Using SCADA for Production Monitoring

The Manufacturing Lesson

Rick CaldwellPresident, SCADAware

Me and Dick“The Day We Failed”

SUCCESS STORY

SCADA For ManufacturingData Acquisition Only

REPORT SERVERI/O SERVER 1

TREND SERVERI/O SERVER 2

ALARM SERVERIO SERVER 12

FILE SERVERIO SERVER 11

OP MBS UBFS FloorMBR

SIDE BODY RES. LS2 0 0 SHL

TRUNK L IDTL 11 7

HARDWARE MOUNTED IN ENCLOSURE - PROTECTED BY UPS

PORT 6

MAIN BODY CHAIN

PORT 1

PORT 3

MAIN BODY O/H

PORT 4

PORT 5

PORT 4

PORT 3

PORT 1

L OCAL PL C' sS2 0 1 ~S21 0 & O/H

L OCAL PL C' sM1 0 1 ~M11 4

MAIN BODY J IGM1 0 0 SH

PORT 2

MAIN BODY RESPOTM2 0 0 SH L OCAL PL C' s

M2 0 0 ~M21 2

MAIN BODY SETTINGM3 0 0 SH L OCAL PL C' s

M3 0 1 ~M31 4

PORT 5

L OCAL PL C' sTL 11 5 /11 9 ,TL 11 2 /11 4 ,TL 111 /11 3 ,TL 1 20 -1 2 3 ,TL 11 8 ,TL11 6

SIDE BODY RES. RS2 0 0 SHR

PORT 7

L OCAL PL C' sS2 0 1 ~S21 0 & O/H

UNDER BODY RESU1 0 0 SH.

