accelerating the performance of your production enterprise - managing automation suppleme

8/14/2019 Accelerating the Performance of Your Production Enterprise - Managing Automation Suppleme

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Competing in an increasingly fast-moving,

global market is all about tightly integrating

manufacturing operations with the rest of

the business. Implementing a flexible plant

software platform that provides access to

real-time manufacturing intelligence is the

only way to win the race.

INSIDE THIS SPECIAL

SUPPLEMENT

BUILDING FOR

SPEED & AGILITY

Power up with real-time operations

management tools & techniques.

CASE STUDY:

CITROSUCO

Orange juice producer squeezes

more efficiency out of production.

CASE STUDY:

DB BREWERIESBrewery taps Wonderware to locate

and solve problems.

Accelerating the Performanceof Your Production Enterprise

SPECIAL ADVERTISING SUPPLEMENT

Sponsored by


2/8

Manufacturers can synchronize manufacturing operations with the

demands of the business by utilizing Real-Time Operations

Management tools and techniques.

In manufacturing these days, everything hinges on perfect tim-

ing being in the right place at the right time to make a deal,

completing a project on time, and delivering product just in time

to meet market needs.

Speed, of course, is a major element in the strategy of any

business. But manufacturers cant compete on speed alone.

Thats because manufacturing is not simply a race to the finish line.

Rather its much more like an Olympic contest where the winning

strategy is a result of the perfect synchronization of mind, body,

and spirit.Of course, manufacturing is much more complex than racing

around a track. It requires companies to distribute production

around the world while keeping supply networks lean. The only

way to achieve this, say experts, is to tightly synchronize manu-

facturing operations with the rest of the business.

In fact, manufacturing has entered the era of what AMR Re-

search Inc. calls demand-driven transformation.

It is the need to connect manufacturing in a ver y substantial

way into the business process backbone, says Alison Smith, a re-

search director at AMR.

In other words, manufacturers must be able to quickly adapt

their processes to shifts in the market. And, in order to do this,

they need an up-to-the-minute understanding of whats going on

throughout the global organization.

Information from manufacturing is needed in order to make

a decision about what can be made, where to make it, and the

overall design of the supply network, Smith explains. For ex-

ample, if I want to serve southern Asia, can I use existing ca-

pacity, do I need additional capacity, which facilities can serve the

market most profitably? These are important questions that

need real-time answers, she says.

Plant-to-enterprise systems integration has long been held up as

the way to link manufacturing operations with the rest of the en-

terprise. And, indeed, it is a slice of the solution. But now, manu-

Building forSPEED & AGILITY

O V E R V I E W

There are two dimen-

sions: First, how good

is my data and, second,

how real-time is my

data? Wonderwares

Bhattacharya

2


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facturers are realizing they need a more comprehensive remedy that

will aid them through this demand-driven transformation.

The complexity of the situation requires an architecture that

enables flexible interoperability, applications that provide visibility,

and a technology and partner network that creates natural agil-

ity. More important, it all has to happen in real time.

Thats where Wonderware, a business unit of Invensys, steps in.Wonderware, the market leader in operations management

software, offers a portfolio of products focused on powering op-

erations management in real time. Its technology can also integrate

information from multiple data sources, helping manufacturers

drive speed, agility, efficiency, quality, and performance across dis-

crete, process, and hybrid manufacturing operations.

According to Sudipta Bhattacharya, president of Wonder-

ware, most of the real-time information that companies need to

access in order to drive decisions comes directly from the plant

floor. When we talk about effectively managing information,

there are two dimensions, Bhattacharya says. First, how good

is my data and, second, how real-time is my data?Wonderware software paves the way for companies to access

and execute on that information. It includes Supervisory HMI,

GeoSCADA, Production Management/MES, Performance Man-

agement/Enterprise Manufacturing Intelligence (EMI), and Arches-

trA the technology foundation that enables integration with as-

set management, supply chains, and ERP applications.

Collectively, this software portfolio forms the foundation to

empower plant workers by enabling them to easily access data,

regardless of where it resides. That, Bhattacharya says, is some-

thing that Wonderware does better than anyone else in the in-

dustry, and has for a long time.

Indeed, Wonderware has always been a hardware-independ-ent software company. Its applications are designed to work

with any control architecture and any device.

Wonderware has a long history as a software company sell-

ing platform-independent HMI, AMRs Smith says. So they had

a head start on the market ... I have to say, when you look at the

set of devices they can connect to, its mind-blowing.

