i2 - an overview of wonder ware mes products - jan rasmussen version 0.92 nxpowerlite
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An Overview Of Wonderware MES Products
Jan RasmussenSales Director EMEA - MES
Microsoft Technology & Industry Standards
System Platform
Clients
EnterpriseIntegration
Industry Applications
&IndustryPacks
Wonderware MES & EMISoftware Solutions
Operations PerformanceQualityBatch
Asset Monitoring Food &
Beverage
Local Scheduling
WonderwareOPERATIONS 3.5 - STANDARD
WonderwarePERFORMANCE 3.5
WonderwareOPERATIONS 3.5 - PREMIUM
Wonderware Manufacturing OperationsSoftware Solution Offerings
WonderwareQI Analyst
WonderwareInBatch
‘Mtelligence forWonderware’PartnerSolution
WonderwareEMI Offerings
Microsoft Technology & Industry Standards
System Platform
Clients
EnterpriseIntegration
Industry Applications
&IndustryPacks
Wonderware MES & EMISoftware Solutions
Operations PerformanceQualityBatch
Asset Monitoring Food &
Beverage
LocalScheduling
Wonderware System Platform Native integration of plant model with MES
production model for low TCO
Superior reusability via object templates and deployment with sharing of best practices
Intuitive user interfaces for appropriate operator involvement
Unparalleled data connectivity incl. leading historian for process data, and advanced security model
Common Industrial IT Services for Increased Sustainability
Platform
Microsoft Technology & Industry Standards
System Platform
Clients
EnterpriseIntegration
Industry Applications
&IndustryPacks
Wonderware MES & EMISoftware Solutions
Operations PerformanceQualityBatch
Asset Monitoring Food &
Beverage
LocalScheduling
Batch
Wonderware Operations Software Simple batch management with recipe
definitions using site specific processes
Accurate equipment setup with automatic download of set points
Wonderware InBatch Powerful batch execution engine with
dynamic allocation of shared equipment for even the most complex batch processes
Graphical recipe definitions according to S88 with unit procedures, operations and phases for equipment independent master recipes
Accurate Management of Batch Processes
Microsoft Technology & Industry Standards
System Platform
Clients
EnterpriseIntegration
Industry Applications
&IndustryPacks
Wonderware MES & EMISoftware Solutions
Operations PerformanceQualityBatch
Asset Monitoring Food &
Beverage
LocalScheduling
Operations
Wonderware Operations Software Dispatching and management of electronic
work orders, with multilevel BOM
Improved process and production consistency and repeatability
Accurate inventory mgt and operational enforcement through procedural steps
Equipment Operations Modules Non-model based approach for recording
of production events and ‘as-built’ records as simple extension of supervisory system
Improved Execution of Operational Activities
Wonderware Operations Software…
Provides a scalable & configurable Manufacturing Execution System
solution for a wide range of industries
Provides a scalable & configurable Manufacturing Execution System
solution for a wide range of industries
Background:Core MES software capability (formerly Factelligence) obtained from 2007 acquisition of leading MES software provider, CIMNET
Product History
2002
July 2007
October 2007
February 2008
November 2008
Wonderware Operations Software…
► Comprehensive MES Functionality▪ Bill of Material, Work Orders, Events, Data Collection,
Specifications, Set Point Download, Inventory, Certifications, Steps/Procedures, Labor Management, User Management, Genealogy, Traceability, Web Reporting
► Fully Scalable▪ Functionality – Standard & Premium Edition, Enterprise
Integration, MES Clients plus .net controls to embed in InTouch▪ Physical Scalability – equipment, lines, plants▪ Taking advantage of ArchestrA services
► Highly Configurable Application
Highly Configurable User Interface
Wonderware MES Features
Deliver planned vs. actual production•Electronic Work Order Management•Recording of Production Events•Electronic Work Order Management•Recording of Production Eventsusingusing
Improve process and production consistency
•Centralized Manufacturing Model•Production Rules•Certifications
•Centralized Manufacturing Model•Production Rules•Certifications
usingusing
Improve inventory velocity
•Real time inventory management•Detailed definition of materials, substitutes and byproducts•Bill of Materials
•Real time inventory management•Detailed definition of materials, substitutes and byproducts•Bill of Materials
usingusing
Reduce order lead time•Dynamic prioritization and sequencing•Labor management •Connection to HMI/SCADA
•Dynamic prioritization and sequencing•Labor management •Connection to HMI/SCADA
usingusing
Monitor and analyze production performance
•Downtime•Utilization•OEE
•Downtime•Utilization•OEE
usingusing
Solutions “Powered By” MES Modules…
► Track & Trace► Error Proofing► Electronic Batch
Records (EBR)► Electronic Work
Instructions► Procedural Execution► Performance Mgt. (OEE)► Asset Utilization► Labor Mgt.