PORT 8

L OCAL PL C' sU1 0 1 ~U11 2

HEAD L AMP PUNCH

PORT 1 0

UNDER BODY BANK

PORT 9

ROOFRFSH

PORT 2

L OCAL PL C' sRF1 0 0 ~RF1 0 4 ,

DOL LY A&B, DOL LY C,

F4 1 FRONT DECKFD3 0 L OCAL PL C' s

FD3 1 ~FD3 3 & TRANSFER

F2 4 FRONT DECKFD1 0 L OCAL PL C' s

FD11 ~FD1 6 & SHUTTL E

SIDE BODY J IG 1 LS1 0 0 L L OCAL PL C' s

SIDE BODY J IG 1 RS1 0 0 R

PORT 6

L OCAL PL C' s

SIDE BODY J IG 2 L3 0 0 L

PORT 7

L OCAL PL C' s

QUARTER INNER R

PORT 8

L OCAL PL C' s

SB AUTO TRUCK 1

PORT 9

FS L OADER

PORT 1 0

QUARTER INNER 1L EFT

PORT 1

L OCAL PL C' sS3 0 0 ~S31 2 &

QI3 0 , QI31 , QI3 2 -5

SIDE BODY J IG 2 RS3 0 0 R

PORT 2

L OCAL PL C' sS3 0 0 ~S31 2 &

QI3 0 , QI31 , QI3 2 -5

REAR FL OOR PANRFP1 0 0

PORT 3

L OCAL PL C' sRFP1 0 0 ~RFP1 0 4 &

RFP1 0 5 -7

REAR FL OOR PANO/H

PORT 4

REAR SIDE MEMBERTRANSFER

PORT 5

L OCAL PL C' sRS0 1 ~RS0 5

REAR FL OORSHUTTL E

PORT 6

L OCAL PL C' sR9 9 ~R111 &

REAR SIDE MBR. O/H

FL OOR O/H BANK

PORT 7

FRONT FL OORSHUTTL E

PORT 8

L OCAL PL C' sF1 0 1 ~F10 9

DASH PANELDP0 6 7 8

PORT 9

L OCAL PL C' sDP0 1 -2 , DP0 3 , DP0 4 , DP0 5 ,

DP0 9 ,1 0

FRONT ENDFETRANS

PORT 1 0

L OCAL PL C' sE1 0 1 ~E11 0

FENDER SHIEL D LFS1 0 0 L

PORT 1

L OCAL PL C' sFS1 0 1 -2 , FS1 0 3 , FS1 0 4 -5 ,FS1 0 6 -7 , FS1 0 8 , FS1 0 9 ,

FS11 0 , FS111 -1 2

FENDER SHIEL DO/H L &R

PORT 3

REAR DOORRD1 0 0

PORT 4

L OCAL PL C' sRD1 0 1 ~RD1 0 4 -5 ,

MAR.O/H1&2 , RD111 ,RD11 2 , RD11 4 L , RD11 4 R,

RD11 8 O/H1 &2 ,RD11 5 ~RD11 7 , SKIP&D/L ,

MBO/H1 &2 , M3 0 3T/F3

FRONT DOORFD1 0 3

PORT 5

L OCAL PL C' sFD2 0 1 , FD2 0 2 , FD2 0 4 /2 0 5 ,FD2 1 0 /2 11 , FD2 1 2 , FD2 13 /

2 1 4 , FD21 4 /2 1 5 OH,FD2 1 5 /2 1 6 R, FD2 1 5 /2 1 6L ,

FD2 1 8 OH, FD2 1 8 /2 1 9 ,FD2 1 7

F4 1 FRONT DOORFD3 0 3 In r Sh t

PORT 6

L OCAL PL C' sFD1 0 4 , FD1 0 5 , FD1 0 6 ,FD1 0 7 , FD3 11 , Ou tr Sh t,

FD11 2 , FD11 3 /11 4 , FD11 6 L ,FD11 6 R, FDOH, FD11 9 L ,FD11 9 R, OH1 &2 , FD1 2 1 ,

FD1 2 2 , FD1 2 3 /12 4 ,SKIP&D/L , Tfr1 &2 , OH3

TAIL GATEG2 1 4 /2 1 5 /1 0 8 -1 /1 0 8 -2

PORT 7

L OCAL PL C' sG1 0 9 /11 6 /11 7 , G11 8 /11 9 ,

G2 0 1 /2 0 2 , G2 1 0 /2 11 , G2 1 2 ,G2 1 3

HOODHL 1 3 6

PORT 8

L OCAL PL C' sH1 3 5 , H10 3 , INR-O/H,

H1 0 2 , H10 1 , H111 , H11 4 ,H1 2 2 , H12 5 , H1 2 8 , H1 3 9

BODY OFF READER

PORT 1 0

METAL FINISHOL D BOOTH

PORT 9

L OCAL PL C' sREPAIR, WBS, NEW

BOOTH, NEW CONVEYOR

Remote AccessNode

Printer

Remote AccessServer

Printer Printer PrinterPrinter

SERIAL LINE FOR DISPLAYS

UTICOR PMD 3000

SJ L

SJ R

SJ L

SJ R

SRL

SRR

RF

FF

UBR

MBJ

FE

MBR

DP

FS

MBS

RD

FD

HD

TG M

F

BODY SHOPSTATUS

MAIN BODY RESPOTOUTPUTS Y140~Y17F

MBR

UTICOR PMD 1200

SJ L

SJ R

SJ L

SJ R

SRL

SRR

RF

FF

FP

UBR

MBJ

FE

MBR

DP

FS

MBS

RD

FD

HD

TG M

F

RF TL

PMD1400 PMD1400 PMD1400PMD1400

PMD1400 PMD1400

PMD1400

PMD1400 PMD1400

DASH PANEL FENDER SHIEL D FRONT END UNDERBODY

PL ANNED

CYCL E TIME

ACHIEVEMENT

BODY SHOPSTATUS

UTICOR PMD 3000

SJ L

SJ R

SJ L

SJ R

SRL

SRR

RF

FF

UBR

MBJ

FE

MBR

DP

FS

MBS

RD

FD

HD

TG M

F

BODY SHOPSTATUS

MAIN BODY JIG OUTPUTSY140~Y17F

MBJ

UTICOR PMD 3000

SJ L

SJ R

SJ L

SJ R

SRL

SRR

RF

FF

UBR

MBJ

FE

MBR

DP

FS

MBS

RD

FD

HD

TG M

F

BODY SHOPSTATUS

UNDER BODY RESPOTOUTPUTS Y140~Y17F

UBR

UTICOR PMD 1200

SJ L

SJ R

SJ L

SJ R

SRL

SRR

RF

FF

FP

UBR

MBJ

FE

MBR

DP

FS

MBS

RD

FD

HD

TG M

F

RF TL

PMD1400 PMD1400 PMD1400PMD1400

PMD1400 PMD1400

PMD1400

PMD1400 PMD1400

R-SIDE MEMBER FRONT FL OOR REAR FL OOR UNDERBODY

PL ANNED

CYCL E TIME

ACHIEVEMENT

BODY SHOPSTATUS

AUTOMOBILE MANUFACTURING SCADA SYSTEM

I/O 1 Board 1 I/O 1 Board 2 I/O 2 Board 1 I/O 2 Board 2