Wonderware has also established a strong circle of partners in

the form of distributors and systems integrators located in more

than 100 countries around the world. These local and regional

service providers, which reach 3,500 or more companies globally,

are backed by the expertise of the Wonderware Global Cus-

tomer Support & Service team.As a result of this partner ecosystem, we have what we call the

real-time platform on the plant floor, and we have the widest

reach, Bhattacharya says. This is important in todays global econ-

omy where manufacturers have facilities located around the world.

Now, not only is Wonderware technology scalable, but so, too,

is its service and support business model.

To that end, Wonderware provides its customers in a variety

of industries including food and beverage, power, water and

wastewater, facilities management, transportation, upstream oil

and gas, mining, metals, and others with the ability to orches-

trate information management and accelerate decision-making.

Real-time operations management is the ability of any com-pany to access and execute information to drive operations

across an extended supply chain network, Bhattacharya says.

Real-Time Operations on the Rise

Manufacturing operations software, as defined by AMR, includes

three main categories: enterprise asset management (EAM), en-

terprise manufacturing intelligence (EMI), and manufacturing

execution systems (MES). Collectively, these applications, which

generated $5.1 billion in worldwide revenue in 2007, are ex-

pected to grow to represent an $8 billion market by 2011, AMR

Research predicts (see table, above).

The reason for the upsurge is that many manufacturers are

looking beyond their ERP systems to help them close the infor-

mation gap between the plant and the enterprise. SAP, for ex-ample, is working closely with Wonderware to bring together

core strengths that provide a better solution that can be de-

ployed faster at the customer site. The two companies are work-

Manufacturing OperationsMarket Growth

A

ccording to AMR Research Inc., the manufacturing operations software

application market is divided into three major revenue subsegments:

enterprise asset management (EAM); enterprise manufacturing intelligence(EMI, increasingly referred to as operations intelligence); and manufacturing

execution and management (including MES quality processes, in-plant produc-

tion performance management, batch and recipe management, etc.).

*Forecast

Source: The Manufacturing Operations Software Application Market Sizing Report, 2006-2011. AMR

Research Inc., 2007

2006 2007 2008* 2009* 2010* 2011*

$4.6

billion

$5.1

billion

$5.8

billion

$6.5

billion

$7.4

billion

$8.3

billion

The manufacturing operations software application

market will experience a five-year 13% CAGR,

reaching more than $8 billion in revenue by 2011.

3

We bring a rich set

of tools ... So when you

think of the analytics

side, think about

visibility around data.

Microsofts Colyer


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ing on delivering software capability that ef-

fectively helps each end of the organization

business and manufacturing interoperate almost transparently.

Traditionally, Wonderware focused on plant-level execution

while SAP focused on enterprise business processes, says Vivek Ba-

pat, SAPs vice president, suite solutions marketing, product, sup-

ply, and manufacturing solutions. In the new world of manufacturingoperations management, both companies are working jointly to

close the gap between the plant and the enterprise by providing new

solutions that combine visibility and process orchestration. The goal

is to ensure that mutual customers are able to seamlessly inte-

grate manufacturing execution into the business process.

In addition, Wonderware is the worlds lead-

ing industrial software business, with more than

500,000 active software licensees around the globe. This represents

approximately one-third of the worlds industrial facilities. So its no

surprise that SAP, the predominant ERP supplier, and Wonderware

share many of the same customers. And many of them are looking

to tie the two environments together, says Tim Fief, chief soft-ware architect at Progressive Software Solutions (PS2), a Won-

derware systems integration partner. More companies want to use

Wonderware for integration into ERP than ever before.

But the value-add offered by Wonderware, Fief says, goes

beyond the ability to easily integrate plant floor and enterprise

systems. Wonderware also adds a layer of redundancy and avail-

ability around control and safety systems, he says.

Another key Wonderware partner is Microsoft. Wonderware

has built its applications on Microsoft technology, including .NET

at the foundation layer, SharePoint Portal Server to enable col-

laboration, and BizTalk Server for integration and scalability. The

company also leverages the analysis and reporting services builtwithin SQL Server.

Microsoft is working with key partners, and Wonderware is

one of our primary partners on the manufacturing operations

end, says Chris Colyer, Microsofts worldwide director, manu-

facturing operations strategy. Microsoft helps companies build out

a data strategy by making it easy for users to manipulate and

manage data as it relates to business. We bring a rich set of

tools and a technology platform. ... So when you think about the

analytics side, think about visibility around data, Colyer says.

Making Sense of the Data

Indeed, visibility into real-time data is, in many ways, the key tomaking a manufacturing business more responsive. So its not

surprising that EMI (also known as operational intelligence) ap-

plications are suddenly coming together with MES. And Won-

derware is ahead of the market curve on this as well, as a result of

its 2007 acquisition of Cimnet, a leading MES software solutions

company whose offerings include intelligence applications.

