zenon analyzer

dynamic production reporting

zenon Analyzer Use clever reports, identify hidden potential and advance your production.

Why wait to get the most out of your production

data? In times of volatile raw materials prices,

unpredictable demand and the cost pressure of

global markets it is essential that your production

facility is constantly finely tuned to produce as

efficiently and effectively as possible. Having

exact information on how well your equipment is

performing is essential to help you take the

right action.

Dynamic Production Reporting is what we call our

approach to analyzing production data – as it hap-

pens. The reports generated reflect even the most

recent events and production data.

Now you can create comprehensive reports con-

taining both process data and historical data, which

was previously only available after significant time

delays. This enables you to diagnose underperfor-

mance and immediately take corrective actions.

Realtime production reports enable you to make

immediate decisions on how to enhance your pro-

duction efficiency and output. By dynamically op-

timizing production in this way you can achieve

significant savings in costs and resources and match

supply and demand far more closely.

zenon Analyzer dynamicproductionreporting.

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zenon OperatorEmbedded HMI System

zenon LogicIntegrated PLC System

zenon SupervisorIndependent SCADA System

zenon AnalyzerDynamic Production Reporting

productoverviewzenon Analyzer is the reporting tool that enables

Dynamic Production Reporting.

It is extremely easy to configure and install and

has the capability to process and analyze data from all

automated production equipment within your facility

and other sources of data (e.g. manual data input). So

you not only get immediate information, but also a

complete picture of the status of productivity within

your facility.

So you know exactly and immediately ...

... where you are losing money

...where you can increase output

... where you can save resources.

And much more.

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zenon Analyzer processes data

both online – directly from

your equipment – and/or

offline from a central database.

This means you can combine

the advantages of both online

and offline reporting. Analyze

up-to-date production data

and do analyses of different

production time frames.

usingthesystemzenon Analyzer delivers ready-made report templates and allows new

reports to be created with an advanced graphic design. In addition the

system is multi-lingual – you can implement your language of choice.

Reports can be specified to reflect the needs of the individual produc-

tion team member. Operations and maintenance staff get operational

and maintenance data; management get management-relevant data,

and so on.

Advanced filtering functions allow you to analyze data inter-

actively according to multiple parameters, such as:

by equipment: area, line, machine etc.

by time: month, week, day, shift, hour, from/to

by production entities: article, batch, order

by length or numer: of e.g. breakdowns or alarms

by consumption of media

In all cases you can drill down and through to the details to get to

the bottom of specific events.

Powerful, flexible andeasytouse

Consumption analysis of

different media

Occurence Number per Alarm

Total Duration per Alarm (seconds)

Copa-Data (www.copadata.com)zenon Analyzer Page 1 of 3

Report generated by CD\Phillip.Werr at 19.09.2011 08:46:02

ALARM ANALYSIS ON FREQUENCY AND DURATION

10 ALARMS19.09.2011 07:46:02 - 19.09.2011 08:46:02Period Nr. of alarms

OEE Indicator

Availability Performance Quality Total Units Good Units

19,98% 69,58% 29,14% 98,56% 182512 179875

OEEAvailability

PerformanceQuality

COPA-DATA (www.copadata.com)zenon Analyzer Page 1 of 1

Report generated by COPA-DATA\DEMO at 13.05.2011 09:58:05

OEE Indicator

Filler11.05.2011 08:57 - 12.05.2011 09:57Period Equipment

Analysis on frequency

and duration of alarms

OEE Indicators to analyze

Overall Equipment Effectiveness

4

Alarm analysis on frequency and duration OEE Indicator

B 68 - 76

C 76 - 84

< 68 A

D 84 - 92

E 92 - 100

F 100 - 108

G> 108

1,00

69,08

More efficient

Less efficient

Current ClassEnergy Scale (kWh in 1 h)

Current Value (kWh in 1h):

Time Duration [h]:

Copa-Data (www.copadata.com)zenon Analyzer Page 1 of 2

Report generated by COPA-DATA\EmilianA at 05.07.2011 09:27:56

ENERGY CLASS

1/4 h05.07.2011 08:27 - 05.07.2011 09:27Period Aggregation

Energy consumption per machine

Energy consumption per machine

Variable nameAbsolute

consumptionRelative

consumptionGlass Bottle Line#Bottle Washer 122.848 kWh 10.70 %

Glass Bottle Line#Crate Washer 114.978 kWh 10.01 %

Glass Bottle Line#Depalletizer 124.384 kWh 10.83 %

Glass Bottle Line#Filler 113.192 kWh 9.86 %

Glass Bottle Line#Inspector 101.364 kWh 8.83 %

Glass Bottle Line#Labeller 98.822 kWh 8.60 %

Glass Bottle Line#Packer 81.508 kWh 7.10 %

Glass Bottle Line#Pallet Conveyor 70.705 kWh 6.16 %

Glass Bottle Line#Palletizer 93.150 kWh 8.11 %

Glass Bottle Line#Pasteurizer 123.104 kWh 10.72 %

Glass Bottle Line#Unpacker 104.496 kWh 9.10 %

Energy

10/16/2013 4:56:00 PMFrom

Equipment model

To

10/17/2013 4:56:00 PM

Variables

Glass Bottle Line#Bottle Washer, Glass Bottle Line#Crate Washer, Glass Bottle Line#Depalletizer, Glass Bottle Line#Filler, Glass Bottle Line#Inspector, Glass Bottle Line#Labeller, Glass Bottle Line#Packer, Glass Bottle Line#Pallet Conveyor, Glass Bottle Line#Palletizer, Glass Bottle Line#Pasteurizer, Glass Bottle Line#Unpacker

zenon Analyzer | www.copadata.com Page 1 / 1

Your production line is producing a large batch, but how efficient are you compared to your benchmarks?