► Receiving► Order Management► WIP Management► Inventory Management► Quality Data Collection► Weigh & Dispense► Batch Processing► Recipe/Spec. Mgt.► Master Data Mgt.
General OverviewWonderware Operations & Performance
System Platform benefits on MES
Lower Cost of IT in Industrial Applications for data collection and automated transactions
Connect and Collect : out of the box connectivity to any information source
Reduce effort and cost on designing, building and maintaining system
Complete scalability, upscaling in size and functionality without impact to existing system
Lower Cost of IT in Industrial Applications for data collection and automated transactions
Connect and Collect : out of the box connectivity to any information source
Reduce effort and cost on designing, building and maintaining system
Complete scalability, upscaling in size and functionality without impact to existing system
Building the Production Model
Highly configurable & customizable to ensure a complete & accurate model of your production processes
Microsoft Technology & Industry Standards
System Platform
Clients
EnterpriseIntegration
Industry Applications
&IndustryPacks
Wonderware MES & EMISoftware Solutions
Operations PerformanceQualityBatch
Asset Monitoring Food &
Beverage
LocalScheduling
Quality
Wonderware Qi Analyst Realtime and historical SPC with
comprehensive charts and custom run rules with alarm generation upon violations
Minimize costly scrap and rework through detection of process variations better understanding of actual process capabilities
Wonderware Operations Software Central administration of process and
product specifications with versions and min/max limits per BOM entity
Reduce Variances with Specification and SPC
Using Standard Deviation
► Cream Cheese▪ Online Controlling Water percentage▪ Operators only allowed to adjust paramaters
based on rule violations from QIAnalyst▪ Water is cheaper than milk
► Mozarella▪ Planning production based on the orders solid
material requirements in the cheese► Cream Cheese
▪ On line Weight control in filling line► Butter
▪ On line controlling fat and water
Using standard deviation
Microsoft Technology & Industry Standards
System Platform
Clients
EnterpriseIntegration
Industry Applications
&IndustryPacks
Wonderware MES & EMISoftware Solutions
Operations PerformanceQualityBatch
Asset Monitoring Food &
Beverage
LocalScheduling
Performance
Wonderware Performance Software Improve asset utilization by automated
data collection and selective involvement of operators
Consistently monitor and compare equipment performance and OEE.
Wonderware System Platform Powerful reporting infrastructure through
Information Server
Rapid and Accurate Decision Making via Realtime Visibility
Improve Asset Utilization and OEE
Operations / Mgt Engineering IT & Infrastructure
Productivity gains drop straight to bottom line Productivity gains drop straight to bottom line
Engineering Efficiency
Operations / Mngt Engineering IT & Infrastructure
IT Environment Consistency
Operations / Mngt Engineering IT & Infrastructure
Increase Capacity
► Reduce unplanned equipment downtime▪ By tracking and analyzing equipment downtime
► Improve the output of existing equipment▪ Track and analyze equipment output (performance)
► Reduce quality related losses (scrap)▪ Track and analyze first pass yield
All require detailed equipment performance information
Empower Operators
► Leverage existing automation system▪ Provide more accurate, reliable and granular downtime data than
manual systems
► Flexible capture of downtime events with unlimited downtime reasons per equipment
► Enhanced operator involvement with highly configurable.NET based Operator interface
Real-time Graphics
► OEE KPI Control ▪ Displays OEE value and/or the
OEE components (Availability, Performance, Quality)
► Count/Duration KPI Control▪ Displays the number and
duration of events for the current entity
► Production Progress Control▪ Displays the current progress
of production for the current shift compared to a provided target
Drill Down to Root Cause
Enterprise Integration
Enterprise Integration Out-of-the-box integration using pre-
defined mappings.
