mfgsummit 201003 improve flexibility and efficiency 2

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

Chatchai Wajakiet / Chee Hoe Lee

Solution for Manufacturing Flexibility and Efficiency

Business Intelligence

Copyright © 2009 Rockwell Automation, Inc. All rights reserved. 2Copyright © 2009 Rockwell Automation, Inc. All rights reserved. 2

Agenda

1. Basic Manufacturing Problem

2. The FactoryTalk VantagePoint Solution

3. Built-In Functionality for Plant Floor

4. FactoryTalk VantagePoint Advantages

5. Ordering, Training and More Information

Copyright © 2009 Rockwell Automation, Inc. All rights reserved. 3

Manufacturing: An Information Problem

Material

Time

People

Energy

Product

Waste

Copyright © 2009 Rockwell Automation, Inc. All rights reserved.3

Data: Control systemsHMI systemsAlarm and event systemsHistorians


Universal Problem


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Alarms &Event History

Alarms &Event History

Control SystemsControl Systems HMI /

SCADAHMI /

SCADA

HMI / SCADA

HMI / SCADA

ProductionHistoriansProductionHistorians

Manufacturing Information WorkersManufacturing•Production

•Testing•Rework

•Inventory•Shipping

Information Workers•Co-workers•Management•Production Supervisor•Quality Department•Sales•Marketing

BAD INFORMATIONPOOR DECISIONS

? ?

??


Agenda







Two Products for Two Solutions

6Copyright © 2009 Rockwell Automation, Inc. All rights reserved.


FactoryTalk VantagePoint


Visualization & Reporting

LINKLINK


FactoryTalkHistorian

RS Logix OPC DA OPC HDA InTouch ProficyFactoryTalkAlarms/Events

OSI PI InSQLFactoryTalkView

Multiple Sources of Manufacturing Data


Area 1

SoCal

Area 2 Area 3Suppliers Customers


All Data in a Unified Production Model (UPM)

Area 1

SoCal







A Realistic, Flexible Model

Area 1

SoCal


ProdMLProdMLProdML

Open O&MOpen O&MOpen O&MISA 88/95ISA 88/95ISA 88/95

B2MMLB2MMLB2MML

Model ReflectsThe Business

Model ReflectsModel ReflectsThe BusinessThe Business






Built in Analytics, Extensibility

Area 1

SoCal


CalculateCalculateCalculate AggregateAggregateAggregate

ScheduleScheduleSchedule ReactReactReact

Unified Production ModelUnified Production Model






Rich Content, Easy to Use and View

Area 1

SoCal


AnalysisAnalysisExcelExcelExcel DashboardsDashboardsDashboards

TrendTrendTrendReportsReportsReportsPortalPortalPortal

KPIsKPIsKPIs

Unified Production ModelUnified Production Model






The VantagePoint Difference

• Deeper Manufacturing Insight– Unified Information– Business Context– Knowledge Building and Sharing

Area 1

SoCal


• Increased IT Agility– Leverage Existing Information Assets– Accommodate Change– Extend Infrastructure

and



Agenda







Rich, Interactive Browser Experience

Start with KeyPerformanceIndicators

Start with KeyPerformanceIndicators

Drill Down to Underlying

Calculations

Drill Down to Underlying

Calculations

• Universal access via a browser

• No client install necessary

• Role based reports and custom links for your users

• Links to reports, client tools and help:

– VantagePoint Manager– Trend– XY Plot– Documentation– Links to Help and Support


Excel Reports Available to Everyone

• Create powerful Excel reports

• Retrieve data from any supported data source

• Calculate, analyze and format reports using Excel functionality

• Publish reports via portal forviewing by anyone with access to a browser—no client install

• Dynamically refresh data

• Pre-configured Excel reports in Sample Reports

Retrieve Data From Any

Source

Retrieve Data From Any

Source

Calculate, Analyze

and Format

Calculate, Analyze

and Format

Publish to the VantagePoint

Portal

Publish to the VantagePoint

Portal


Trending Made Easy

• Easy model navigation

• Diagnose and analyze data from any supported data source

• Access to real-time and historical data

• Powerful trend functionality-Pan, zoom, stack & synchronize

• Publish & share trends to the portal

• Pre-configured trends available in Sample Reports


Powerful Easy to Read Dashboards

• Create powerful dashboards that monitor real-time data and key manufacturing KPIs

