Improve plant and enterprise

operations through better

information and management

of production assets, materials

and labor

Benefits:Increase productivity & efficiency•

Reduce production and process •bottlenecks

Enhanced quality•

Reduce waste•

Reduce unplanned downtime•

•

The ChallengesThe Consumer Packaged Goods market is a highly competitive, fast paced, lower margin industry that counts on efficient operations for its profitability and competitive differentiation. Under performing assets, substandard quality, and scheduling challenges present at many produc-tion facilities leads to difficulty in meeting ever changing consumer demands and profit targets.

In a high volume production environment the inability to accurately identify and quickly react to issues affecting performance, quality and waste can quickly undermine customer satisfaction, margin and brand equity.

Rockwell Automation recognizes these challenges and offers a a perfor-mance management solution that allows customers to set performance goals such as yield, quality, schedule adherence and OEE and track progress in real time against those goals.

Productivity losses for availability, performance and quality are presented on daily and weekly review dashboards and analyzed by user defined categories.

CPG Industry SolutionsOur solutions leverage Rockwell Automation 100+ years of CPG innovation, experience and global support. Industry best practices are incorporated into every application, which is built upon a composite application framework that leverages a Service Oriented Architecture (SOA). This scalable solution, when combined with library-based content, offers personalization options that promote faster user adoption and time-to-value.

Performance Management ApplicationThe Rockwell Software Performance Management Application enables CPG manufacturers to increase enterprise manufacturing productivity and reduce costs by using plant assets, materials, and labor more efficiently through real-time communication of operational performance KPI’s and review and analysis of production performance and losses

Performance Management The Performance Management Application monitors the operational conditions of plant floor assets during production, and assesses the impact of Individual equipment and process failures in the context of plant production and order execution. This provides timely feedback to the operations staff as well as providing a detailed review of packaging performance. Analysis of time, speed and waste losses provide insight into operation issues and areas of concern that allows focused efforts to improve these KPI’s.

Performance Monitoring The Performance Management Application is built on the Rockwell Software ProductionCentre platform and is designed to address operations and execution management performance measures at the site and production line level at a plant. The Application provides line based bottleneck performance measures using standard OEE (Overall Equipment Effectiveness) calculations of Performance, Availability, and Quality. The application also supports productivity measures based on process order performance for production, material and quality key performance measures. Coupled with a powerful analytics and visualization engine, published KPI’s can lead Operations Staff towards answering the question of how a particular production line is performing over time or a process order. Providing a Process Order context allows for comparisons of a specific production run against assets, material, operations staff, or another product type.

Features

Performance Management is a plant level application that monitors process and packaging line efficiency, captures downtime events and provides an approach to comprehensive root cause analysis. It offers:

Performance Monitoring Process Order Management – The application allows for complete management of process orders from creation to the optimum planning of each order. The Process Order Planning Board provides a Drag & Drop Gantt chart visual representation of the orders taken that includes the scheduled start time, order duration and expected order completion, and changeover time. Authorized users can modify the production schedule based on scheduled shifts and production assets availability.

Downtime Monitoring – Once the Process Orders are dispatched to the plant floor the operations staff has the ability to collect faults and production counts automatically from the control system or manually from the production line operators. Each of the stoppage events can have a reason code assigned to quantify the downtime event.

Production Monitoring – Coupled with the Production, Material and Quality Management applications future monitoring of process order performance across the entire production line will be provided. The application will provide for monitoring of all production assets from raw material receipt through finished goods in each phase of goods manufacture.

Performance Review OEE Calculations and Loss Analysis – The Application automatically transforms shop floor data collection into hourly summaries of Overall Equipment effectiveness (OEE) and losses of the bottle neck production assets. The Application utilizes standard OEE calculations and can be customizable to fit customer needs.

Publication RSAPCP-AP010A-EN-P – April 2011 Copyright ©2011 Rockwell Automation, Inc. All Rights Reserved. Printed in USA.

Production, Material, and Quality Analysis – Future capabilities will extend the application to include additional operational measures necessary to accelerate performance. KPI’s will include real-time yield, scrap, waste, material variance, mass balance, on time delivery, and first pass quality among others.

Performance Analysis Through application dashboards & reports User access to the Performance Management system is through a ‘thin client’ dash board accessed from Internet Explorer and user access is fully configurable based on role type. Dashboards and reports include:

KPI’sof the production line asset rolled up across the Enterprise for:

OEE (Overall Equipment Effectiveness)•

Production, Quality and Availability•

Root Cause Analysis – Detailed event KPI’s for root cause analysis •

13 site level reports for all information (event, state, performance) by: Enterprise, Site, and Production Line level dashboards•

Shift or Time base•

Process Order •

Application Configuration and Administration The application provides interfaces to import several aspects of its configuration via the import of Excel files. Importing is supported for Plant Model (Site, area, lines, work cell, equipment, and relationship names and descriptions) Reason codes (Group, sub groups, reason number, text and state) Material definitions and users. The application provides editors for both line configuration and shift patterns.

Application Interfaces The application supports preferred integration with Rockwell Automation’s ControlLogix platform using a defined ControlLogix User Defined Data Type (UDT)., or standard OPC DA