Wonderware has also done extensive development work to

tie some of its applications together with SAPs Manufacturing In-

tegration and Intelligence (SAP MII technology). MII leverages

Web services to extract data from multiple sources, aggregating

the data at the server, transforming it into business context,

and personalizing it for delivery to the appropriate end user.This allows manufacturers to more easily and quickly take action

on the operational insights delivered by EMI software.

Its great to say you have access to real-time information, but you

also need the ability to execute, Wonderwares Bhattacharya says.

These are the types of developments that will drive the next

phase of operational efficiency, say industry observers.

Successful manufacturers in the future will need to master the art

of integrating business processes that transcend their enterprise, i.e.,

across their network of business partners, including suppliers, con-

tractors, and outsourcers to enable network-wide responsiveness

and operational excellence, SAPs Bapat says. Next-generation

plant to enterprise solutions must support this requirement.To deliver a technology solution that incorporates business

Visualizing the Future

The best way to understand Wonderware technology is to describe

its main purpose in the plant. That can be summed up in one word:

visualization. We have enterprise-wide visualization so that you

can see data, whether its real-time or historical data, says Rashesh Mody,

Wonderware vice president of product management. We can get all ofthat information displayed in one spot.

That is accomplished thanks to a flexible framework called the

ArchestrA architecture that underlies Wonderware applications. The plat-

form which Invensys has invested more than $60 million in developing

is built to lower customers integration costs by

enabling connectivity to any control architec-

ture or enterprise application used in discrete,

hybrid, and process industries. Using ArchestrA

technology, Wonderware has developed key

applications to provide a window of insight.

Collectively called Wonderware System

Platform, its a system-based license that

includes all the capabilities needed by a manufac-

turer. Its a universal platform for many differenttypes of applications, such as supervisory con-

trol, HMI, GeoSCADA, historian, production

management (MES), EMI, and Web portal appli-

cations. This information is deliverable to an end user via any client desk-

top or mobile device. The approach is based on a service model that allows

for interoperability among all of the applications. All of the key services you

need are built-in, and all the services interact with each other, which is a key

part of the architecture, Mody says.

A distinction of the Wonderware technology is its ability to access data in

real time, providing a view into what is happening now, in addition to what

happened in the past. Data connectivity occurs via open connectivity (OPC),

and Wonderware technology also leverages industry standards, such as the

ISA-88 batch standard and ISA-95 for plant-to-enterprise integration.

Another important aspect of the Wonderware technology strategy is an

object model that represents plant assets. Adding capability to the model isas easy as inserting a new object; theres no need to deal with complex code.

You can just change an object template, and any part of the application using

that template is also changed, Mody says. The real power is in the ability to

standardize operations, integrate all data, and the flexibility to change any

aspect of the application easily and with minimal engineering effort.

Wonderware continues to build out functionality in all of its applications,

paying specific attention to sophisticated analytics that will help users under-

stand how information from the plant will impact the entire organization.

So, while visualization is a key element of the Wonderware technology,

the architecture enables so much more than just seeing. It provides the

ability to do things based on this new information, such as improving opera-

tions, taking advantage of new opportunities, and becoming more competi-

tive. And, finally, it empowers people with the right information at the right

time and with context in the right form they need it in.

Rashesh Mody

4


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5

processes focusing on best practices around operational ex-

cellence, becoming more responsive to the demands of the sup-

ply networks, or linking design and manufacturing together the

architecture underneath needs to be flexible. Translation: Solu-

tions must be built using services-oriented architecture (SOA)

and composite applications.

Part of the reason that Wonderware applications are so nimblehas to do with its underlying ArchestrA infrastructure, a services-

oriented layer that enhances flexibility. The way that Wonder-

ware technology is built makes it well-suited for building com-

posite applications, says AMRs Smith. This is an area that more

customers are craving, and the company that can deliver what end

users want will be the company with the winning strategy.

Whoever can appeal to the way that users work and get

that user interface to a mobile device just look at the work

Microsoft is doing in the mobility area thats the company that

will explode with innovation, Smith claims.

Wonderware, as a software company that is not tied to any

specific control architecture, has the ability to be nimble, agile, and

respond rapidly to customer needs.

In this world of demand-driven transformations, there is aneed for adaptive business networks. And you cant adapt

processes until you understand how all of the cogs fit into the big

picture, Smith says.

Meanwhile, Wonderware continues to accelerate its own efforts

to ensure that it has a solution for every customer problem. This

is a journey, not a destination, Bhattacharya says. As long as

customer needs change, we will continue to serve their needs.