• Dashboards can update dynamically and on demand

• Easy access to all dashboards via a browser

• Pre-configured dashboards available in Sample Reports


FactoryTalk Vantage Point XY Plot

• Create XY Plots using the XY Plotter Tool

• Analyze one value with respectto another over time

• Publish and share XY Plots to the Portal

• Pre-configured XY plot available in Sample Reports


Composite Reports for Greater Visibility

ReusableComponents

DashboardBuilder Trend

Excel

Plot



Agenda







A Rockwell Solution for Rockwell Products


User Defined Data TypesSave engineering time creating data structuresMake it easier to design and maintain programs


Create Tank Reports, Trends, Dashboards


VantagePoint TypesSave engineering time mapping to data sourcesMake it easier to create, manage, view reports


VantagePoint

Map Logix UDTs to VantagePointTypes


Logix

The Logix tank UDT is mapped to the VantagePoint tank type. Tank UDT members are mapped to tank type properties.


Import Logix Configuration into VantagePoint


Logix

Instances of the tank UDT are imported as items of type tankinto the VantagePoint Unified Production Model

VantagePoint

Users can now easily find tanks and associated tags, and can see the real time value of these tags (via LiveData)


Logix

Correlate Logix Tags with FT Historian Tags


FT Live Data tags are associated with FT Historian tags in the VantagePoint Unified Production Model.VantagePoint can now retrieve the history of a tank from FT Historian, and the real time values of tank tags from Live Data. Users don’t need to know where the data is coming from.

FT Historian

VantagePoint


View Tank Reports, Trends and Dashboards


Tank reports, trends and dashboards work automatically against tank items imported from Logix.

Authorized users can access tank information by browsing to the VantagePoint portal.


One Set of Tools For All Data Sources


Any 3rd Party Data Source


Real World Model For Information the Way You Need It


Process Control Engineer• Pressure • Flow• Speed

Production Manager• Volume pumped • Product throughput• Operation history• Power consumed

Maintenance Manager• Running hours • Performance spec• Manufacturer data• Spares on hand• Maintenance date

Process Engineer• Related equipment • Rating• Vibration data

Asset Manager• Purchase date • Cost• Warranty• Manufacturer• Engineering SpecsQuality Assurance

• Batch record • Leak test data• Lab sample

Live Data: Control System/HMI

Historian

AssetDatabase

ERP, LMS, SQLDatabase

MaintenanceManagement

System


Single Point of Access, One Version of the Truth


• Access to ALL plant floor, production and business systems• Integrate and organize time series and transactional data• Users at all levels of enterprise can view role-based KPIs, reports

and dashboards

30


All You Need is a Browser

• No client install is needed to view trends, reports and dashboards

• Simply publish reports in the portal to allow access


Non-programmers Can Create and Publish Reports, Trends and Dashboards

• Build ad-hoc reports and publishto the model

• Reports can be saved and modified easily as needed

• Reduces the marginal costof curiosity


Agenda







How would you answer these questions?

• What types of control systems do you have?• What types of Historians do you have?• What types of HMI systems do you have ?

• Who has access to the information from these systems?• Would your engineering / maintenance / quality /

supervisory staff benefit from access to this information?• Would it help to have a common set of tools to report

against all of these data sources ?• Would a web based reporting solution help ?

• How much time do you spend creating production / quality / maintenance reports ?

• What happens if the owner of the reports is not available?

• Would you benefit from reports being generated from the structure data types in ControlLogix (UDT)?



Additional Connectivity via FactoryTalk VantagePoint EMI


For connectivity to FactoryTalk Metrics, Transaction Manager, Batch or other manufacturing data sources utilizing a SQL database, a connector is available with FactoryTalkVantagePoint EMI

Contact your local Information Solutions Regional Manager (ISRM)to receive additional information on ordering and configuring


Building Your FactoryTalkVantagePoint Solution



Where to Find Additional Information

Discover Rockwell Automation Portalhttp://discover.rockwellautomation.com/mi• Includes Product Demo / Videos• Discover Webcast Recordings• Product Profiles• Ordering Information• System Requirements• Case Studies



Training

• Training is available for FT VantagePoint and FT VantagePoint EMI through Rockwell Automation’s training site at:

– http://www.rockwellautomation.com/services/training/schedules.html



Customer Value – Food & Beverage

SCOPE• 69 plants• 140+ data sources – SCADA, control, MES, LIMs,

Asset Management, SAP, ORACLE & SQL databases, InSQL historian

• Many legacy systems and in-house designed MES• 2.5 MM – 10 MM objects in the database