FENDER SHIEL D RFS1 0 0 R

PORT 2

L OCAL PL C' sFS1 0 1 -2 , FS1 0 3 , FS1 0 4 -5 ,FS1 0 6 -7 , FS1 0 8 , FS1 0 9 ,

FS11 0 , FS111 -1 2

3Com SuperStack IISwitch 1000

BODYSHOPL INEMASTER

PORT 11

ALC CONNECTION

U101Printer

Hub - NorthWiring Closet

Hub - CenterWiring Closet

Hub - SouthWiring Closet

SBPrinter

100MB Fiber between DownlinkModules

3Com SuperStack IIHub 100

3Com SuperStack IISwitch 1000

Hub - NorthWiring Closet

Shop Floor Nodes Office Nodes

SB SB SB SB SB

SB SB SB SBSB

SB SB

SB

SCADA For Manufacturing

•Great Visualizations

•Need Better Reporting

Largest Project Ever

•Customer has large install of SCADA system for monitoring production.

•Target improvements have not been achieved.

•Customer asks for flexible reporting system including OEE (Overall Equipment Effectiveness) for corporation wide SCADA

•All custom development

Years of Development

•Software is developed as modules so early installations can be made with enhancements and features added over time.

•Customer agrees to purchase early versions in small quantities as a test.

Technology Commercialization Department

Caterpillar: Confidential YELLOW

2 Q

2005 2006StatusWatch Project with SCADAware

• Rev 0 Development

• Rev 0 Installations

• Rev 1 Development

• Market Launch prep

3 Q 4 Q 1 Q 2 Q 3 Q 4 Q

Technology Commercialization Department

Caterpillar: Confidential YELLOW

1 Q

2007 2008 and BeyondStatusWatch Project with SCADAware

• Rev 0 Development

• Rev 0 Installations

• Rev 1 Development

2 Q 3 Q 4 Q 1 Q 2 Q 3 Q

• Market Launch• Literature• Sales promotions

• Commercial Launch

• Production

• Rev 1 Installations

Years of Development•Installations were showing good improvements on efficiencies, but only on the newer automated machine tools.

•There was not widespread acceptance of this software as the solution.

•Development continued until all features were added and the product was completed and ready for a release to the customer on a large scale.

Invitation to Introduce New System

New System Being Introduced

Customers were invited to a showing of the new release.

One week before the software showing I had an idea.

The customer needs a response light for the manual stations and assembly lines.

Friday, February 29,

2008Everyonearrives.

Day of Presentation

Entertainment – Morley

But we really brought him in for the….

Food – Chowder and Chili

Presentation

The Boring

Engineer

Dick says, “Fire the boring engineer!”

Can’t see the screen

Boring Engineer

Dick Says “Failure”Guy on

cell phone

Guystalking during

presentation

Everyone Focuses on the Light

Everyone Focuses on the Display

Weekend Worry

Monday Morning - Customer Calls

Saw the Light

“Do you have the light?”

Wants to buy software/hardware combo

“Do you have both?”

Hmmm….

“Of Course!”

Quickly Design Light and Controller

Installations in three weeks

The customer loves the solution

We won the order - $20M USD Potential

Customer wants installations in 110 Factories

Most ImportantCustomer has success!

•20% to 40% improvement in production efficiencies

•Widespread acceptance in all areas of manufacturing

Current Installations

3,428 installations, in 62 plants, in 9 countries

Lessons•What did we do wrong in the beginning?

•We followed all the steps correctly with the design meetings and customer involvement.

•How did we almost miss the opportunity to help our customer?

•The didn’t want a software reporting system. They wanted efficiency.

Take a step back.Look at the big picture.Be ready to think outside the box.Don’t be afraid of your ideas.Know your customer (internal and external)

Thank you!