typical reports looks like
- 11. Bamberg plant – Sensor element Project phase 1 – Challenges SPL – Raw data Internal | ATMO-1DE/SGS | 2018-10 © Robert Bosch Manufacturing Solutions GmbH 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. 5 200.000 dat-files per line per day (with 97.5 % of empty structures in every file) Time for data-transfer to linux-VM for preprocessing: 28 hours for data of 24 hours Solution: Local linux-VM for preprocessing ✓ Overlap of part-ID between lines Solution: Introduction of new extended-part-ID ✓ (implemented in preprocessing)
- 12. Bamberg plant – Sensor element Architecture – Operated by Robert Bosch Central IT Internal | ATMO-1DE/SGS | 2018-10 © Robert Bosch Manufacturing Solutions GmbH 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. 5 File-base data (e.g. SPL, KPL) Databases Bamberg Linux VM Heavy Forwarder Python-Converter Index-Cluster Stuttgart Search-Head 2 CPU´s with 4 GB RAM 4 x 8 CPU´s with je 8 GB RAM 12 CPU´s wtih 24 GB RAM
- 13. Bamberg plant – Sensor element Project phase 1 – Challenges SPL data structure (1/2) Internal | ATMO-1DE/SGS | 2018-10 © Robert Bosch Manufacturing Solutions GmbH 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. 5 Lead-time for single part / charge up to 2 weeks to be considered in searches As of very high number of data, very long processing times for searches (or timeouts) Data for single part-ID separated into 14 files with different time-stamps As time-stamps (or other single field) can not be as a base for joining, very high numbers of results lead to termination of job (searches with up to 120 lines incl. >5 joins)
- 14. Bamberg plant – Sensor element Project phase 1 – Challenges SPL data structure (2/2) Internal | ATMO-1DE/SGS | 2018-10 © Robert Bosch Manufacturing Solutions GmbH 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. 5 Workout of 2 approaches together with splunk Professional Service Approach 1: Introduction of accelerated data-model ✓ Extremely fast ✓, but wildcards for fields in tstats-searches not allowed customer request for search-criteria could not be fulfilled ☓ Approach 2: Buffering of data on linux-VM and creation of one event per part-ID with all fields from 14 result files ✓ Flexibility of splunk is base to find best performing solution
- 15. Bamberg plant – Sensor element Project phase 1 – Summary Internal | ATMO-1DE/SGS | 2018-10 © Robert Bosch Manufacturing Solutions GmbH 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. 5 Total hours spent 160 h Duration 6 month (September 2018 – February 2019) Very high costumer satisfaction Time reduction for core-analysis from 15 min. down to 20-90 seconds >80 Alerts implemented by costumer itself, e.g. Identification of work piece carrier with high NIO-rates Condition monitoring for single fields or field correlations
- 16. Bamberg plant – Sensor element Project phase 2 – Summary Internal | ATMO-1DE/SGS | 2018-10 © Robert Bosch Manufacturing Solutions GmbH 2018. All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, as well as in the event of applications for industrial property rights. 5 Another 3 key processes connected GFM (Schichtdickenmessung) 6 lines (summary event) Besatzabbau (after sintering) 2 station for all 17 sintering furnaces Pastenraum 4 station for entire manufacturing area Total hours spent 100 h Duration 3 month (March 2019 – July 2019) Challenges None Current no. of events 455 Mio. (01.06.2020 from previous 3 years)
- 17. ANY QUESTIONS ?