(FactoryTalk VantagePoint model)• Corporate portal system

available to 28,000 employees

SCOPE• 69 plants• 140+ data sources – SCADA, control, MES, LIMs,

Asset Management, SAP, ORACLE & SQL databases, InSQL historian

• Many legacy systems and in-house designed MES• 2.5 MM – 10 MM objects in the database

(FactoryTalk VantagePoint model)• Corporate portal system

available to 28,000 employeesTV (One plant)

• TV monitor above every production line• Dashboard tracking the following for each line

• Production target• Results so far• Current projection against target

• Targets• Cost• MTBF/MTTR• Downtime cause

TV (One plant)• TV monitor above every production line• Dashboard tracking the following for each line

• Production target• Results so far• Current projection against target

• Targets• Cost• MTBF/MTTR• Downtime cause

RESULTS• Improved throughput by 8%• Reduced waste by 3%

RESULTS• Improved throughput by 8%• Reduced waste by 3%


Customer Value – Chemical

SCOPE/OBJECTIVE• A global fortune 500 manufacturing company• Objectives

• Increase production due to higher demand• Without adding new capital or resources• Replace antiquated batch reporting• No rip-replace of other legacy systems

SCOPE/OBJECTIVE• A global fortune 500 manufacturing company• Objectives

• Increase production due to higher demand• Without adding new capital or resources• Replace antiquated batch reporting• No rip-replace of other legacy systems

Rational for EMI• Integrated easily with existing production control

systems• Provided deep insight into our batch processes• Reports available to production and management to

monitor production in context of individual’s role• Future expansion capabilities for integration with

our ERP

Rational for EMI• Integrated easily with existing production control

systems• Provided deep insight into our batch processes• Reports available to production and management to

monitor production in context of individual’s role• Future expansion capabilities for integration with

our ERPRESULTS

• Changeover time reduction• Control Loops optimized• Schedule improvements• More product produced in 2

shifts than previously done in 9

RESULTS• Changeover time reduction• Control Loops optimized• Schedule improvements• More product produced in 2

shifts than previously done in 9

“One of the main benefits of using FactoryTalk VantagePoint was greater performance. We have better insight into how we perform, how long processes take and how fast we can make our products. We’ve reduced our production cycle times by 90% already.” Manager

“One of the main benefits of using FactoryTalk VantagePoint was greater performance. We have better insight into how we perform, how long processes take and how fast we can make our products. We’ve reduced our production cycle times by 90% already.” Manager


Customer Value – Energy Management

SCOPE• Small university – 70 buildings• Central plant to manage: electricity, heat and cooling• Cogeneration of electricity and heat from fuel oil• Buildings metered / data stored in historian and control

OBJECTIVE• Manage/reduce energy consumption• Make vs. Buy

SCOPE• Small university – 70 buildings• Central plant to manage: electricity, heat and cooling• Cogeneration of electricity and heat from fuel oil• Buildings metered / data stored in historian and control

OBJECTIVE• Manage/reduce energy consumption• Make vs. Buy SOLUTION

• Track and accurately predict electricity and oil consumption

• Reduce impact of high cost peak-demand energy• Calculate / predict individual building demands• Integrate “islands” of information from water treatment,

HVAC, co-generation and weather reports

SOLUTION• Track and accurately predict electricity and oil

consumption• Reduce impact of high cost peak-demand energy• Calculate / predict individual building demands• Integrate “islands” of information from water treatment,

HVAC, co-generation and weather reports

RESULTS• Reduced overall energy

consumption by 23%• Lowered total energy bill by

$3M / year

RESULTS• Reduced overall energy

consumption by 23%• Lowered total energy bill by

$3M / year


Customer Value – Water Management

SCOPE/ENVIRONMENT• Mid-size city municipality• Multi-vendors – SCADA and Control• Many disparate data sources• Facing severe environmental issues with

storm run-off

SCOPE/ENVIRONMENT• Mid-size city municipality• Multi-vendors – SCADA and Control• Many disparate data sources• Facing severe environmental issues with

storm run-off OBJECTIVES• Consistent reporting

• Yield• Quicker leak detection• Reduce contamination• Improve water quality• Reduce energy

consumption

OBJECTIVES• Consistent reporting

• Yield• Quicker leak detection• Reduce contamination• Improve water quality• Reduce energy

consumptionRESULTS

• Remediated detection, quality and energy issues

• Reduced operating cost (dbl digits)

RESULTS• Remediated detection, quality and

energy issues• Reduced operating cost (dbl digits)

“We’re taking business intelligence to the next level because our departmental staff recognize opportunities earlier, react more swiftly to them, more easily communicate the issues involved, and make better decisions.” Manager

“We’re taking business intelligence to the next level because our departmental staff recognize opportunities earlier, react more swiftly to them, more easily communicate the issues involved, and make better decisions.” Manager


Backup Slides


How do you manage your challenges?