Simple, yet powerful integration capabilities in a standardized formats
Tight Alignment withBusiness Processes
Microsoft Technology & Industry Standards
System Platform
Clients
EnterpriseIntegration
Industry Applications
&IndustryPacks
Wonderware MES & EMISoftware Solutions
Operations PerformanceQualityBatch
Asset Monitoring Food &
Beverage
LocalScheduling
• Attributes• BOM Item / Oper. Links• BOM Item / Oper. Step Links• BOM Item Substitutes• BOM Items• Data Log 16 and 48• Folders & Files• Operation Routes• Operation Step Entity Excl.• Operation Steps• Operations
• Operations Step Groups• Operation / BOM Spec Links• Operation / Entity Links• Operation / Entity Spec Links• Operation Attributes• Process / Item Links• Process Attributes• Processes• Rework Process Usage• Specifications
• Item Attributes• Item Classes• Item Folders• Item Reasons• Item Substitutes• Items• Standard Operations• Standard Operations Entity Links• Standard Operations Attributes• Utilization Reasons
Master/Static Data (30+ templates):
Dynamic Data (20+ templates):• Customer• Inventory Items• Job Attributes• Job BOM• Job Step Links• Job BOM Substitutes
• Sales Order• Sales Order Items• Work Order Attributes• Work Order Folders• Work Orders (with Process)• Work Orders (without Process)
• Job Routes• Job Specifications• Job Step Groups• Job Steps• Jobs• Lot Attributes
► Provides standard mechanism to import and export data from WW Ops & Perf Database
► Provides a set of data import and export templates► Integrate with ERP, SCM, LIMS and other business level
or plant level systems ► Used to synchronize BOM, orders, WIP, items, specs,
certifications, attributes, etc.► Configurable data formats including XML, flat file, and
Database table transfers► Configurable triggers including period, weekly, data
changes, table data exists, file exists► Delivers standard production reports, exception reports
and email alerts
Enterprise IntegrationBasic Features
Microsoft Technology & Industry Standards
System Platform
Clients
EnterpriseIntegration
Industry Applications
&IndustryPacks
Wonderware MES & EMISoftware Solutions
Operations PerformanceQualityBatch
Asset Monitoring Food &
Beverage
LocalScheduling
Industry App for Packaging
Vertically oriented Packaging Solution Leverage System Platform, InTouch,
Performance Module and Information Server
Provides a window for Planners (job sequencing and dispatching), Operators and Supervisors (line and machine state, status, yield, Performance, Events and alarms)
Generates and distributes reports via Wonderware Information Server
State Model Compliant with OMAC and PackML
Food& Beverage, Tobacco, Consumer Packaged Goods (CPG)
Easy setup via Excel Utility
Alternative to traditional MES/Performance project
Wonderware InBatch Powerful batch execution engine with
dynamic allocation of shared equipment for even the most complex batch processes
Graphical recipe definitions according to S88 with unit procedures, operations and phases for equipment independent master recipes
Comprehensive Application for Packaging Lines
Microsoft Technology & Industry Standards
System Platform
Clients
EnterpriseIntegration
Industry Applications
&IndustryPacks
Wonderware MES & EMISoftware Solutions
Operations PerformanceQualityBatch
Asset Monitoring Food &
Beverage
LocalScheduling
Condition Based Monitoring - Mtelligence Endorsed Partner Solution
Equipment run-time hours fed to maintenance system with automatic generation of work orders
Detect health degradation and prevent equipment failures
Open Standards eliminate Upgrade and Migration Risk (MIMOSA, ISA-95)
Improved Maintenance Strategy with Condition Based Monitoring
Asset Monitoring
Microsoft Technology & Industry Standards
System Platform
Clients
EnterpriseIntegration
Industry Applications
&IndustryPacks
Wonderware MES & EMISoftware Solutions
Operations PerformanceQualityBatch
Asset Monitoring Food &
Beverage
LocalScheduling
Preactor Finite Scheduling Wonderware offers you a world class MES
solution
Preactor offers the best available finite scheduling tool available on the market today
The two have been integrated to offer both scheduling and manufacturing shop floor control
Improved Maintenance Strategy with Condition Based Monitoring
Local Scheduling
Certified !!