C A S E S T U D Y

Orange juice producer turns to Wonderware for integrated

plant-enterprise data and real-time access over the Web

to ensure fast, efficient production.

Squeezing More EfficiencyOut of Production

Citrosuco, a business unit of Fischer

Group, is one of the worlds largest orange juice producers. It

operates four plants in Brazil a country where 80% of the

orange juice consumed in the world originates as well as

one processing facility in Lake Wales, FL.

Production speed and product quality are two important

aspects of the business, and the company is always seeking

ways to fine-tune each step of the process, whether it is receiv-

ing raw materials, monitoring variables while

producing a batch, or shipping the end product

to distribution terminals.

To gain total control over the many steps ofits process, Citrosuco realized it needed to tie

information from the plant floor to its enter-

prise business system. To accomplish that

formidable task, the company turned to two

of its key technology partners, Wonderware

and SAP.

Years ago, Citrosuco decided to standardize

on SAPs R/3, which included a manufacturing

module. More recently, the company began to

leverage its use of Wonderware applications,

including InTouch HMI and the Wonderware

Historian software, to provide a deeper viewinto what is happening on the plant floor. In

addition, Citrosuco recently adopted the Wonderware

Information Server as a way to aggregate and present plant

production and performance data in real time over the Web.

Many of the manufacturing processes are tied to SAP, but we

need to get information about the process from the automation

system, explains Milton Bilar Montero, a project engineer at

Citrosuco. We chose the Wonderware Application Server as

the platform to provide this communication with SAP.


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6

C A S E S T U D Y

Wonderware user-friendly software solutions enable brewery to gather

far-flung data to pinpoint problems and act quickly to address them.

DB Breweries Reduces

Complexity andImproves Efficiency

Nobody wants to waste a drop of

good beer, whether youre drinking it or making it.At DB Breweries, a New Zealand-based brewery, finding a way

to capture the 2% to 3% of the bottom beer that leaks from a

tank during the brewing process means saving money from going

down the drain literally.

When company engineers began looking at ways to improve

utilization, they used proactive monitoring technology from

Wonderware to identify the root cause of the waste. The prob-

lem: a leaky valve. The solution: a new centrifuge to extract the

beer and pull it back into the process.

This was hardly a make-or-break situation for the maker of the

legendary Tui beer and other brands, including Heineken, Mon-

teiths, Export Gold, Amstel, and DB Draught. But for a companywith four breweries and an emphasis on double-digit annual

growth, every drop counts.

The key is that we can make changes rapidly, says StephenVidulich, DB Breweries business systems manager.

The leaky valve example is just one of many ways that the

companys Brewing Process Improvement Team, a group that

blends IT and production expertise, is taking action. Other areas

of concentration include automating data collection, tracking

batches, building a common reporting system, and loosely cou-

pling ERP and plant floor systems.

DB Breweries faces the same problem that manufacturers in

every industry struggle with: how to extract data and, more im-

portant, act on it. The brewery, which was acquired by Asia Pacific

Breweries in 2004, must also be able to share best practices com-

pany-wide and find effective ways for everyone plant managers,engineers, IT, and executives to access the right information

Like any manufacturer operating in a highly

regulated industry, Citrosuco must be able to

trace every lot of raw material, which means it needs to have

the complete history on each batch, and have it available for

many years. Thats where the Wonderware Historian applica-

tion helps. And, like any manufacturer in any indu str y,

Citrosuco strives to be the best at what it does producinghigh-quality orange juice at high speed and it is leveraging

Wonderware Information Server to help.

We need a system that can help us deal with a lot of infor-

mation, Montero says. More important, we must be sure the

information is correct.

The Wonderware applications extract information from the

source at the plant, which ensures the accuracy of the informa-

tion, he says.

Prior to tapping into the power of the Wonderware

Information Server, Citrosuco tried to tie its PLCs and process

control directly to the ERP system. But this information was

very restricted to the process, Montero says.Now, the company can expand the breadth of interaction

to include purchasing and receiving in order to calculate

how much raw material is coming in from the orchards and to

quickly make the correct payments to the

fruit producers, according to Montero.

Integration between plant and enterprise applications

occurs via standard Web services, XML, and SAPs Exchange

Infrastructure (XI) software. Wonderware Information Server,

which acts as a portal providing plant managers and corporate

executives with visibility into the process, interoperates easilywith the Web services environment.

The Wonderware Information Server tracks KPIs for each

step in the process so that managers can monitor what is hap-

pening in real time. And the applications object database

allows Montero to easily replicate processes from one plant to

the next.

