ts04 - accelerating manufacturing productivity · months to 3 months, as part of company’s six...

Copyright © 2012 Rockwell Automation, Inc. All rights reserved.Rev 5058-CO900B

TS-04 Accelerating Manufacturing Productivity & Performance through Manufacturing Intelligence

Imtiaz Javeed Product Manager- Visualization & Information Software Suite

Copyright © 2012 Rockwell Automation, Inc. All rights reserved.

Scheduling• Production Planning

• Utilization / Capacity

• Capable to Promise

Planning & Logistics• Facility Systems

• Shipping

• Inventory Control

Maintenance• Equipment Monitoring

• Predictive / Preventive

• Scheduled / Unscheduled

Operator• Uptime

• Throughput / Cycle Time

• Quality

Manufacturing: Islands of Information

2

Plant Management• Profitability

• Utilization / Capacity

• Asset Utilization

• Energy

Each functional area of a plant generates data…

…This data is typically isolated creating “Islands of Information”


Manufacturing Landscape

3

Productivity

• Unplanned Downtime

• Equipment Efficiency / OEE

Quality & Operations

• Compliance Tracking

• Improved First Pass Quality /

Process Consistency

Network Convergence & Security

• Infrastructure Modernization

• Security & Anti-Virus / Anti-

Tampering Protection – Top

Floor to Shop Floor

Virtualization & Thin Clients

• Reduction in Physical Servers

• Shop Floor Thin Clients

Common Issues

• Manual Data Collection

• Data consistency /

Standardization

• Energy Usage / OptimizationAsset Management

• Preventative / Predictive

Maintenance

• Reduced MTTR


Maintenance

What is the maintenance

schedule?

Actual Scrap/Rejectsfrom OEE System

What is the reject

rate?

Actual Cycle Timefrom Control System

Average rate

during shift?

What is the production

plan?

Production Schedule Quality Data

What is the

quality?

What is target?

Order Management

Order = 900 units

10 minutes

scheduleddowntime

95%pass rate

5 rejectsper hour

132 units per

hour

150 units per

hour

Islands of Information: Founded on multiple sources of data

4

How many systems are currently needed to make a simple calculation…

“Can I produce 900 units this shift to fulfill a customer promise date?”

Will the

customer

order ship on

time?

Plant Management

105 * 95%

= 100

units

Capacity

=150

units

150 * 50/60

= 125 units132 * 50/60

= 110

units

110 – 5

= 105

units

Current Shift Production = 800 units

Time remaining = 1 hour

Target

=900

units

YES!

ERPProd

SchedCMMS LIMS

ControlSystem

OEESystem


The CEO’s Reality

60% of CEOs:

“Need to do a better job capturing and understanding information rapidly in order to make swift business decisions…”

5

40% of IT

budgets are

spent on

integration

Source: IBM & Industry Studies; Customer Interviews

Source: Gartner

42% of transactions: paper-based

85% of information: unstructured

30% of people’s time: searching for relevant information

Timely, accurate information is critical for business success


A House Divided - a Universal Problem

6

1 98 1

981 38

199

8

1 981981 78

199

81 9

8 1981 88

199

8

1 981981 58

199

8

… the lack of adequate

1 98 1

981 98

199

8

?

?

??

?

Alarms &

Event History

Control

Systems HMI /

SCADA

HMI /

SCADA

Manufacturing Information Workers

Production

Historians

• Unique Reporting Tools

• Proprietary User Interfaces

• Different security measures

• Dissimilar data formats

• Diverse protocols


Reports/Visibility

Analytics

Current State: A Highly Fragmented ‘MESS’ in the Plants

The majority of plant floor systems are custom, stand-alone applications

Production Monitoring

Downtime Analysis

Production Counts

Constraint ID & Analysis

Schedule Execution/

Hit to Hit

Process Control Boards

Dock Inventory

Process Sheets

Manual Production Count

Cycle Time Analysis

Environmental Systems

Metrics (DTD, BTS)

Shipping

Container Track’g

Lot Tracking

Rack Tagging

Raw Mat Ordering & Inv

Dock Inventory

Schedule Optimization

Inventory Control

Line Side Replenishment

Part Consumption

Campaigns

Shipping – Error Proofing

External Metrics

Internal Metrics

Traceability

Error Proofing

Defect Tracking

SPC

Repair Bay OI

Quarantine

Scrap & Reject Reporting

Tool Monitoring

Predictive

Preventive

Crisis

Reliability & Maintenance

Downtime Analysis

Fluid Tracking

Programmable Dev Supp

Plant Design & Layout

Die Re-Chroming

Information Portal

Energy/Building Mgmt

Cost Management

Policy Deployment

Best Practice

Timekeeping

Metrics for Workforce

Issues Management

Production Log

Knowledge Management

Training

Birth History Sequencing

Logistics Quality Production Maintenance Management


Maintenance

What are my downtime

causes?

