the bread line demonstration - rockwell automation -...

The Bread Line Demonstration

Plant Manager

Maintenance ManagerEnergy Manager

Process EngineerAre we

meeting

OEE targets?

Quality targets?

Batch losses

resolved?

How much

energy are we

using?

Is the weather

affecting my

energy consumption?

Are we reaching

our Sustainable

Initative Goals?

Are some machines

consuming more

energy than others?

Are the Oven

Temps

Optimized?

What machines

are causing

the most issues?

What is my

MTTF?

What

machines

need service

Which recipes

are having quality

issues?

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.PUBLIC

The FactoryBread Line 1 – Anaheim, California

MIXER PROOF OVEN PACKAGING

Ingredients

Electricity

Water

Bread

Alarms and

Events

Process

Data

OEE and

Downtime

Energy

Consumption

Batch

Data~10min Batches

1hr Shifts

Production

Data

Weather

Weather

Data

Natural Gas

ConsumablesScrap

FT View SE Server• Server O/S • FT View SE Server• RSLinx Enterprise Server• RSLinx Classic• FT Tag-based Alarm Server• FT Historian SE FTLD Interface• MSSQL Express

FT Directory Server• Server O/S• FT Directory Server• MS SQL Express 3

FT Historian SE Server• Server O/S• Historian SE Server

FT VantagePoint Server• Server O/S• FT VantagePoint Server• FT VantagePoint Mobile• FT VantagePoint Portal• Excel 2013 (32bit)

Engineering Workstation• Workstation O/S• FactoryTalk View Studio

Desktop Clients• Workstation O/S• FT View SE Client

Domain Controller 1

• Server O/S • For the Ctl Sys Domain

Mix Area• ControlLogix

Managed Ethernet Switch for Control System Network (CSN) – FT Live Data & Ctrl to Ctrl Communications

Managed Ethernet Switch for Control System Network (CSN) – FT Live Data & Ctrl to Ctrl Communications

Microsoft SQL Server 2

• Server O/S• SQL Server Standard• SQL Server Reporting

Services

Smart Devices and Tablets 4

• Mobile O/S• Mobile FavoritesWindows 8 KPI

• Windows 8.1

Wireless

Router

Proof Oven• ControlLogix

Packaging Line• ControlLogix

FT Energy Metrix Server• Server O/S• Energy Metrix

FT Metrics Server• Server O/S• ODBC Data Source• FT Metrics3

• Report Expert


Unified Production Model (UPM)

Integration of all data sources and reports

Organized by Equipment

Sites, Areas, Lines, Assets

Key Performance Indicators for each Bread Line

Organized by Reporting Role

Energy Manager

Maintenance Manager

Plant Manager

Process Engineer

Modeled equipment for easy access to data from various data sources (FTHistorian, FTMetrics…)

Key Value Propositions – the UPM


Portal Content

Themed Portal

Access to the UPM via Menu Link

Access to Role Based Reporting also via Menu

Link

Key Value Propositions – Navigating the Menu


Portal Content

Portal Tree organized by as per UPM

Integration of Reports from various Data Sources

FTHistorian, FTMetrics

FTEnergyMetrix and Custom Database

Demonstration of various reporting tools

Dashboards

Trends

Excel Reports

SQL Server Reporting Services

Integration of Mobile Dashboards and Reports

Portal Tree organized by Reporting Roles

Key Value Propositions – the Portal UPM


Portal ContentKey Value Propositions – Dashboards

Drill from the Baking Overview

to the Line Overview to the

Equipment Detail Dashboards

Visualize Operation

of the Baking Line,

Performance and

Process Variables

Combine Energy

and Performance on

a single Dashboard


Portal ContentKey Value Propositions – Line Reporting with Excel

Current Line Performance

with high level details

Drill through to

current Batch Details

Combined material and

Performance detail on

Batch Details report


Portal ContentKey Value Propositions – Trending Process and Performance Variables

Trend of overall

Line Performance:

OEE and Units Produced

Trend of Proof Oven

Temperatures


Portal ContentKey Value Propositions – Role Reporting – Plant Manager

Line State (Idle, Slicing…)

based on Packaging Machine, with

ability to filter by Product and State

Provides Performance details

for each Machine in the Line

Provides Performance details

for the Site, with drill down

capabilities


Portal ContentKey Value Propositions – Role Reporting – Maintenance Manager

Report on your Top Alarms

by Duration from the Alarms

and Events Database

The Top 10 report provides a

quick overview as to what to

focus on to improve

overall performance

The Faults This Week report

includes Mean Time to Failure and

Mean Time to Repair


Portal ContentKey Value Propositions – Role Reporting – Energy Manager

Overall weather conditions at site

- weather has a great affect on overall

Energy consumption at this Site

For the Packaging Machine,

we can monitor and report on

Energy Consumption

Energy analysis based on

BatchID, Product, State or Shift


Portal ContentKey Value Propositions – Role Reporting – Process Engineer

Detailed review of

Ingredients used

Alarm Report

Trend of ingredients used


Mobile ContentKey Value Propositions

the bread line demonstration - rockwell automation -...

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