With a record that shows a ROI which is unsurpassed
Largest installed base of any independent planning & scheduling software company for the manufacturing sector
>2,300 companies in almost every manufacturing sector
Discrete/process/hybrid
>10,000 licenses Users in 64 countries
Translated into 30 languages
Adopting a Flexible Approach to Improve Your Manufacturing Operations
Enable an incremental, low-risk deployment of increased application functionality, one step at a time.
Enable an incremental, low-risk deployment of increased application functionality, one step at a time.
Milkshake Manufacturer – Scenario #1
► Three Lines Produce Milkshakes► Two Manufacturing Sites► Currently, no MES
► Goal: Monitor/Improve equipment performance ▪ Answer the question, “How are we doing?”
• Overall Equipment Effectiveness (OEE)
• Downtime
• Asset Utilization
Manufacturing ‘Pains’
► Fillers not running at designated capacity▪ Output & profits lower than forecast
► Not meeting daily schedule► Pasteurization process blocked
▪ Production storage is full► No information about filler stops► Operators often wait around
▪ Don’t knowing how to resolve issues
Scenario #1: Performance
Line 1 Clients Line 2 Clients Line 3 Clients
System Platform
Production Server
MES database
Historian
Info Server
Install System Platform
Install InTouch, ‘WW Op’s & Perf’
Install Historian, ‘WW Op’s & Perf’, Info Server
Install InTouch, ‘WW Op’s & Perf’
Install InTouch, ‘WW Op’s & Perf’
Install System Platform license
Install InTouch license
Install InTouch license
Install InTouch license
Install Historian, ‘WW Op’s & Perf’, WIS licenses
Initial Deployment of Performance
Manufacturing Scenario #1
Machine Utilization
Reports
MES Configuration
Scenario 1: Machine Utilization
Solution Diagram
Reports
► Scenario #1 – Asset Utilization▪ Downtime▪ OEE▪ Utilization
Milkshake Mfgr – Scenario #2
► Mfgr now has visibility to performance▪ OEE & Downtime ▪ Asset Utilization
► Goals (one or more): ▪ Increase consistency using electronic work
orders for line management▪ ‘Track & Trace’▪ Consistent data model
Manufacturing ‘Pains’
► Possible pains▪ Can’t correlate process conditions with WOs or batches when issue detected▪ Small issues become big problems because impacts can’t be easily assessed.▪ Mistakes are made repeatedly▪ Major concerns about recalls▪ Operators waste time figuring out what to produce next▪ Differences in time to complete jobs between lines, shifts, operators▪ Different definitions of product formulas / recipes ▪ Introducing new product variants causes issues▪ Too much time spent compiling manual reports
► Potential Self-Diagnosis▪ Increased requests for additional / special reports▪ ‘Firefighting’ since information not shared across
shifts and departments▪ Reduction in customer service due to delays in
response time▪ Rework has increased ▪ Production costs have increased▪ Changeovers take too long
Scenario #2: Op’s Standard
Line 1 Clients Line 2 Clients Line 3 Clients
System PlatformProduction Server
MES database
Historian
Info Server
Install Op’s Standard license
Deployment of Operations (Standard)
Manufacturing Scenario #2
Machine Utilization
Reports Reports
MES Configuration MES Configuration
Machine Utilization
Scenario 1: Machine Utilization
Scenario 2: Work Order Execution
Solution Diagram Solution Diagram
Reports
► Scenario #2 – Track and Trace, Execution▪ Consumption and
Waste▪ Production and
Rejects▪ Genealogy▪ Traceability ▪ Yield
► Scenario #1 – Asset Utilization▪ Additional domains▪ By item, work order
Milkshake Mfgr Scenario #3
► Mfgr now has… ▪ Visibility to equipment performance▪ Increased consistency w/electronic work orders▪ ‘Track & Trace’
► Goal #3: Add more MES capabilities…▪ Inventory tracking capability▪ Reduce WIP inventory▪ Manage expiration of WIP▪ Improve inventory turns▪ Reduce inventory costs ▪ Reduce order lead time ▪ Reduce Time-to-volume