Production Manager

What are my bottlenecks?

8

Extending Automation Investments To Provide Operations Knowledge

Engineering

What is my equipment

utilization?

Plant Manager

What is my response time to a

new order?

Quality

What is my rejection rate?

Operations

How are we doing against

plan?

ERP

8

Copyright © 2012 Rockwell Automation, Inc. All rights reserved.Copyright © 2011 Rockwell Automation, Inc. All rights reserved. 9

How is data analyzed today?

Copyright © 2009 Rockwell Automation, Inc. All rights reserved. 9

Hmm… I have a

theory. I’ll need to find

someone who can

help me find the data I

need…

Historian Batch LIMS

The local ‘data expert’

uses their ‘inside

knowledge’ to

• connect Excel to

multiple data

sources…

• extract the relevant

data from the period

of interest…

• manually collate it together…

… and send the

result to the person

requesting the data.

… I don’t have time

for this… What

system is it in? How

do I access it?

Time…


Source: McKinsey & Company

39% Support

collaboration

Source: Aberdeen

BIG DATAand ANALYTICS

DRIVERS: 37%Fact-based

decision 33%Better ways to

serve

customers

BIG DATA

10

Exabytes2Real-Time Control in Manufacturing Produces Big Data

Manufacturing generates more BIG

DATA than any other sector.


What is Manufacturing Intelligence ?

11

+ = IMPROVEDDecisionMaking

� Manufacturing Intelligence

� Software used to bring a corporation’s manufacturing data together from many

sources for the purpose of reporting, analysis, and visualization.

� As data is combined from multiple sources, it can be given context that will help

users find what they need regardless of where is came from.

� The primary goal is to turn data into real knowledge (information), and drive

business results based on that knowledge.

Source: Wikipedia http://en.wikipedia.org/wiki/Enterprise_manufacturing_intelligence

The Data Exists in Your Systems – Finding and Contextualizing is the key


Enterprise Manufacturing Intelligence Includes

13


Unified Production Model (UPM)

14

My Enterprise�

Chicago Plant

�

Line 1

Area 1�

Area 2

�

Tank ReportBatch TrendActual vs Target

Equipment�

Pump 001Uptime Dashboard

Pressure

�

Pump 002

�

�

Mixer 001�

Chicago

Dallas

Cleveland

TICHMI4n21

TICArea2_4n21

TICArea2Ext4n21

References data directly

at its source - “Single

Version of the Truth”

Maps data from multiple

sources into logical unitsPumps, Valves, etc.

Plants, Lines, Workcells, etc.Products, Ingredients, etc.

Combines relevant data from

multiple systems to present the

entire story !Control / Plant Floor

Operations / Production SchedulingMaintenance, Quality, etc.

Line

Cleveland Plant�

Reports�


Building a Logical ModelThe power of a Unified Production Model

Physical ModelConnect data sources

Logical ModelOrganize for Presentation


Why is a Model Important?

� Organize the Model fit Your Needs

� Production Managers may want to see the logical

layout of the plant that matches the physical

equipment

� But Maintenance may want to see this in a way

that groups ALL like equipment together, they see

the SAME data, but can navigate to the

information differently.

� An Easy to Understand Model

� Individual Plant Areas May not use the same

terms or same systems

� Using a model can be a way everyone is using the

terms that make sense to them


For the Operators

� Monitoring process to keep production running

� Identifying relationships to optimize the process

Operator

For the Production Manager

� Schedule, track production activity

� Way production is running, ways to improve

Production

For the Engineering / Maintenance

Manger

� Keeping plant running

� Predicative maintenance, asset optimization

Engineering

For the Quality Manager

� How product was made, ensure compliance

� Ways to improve product and yield

Quality

For the Executive� Costs, schedules, production output

� Financial indicators, sustainability

Plant Mgmt.

Different Users, Different NeedsRole-based Reporting and Analytics The Right Information at the Right Level


Information at a GlancePowerful Easy to Read Dashboards

• Data collected for all monitored machines

• OEE and 3 components

• Production counts – Total, Good, Scrap

• Available time, Downtime, Running time

• Slice and dice in up to 9 dimensions for reporting

• Date/time, Plant Model, Shift, Part, 5 user-defined

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 19

Mobile Capabilities


FactoryTalk® VantagePoint KPIAutomatically Display & Share KPIs!