Reduced Mfg CostReduced Mfg Cost

Improve Mfg AgilityImprove Mfg Agility

Improve QualityImprove Quality

Reduce Mfg Lead TimeReduce Mfg Lead Time

Reduce FG InventoryReduce FG Inventory

Improve Schedule ComplianceImprove Schedule Compliance

Improve ThroughputImprove Throughput

Reduce Raw Material InventoryReduce Raw Material Inventory

Reduce WIP Inventory Reduce WIP Inventory

SYSTEMATIC DATA COLLECTION A MUSTSYSTEMATIC DATA COLLECTION A MUST

BEST IN CLASSBEST IN CLASSTOP THREE TOP THREE OTHERSOTHERS

Source: Aberdeen Group, Mfg Perf Mgt2, 2006



Applications for Manufacturing Historians

• Historians are utilized across many industries and applications:– Consumer Products, Food and Beverage, Automotive, Life Sciences– Continuous Process, Packaging, Material Routing, etc.

• Key benefit of a Historian:– Capture and process high-speed, time-series data– Store in a central (Site or Enterprise) data repository for future analysis

• Historical data is used for:– Analysis through calculations, statistical processes, quality controls, etc.– Supports business and operational analysis:

• Trends and graphs of data

Turns Data into Information !Turns Data into Information !Turns Data into Information !



Value of a Data Historian

Helps improve overall operations through analysis of manufacturing, process and production data.

• Accelerate Six Sigma and Lean initiatives• Identify under-performing production areas• Increase quality

– Identify the root causes of process variability

• Improve processes– Analyze complex process data easily

• Capture non-relational data very efficiently– Extreme capture speed and

compressed storage

• Reduce variability– Verify production parameters versus

targets/norms• Capture critical performance and quality

data in real-time• Decrease overhead costs

– Save time in collecting data and preparing reports

• Centralized storage repository– Enables a platform for standardization of

data collection and reporting of key performance indicators (KPIs)



A New Twist – Distributed Strategy

Pervasive Information Across Enterprise, Site, Machine/DevicePervasive Information Across Enterprise, Site, Machine/Device



Distributed Historian Strategy

The Right Information, at the Right Time, with the Right Fidelity…The Right Information, at the Right Time, with the Right FidelitThe Right Information, at the Right Time, with the Right Fidelityy……

SUPERVISORSUPERVISOR

MANAGEMENTMANAGEMENT

OPERATOROPERATOR



Automation Fair 2006 Announcement



Strategic Partnership

•• Leadership in Automation and Leadership in Automation and Information Information SolutionsSolutions

•• Solution ProviderSolution Provider•• Automation and Controls Automation and Controls

ExpertiseExpertise•• Solution PlatformSolution Platform

•• RealReal--time Performance Management time Performance Management Software Software ProductsProducts

•• Technology ProviderTechnology Provider•• Data Historian and Context Experts Data Historian and Context Experts •• Product PlatformProduct Platform


Market leaders joining together to provide winning solutionsMarket leaders joining together to provide winning solutionsMarket leaders joining together to provide winning solutions


FactoryTalk Historian Machine Edition

• FactoryTalk Historian Machine Edition– Based on FactoryTalk Historian SE– Module-based historian– Data Collection over backplane– More granular data– Solid-state data storage

• Part of the Distributed Historian Strategy

– Three-tiered historian• Aggregating data upward• Auto-discover sources downward

– Auto configure tags– Performance and scalability– 3rd-party connectivity



Platform Architecture

Control Logix Historian ME*HMI

Self Discovery*

UDT Definitions*Structured Data*Alarm & EventsSelf Discovery

Single Operator Interface OPCAlarm & Events

Mobile 3rd Party Controllers

Production DataFactoryTalk Platform

Process Data

ExcelExcelExcel DashboardDashboardDashboard

TrendTrendTrend ReportsReportsReportsPortalPortalPortal

KPIsKPIsKPIs

EAI, SOA Data Rollup



Thank You

mfgsummit 201003 improve flexibility and efficiency 2

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rockwell automation

manufacturing flexibility

basic manufacturing

suppliers customerscopyright

builtin functionality

plant floor4

flexible modelarea

universal problemcopyright