A global deployment affords the company the flexibility to

quickly create, change, and replicate KPIs related to process

improvements.

The main purpose of this system is to have information in

real time so that the plant people can be more productive and

can deal with any day-to-day problems, Montero says.However, the company has quickly realized the value of this

system. It is not just improving efficiency; we need this com-

munication, he says. We have come to depend on this.


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when needed and have it de-

livered in the right context.

To accomplish those goals,

the company formulated a vi-

sion that would leverage

technology to gain efficiency

throughout the business. Andthe first thing executives de-

cided to do was to standard-

ize on its SAP ERP system.

For its operations manage-

ment software, the company

chose Wonderware technol-

ogy, including the Wonder-

ware Historian software to

gather historical data, InTrack

software to trace batches,

and the InTouch HMI oper-

ating interface.The vision came about

because we wanted to get

information that we knew

was rich at the plant floor,

but the IT people didnt know how to get to it, Vidulich says.

The Wonderware-SAP solution is solving the problem, allowing

DB Breweries to execute on its strategic plan of sharing data across

the organization, even if it resides in hard-to-reach places in the plant.

Pouring over the Mix

As with any business strategy, the company needed first to put a

solid plan in place. In order to understand the needs of eachdepartment, Vidulich and his team began to define how infor-

mation needed to be delivered. In any organization, there is so

much complexity, he says. One of the key things that can

break down that complexity is simplicity. Break it down into

simple modules.

To do that, Vidulich outlined what the team needed to achieve

and how far they could push the boundaries of technology. We

put the vision together void of an actual solution. But we asked

the question, What do we want to achieve in an ideal world?

What they realized was that the technology they chose, like

their project strategy, had to reflect a big-picture vision sup-

ported by simplicity.Wonderware technology, such as InTouch HMI, with which

Vidulich was familiar, is simple, but powerful, he says. That

rang true to me.

Simplicity must be inherent in the technology and applications that

the company uses to achieve operational efficiency; otherwise peo-

ple wont understand them and wont use them. Vidulich learned that

lesson firsthand with early Unix-based systems, which required

high-level expertise to maintain. The Microsoft-based Wonder-

ware applications, on the other hand, dont have a complex script-

ing engine, but rather an easy-to-understand modular approach

that enables anyone on the plant floor to find information, he says.

DB Breweries is using Wonderware technology at three brew-eries, and it is already proving to be a valuable asset. The company

rolled out the Wonderware Historian software first, as a way to

understand inefficiencies in the plants energy consumption, in-

cluding carbon emissions and water waste. The team hooked up

7,500 tags to digital valves to measure flows, pressure, and tem-

perature, and tasked engineers with evaluating the energy effi-

ciency of specific pieces.

Within the first month, they found huge inefficiencies in water

usage in pumps. By identifying that issue, we saved $20,000 to$30,000 within the first few weeks, Vidulich says.

As a result, engineers at DB Breweries applied the Wonder-

ware technology more broadly, tagging 20,000 data points and,

again, realizing immediate savings in water usage and CO2 emis-

sions. As part of the solution, there are automatic triggers that

notify key users by text and e-mail when a strategic plant is

down or limits are reached.

In addition, the company tied the SAP plant maintenance ap-

plication together with Wonderware Historian software. If a

particular item goes over a certain pressure for a specific amount

of time, for example, Wonderware Historian software will text

the engineer to say there is a problem, Vidulich says.The key is that the Wonderware software solutions deliver in-

formation in a way that enables people to act decisively. It does

this by interoperating with a variety of existing applications and

control technologies in the plant, such as SAP software or PLCs

from third-party vendors.

Information needs to travel at the speed of light. Whether its

good or bad, it needs to get to the right people at the right time

or its meaningless, Vidulich says.

Wonderware technology, he says, has enabled DB Breweries

to move forward with its vision to use technology to gain effi-

ciencies. Now, Vidulich wonders how the company operated

without the technology. We are using it all the time. Wed belost without it, he says. And so would all that bottom beer.

7


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Breakthrough

2008 Invensys Systems, Inc. All rights reserved. Invensys and Wonderware are trademarks of Invensys plc, its subsidiaries and affiliated companies. All other brands and product names may be the trademarks or service marks of their respective owners.

Operations Personnel: Eliminate the limitations to your organizations operational

efficiency with the NEW Wonderware offeringsInTouch 10.0 HMI and System

Platform 3.0 Software! See for yourselftry the Wonderware Breakthrough

Experience by visiting www.experience.wonderware.com

Theres a reason its called Wonderware.

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