20

� A native Windows 8.1 application that visually shows off your

FactoryTalk® VantagePoint® system in a simple but powerful way

� It uses KPIs (Key Performance Indicators) to focus your attention

� With your KPI’s you can:

� Visually represent your data as a gauge,

bar graph or indicator

� Collaborate by sending an e-mail with

instructions and attaching a KPI

� Drill down to more specific detail

� Leverage Live Tiles to provide continuous

updates by pinning a KPI on the Start page

� See a map view of your KPI’s based on

geographic location

Available for download from the Microsoft Store


FactoryTalk® VantagePoint EMI MobilityProviding Information When and Where you need It

21

� Mobile Landing Page

� Responsive User Interface

� Support for all major mobile platforms (iOS, Android)

� Mobile Model Browser

� Mobile Favorites – personalized, available on any device

� Ad Hoc dashboard or trend creation

� Mobile Content

� Excel Reports, Advanced Reports

� Trend, XY Plot charts

� New Composer – Drag and Drop Dashboard Creation

� Mobile First Design – Optimized for your browsing

experience


ComposerCreate Displays Quickly and Easily

22

� Create new displays on a Tablet or PC Device

� Drag and Drop Canvas for Display Creation

� Library of Widgets (Gauges, Indicators, Trends, Text)

� Save displays as favorites

� Simplified single click functionality for display creation from mobile phones


Why FactoryTalk VantagePoint?Trend Anywhere – PC, HMI, Tablet, or Phone

23

� Create Trend templates for re-use

or ad-hoc trends to analyze

impromptu situations

� Publish trends for sharing /

collaborating with others

� Diagnose and analyze data from

any connected data source

� Powerful trend functionality – Pan,

zoom, stack and synchronize

� Display multiple time period at the

same time to determine batch

variations


Cycle Time, Loading & Unloading Time & SPC Reports

(Conf24

Load & unloading time trends


Leading Automotive SupplierAutomated Data Collection and Reporting Boosts Productivity

• Increased OEE and productivity by 50 percent, helping

the facility execute more than 11.5 million data collection

transactions per day to monitor inventory, production,

budget, equipment operation and more

• Reduced project development time by 50 percent, from 6

months to 3 months, as part of company’s Six Sigma

process

• Eliminated the time associated with manual paperwork

• Needed flexibility to adjust production

volume at any time to meet customer

demands

• Faced ongoing pressures to reduce

downtime and boost productivity

• Needed an automated data collection and

reporting system to replace current manual

system

Tier 1 automotive supplier cuts development time, increases efficiency and eliminates paperwork

• Collect manufacturing performance data with

FactoryTalk® Metrics and use that data to improve processes and

generate production reports

• Execute more than 11.5 million data collection transactions per day

to monitor inventory, production, budget and more

• Oversee maintenance activities through

FactoryTalk AssetCentre

• Achieve real-time data reporting through

Allen-Bradley® PanelView™ and FactoryTalk View software

RESULTS

CHALLENGE SOLUTION

25


Manufacturing Visibility = ResultsOne of top 10 pharmaceutical companies worldwide

26

• Improved process monitoring by using out-of-the-box tools,

such as batch comparison reports

• Reduced batch cycle times by up to 10% through real-time

batch execution cycle reporting

• Reduced unnecessary/unplanned stoppages by monitoring

critical equipment behavior via out of the box reports from

FactoryTalk Metrics

• Reduce the total number of process and

system-related deviations

• Reduce unnecessary stoppage of

equipment in other plant areas

• Reduce batch cycle times

Major US Pharmaceutical company with production in 13 countries and products distributed in 143 countries

improves quality and overall efficiency with Integrated Architecture

• Implemented FactoryTalk Historian SE in full redundant

configuration; leveraged event subsystem to track batch related

events

• Data across plant from OEM equipment is now captured into a

single FactoryTalk Historian providing improved visibility

• Monitor operational equipment efficiency on packaging line with

FactoryTalk Metrics

• Improved insight into cause of machine-based event stoppages by

using FactoryTalk Metrics

RESULTS

CHALLENGE SOLUTION


CHALLENGE SOLUTION

Case Study – Energy Intelligence Global Automotive Manufacturer

• Validated energy consumption data to participate in government energy rebate program

• Reduced energy usage by 15%

• Reduce energy consumption per vehicle

produced

• Affirm energy usage data is collected and

accurate for Plant

• Simplify reporting of energy consumption

Customer turned to Rockwell Automation to help them reduce energy usage

• Utilized FactoryTalk® VantagePoint, Historian,

AssetCentre, and ControlLogix® to collect and visualize

information from the production floor

• Implemented a real-time tracking and monitoring system for

gas, steam and electric usage (WAGES)

RESULTS


Discover Manufacturing Intelligencehttp://discover.rockwellautomation.com/mi

28


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Rev 5058-CO900B

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ts04 - accelerating manufacturing productivity · months to 3 months, as part of company’s six...

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