► Excessive Scrap► Too Much Inventory► Inventory Costs Too High► No Traceability To Quality Check► Accurate Labor Costs Unknown► No enforcement of business rules for
intermediate WIP► Starved processes
Manufacturing ‘Pains’
Scenario #3: Full MES
Line 1 Clients Line 2 Clients Line 3 Clients
System PlatformProduction Server
MES database
Historian
Info Server
Install Op’s Premium license
Deployment of Operations (Premium)
Manufacturing Scenario #3
Machine Utilization
Reports Reports Reports
MES Configuration MES Configuration MES Configuration
Machine Utilization
Machine Utilization
WIP Inventory Tracking
Scenario 1: Machine Utilization
Scenario 2: Work Order Execution
Scenario 3: WIP Inventory
Tracking
Solution Diagram Solution Diagram Solution Diagram
Reports
► Scenario #3 – Inventory Tracking▪ Additional reports available
► Scenario #2 – Track and Trace, Execution▪ Additional information provided to previously
available reports
More Manufacturing Scenarios
► Example 1: Scalability ▪ … from a Small System to Large System
• Scale from a pilot to a larger system with ease
▪ Procedure to scale:• Start with a pilot system
• Add clients and servers without re-engineering the applications
• Reuse library of templates for multisite rollouts
System PlatformProduction Server
MES database
Historian
Info Server
Line 1 Clients Line 2 Clients Line 3 Clients Line 4 Clients Line 5 Clients
Scalability
More Manufacturing Scenarios
► Example 2: Incremental Growth▪ … from One Application to Multiple
Applications ▪ Scale to address additional functional
requirements▪ Procedure to grow ’incrementally’
• Start with Performance
• Add Operations Standard
• Add Operations Premium
… all by simply changing the license file!!!
System PlatformProduction Server
MES database
Historian
Info Server
Line 1 Clients Line 2 Clients Line 3 Clients
Incremental Growth
Differentiators
► Standard application content out of the box► Single comprehensive database for all
MES capabilities – not disparate solutions► Modular operator interface concept► Support for mixed manufacturing modes► Data master flexibility► True integrated SCADA through MES
capability► Modern Microsoft-based architecture
Additional Benefits of Wonderware MES
► Integrated use of System Platform + MES
► Templates for MES User Interfaces
► The Value of a consistent data model▪ Templates ▪ Deployment
In Conclusion…
► Wonderware Operations and Performance Software offers:▪ Rich MES functionality that can be deployed
incrementally▪ Maximizing effectiveness▪ While reducing risk and time to value
Wonderware WorkshopsOperations Management - Monday
Time Topic Zunkles Room
10.00-10.50 An Overview of Wonderware MES Products
Jan Rasmussen
11.00-11.50 NEW! - Wonderware Performance Software - Real-time equipment downtime and performance tracking
Dawid Sadie
14.00-14.50 Manage and maintain your assets utilising Wonderware's condition based monitoring (CBM)
Tim Sowell
15.20-16.10 NEW! - Wonderware Industry Application for Packaging
Andrea Sartori
Wonderware WorkshopsOperations Management - Tuesday
Time Topic Zunkles Room
10.00-10.50 Manage and maintain your assets utilising Wonderware's condition based monitoring (CBM)
Tim Sowell
11.00-11.50 NEW! - Wonderware Operations Software - improve production consistency, visibility and agility
Andrea Sartori
14.00-14.50 NEW! - InBatch 9.0 - Flexible management for batch processes
Jos Peters
15.20-16.10 Advanced Scheduler for Wonderware MES
Chris Mollison - Preactor
Time Topic Injasuti Room
11.00-11.50 NEW! - Wonderware Performance Software - Real-time equipment downtime and performance tracking
Dawid Sadie
14.00-14.50 NEW! - Wonderware Industry Application for Packaging
Andrea Sartori
Questions
Thank [email protected]