With zenon Analyzer you can find out while production is still running and take corrective measures where necessary.

“ “

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Media Absolute Consumption Unit PercentBottle Washer: Additive 0,78 kg 18,75%Bottle Washer: Conditioner 0,52 kg 12,50%Bottle Washer: Disinfectant 0,26 kg 6,25%Bottle Washer: Lye 2,60 kg 62,50%

TOTAL 4,16 kg 100,00%

COPA-DATA (www.copadata.com)zenon Analyzer Page 1 of 1

Report generated by COPA-DATA\DEMO at 13.05.2011 10:03:23

13.05.2011 09:02 - 13.05.2011 10:02

Media Bottle Washer: Additive, Bottle Washer: Conditioner, Bottle Washer: Disinfectant, Bottle Washer: Lye

PeriodChemicalsMedia Group

Absolute consumption distribution per media

The Reports informationinaconcise andunderstandableform

With zenon Analyzer you have complete data

transparency across your entire production.

This wealth of production data and meta data

(e.g. shifts, alarms, prices) is made accessible and

understandable by the concise reports that the

system generates.

typicalexamplesofthereportsare Production reports, which aggregate different

kinds of information (efficiency, consumption,

alarms, etc.) per batch, article, or time filters, e.g.

per shift

Consumption optimization reports showing con-

sumption evolution, cost distribution and correla-

tion with the production, for media such as water,

energy, compressed air, chemicals etc.

Reports for Energy Data Management. zenon

complies with the prerequisites of the TÜV SÜD

Standard “Efficient Energy Data Management” and

meets therefore the requirements of chapter 5.6.1

Monitoring, measurement and analysis of the ISO

50001 standard.

Efficiency reports that calculate KPIs such as

OEE (Overall Equipment Effectiveness) over a se-

lected period of time and production equipment

Alarm breakdown Analysis

and much more...6

zenon Analyzer | www.copadata.com Page 1/1Report generated by CD\Phillip.Werr at 16.09.2011 09:51:01

26.01.2011 13:00 - 26.01.2011 16:00Period Bottle Filler, Bottle Orientor, Bottle Washer, BT1, BT2, BT3, BT4, BT5, BT6, Crate magazine, Crate Packer, Crate Unpacker, Crate-Inspector1, Crate-Inspector2, CT1, Depalletizer1 , Depalletizer2, Empty Bottle Inspector, Filled Crate Inspector, Input, Labeling Machine, Output, Palletizer, Sniffer, Sniffer Block, Unlabeling Machine, Unplausible

Machines

Gantt Chart Report

GANTT Chart processing data according

to Weihenstephan standards

reporttemplateszenon Analyzer provides ready-to-use templates. Alternatively, the report templates

can be custom-designed regarding content and graphical appearance. User-defined

algorithms can be implemented to allow company– specific KPIs to be generated – so

you get exactly the information you need. Both report generation and archiving can

be configured to be carried out automatically.

exportformatsReports can be exported in many formats, depending on how and where you wish to

present them or further process the data.

regulatorycomplianceThe reports also function as a digital protocol for traceability and future reference,

for example to prove compliance to legal requirements.

Your management wants complete KPI analyses for every shift? No Problem – zenon Analyzer can

create the reports automatically after each shift and send them to specified recipients.

“ “

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zenon runtime 6.51 and higher

hmi or scada

3rd party hmi

directly from machines

(PLCs)

sql databases

opc ua

manual data input

otherdatabases

3rd party scada systems

zenon analyzer

dynamic production reporting

zenon runtime 5.50 and higher

hmi or scada

excel files

energy meters

access all kinds of historic and real-time data

zenon Analyzer is extremely easy to implement –

connecting to various data sources e.g. to zenon

HMI/SCADA systems or PLC Systems. It can be

integrated into any existing automation and IT

environment with no or only minor changes to

the infrastructure.

The system works with both centralized databases

such as Microsoft SQL, as well as decentrally, sourc-

ing data directly from the production equipment,

thus collecting online and offline data. In the latter

case, no additional database is needed. Manual data

input is also possible.

Both data structure and interfaces are well-

documented, enabling you to more easily integrate

your own customer-defined features. The latest en-

cryption technology ensures the highest level of

data security.

Getting started – settingupthesystem easy,fastandcostefficient

A wizard to import meta data into zenon Analyzer

is included. Meta data can also be automatically

updated through the wizard. Integrated connectors

collect the necessary data.

zenon Analyzer generates reports from many

different types of data e.g. Alarm, shift-related,

user-related, historical, real-time, batch. The ad-

vantage to you: a reduction in complexity, as only

one system needs to be installed rather than need-

ing multiple systems to acquire and convert these

different types of data.

zenon Analyzer has a web-based interface. This

means that no additional maintenance of clients is

needed and no revalidation of the existing environ-

ment is necessary. This is particularily helpful for

heavily regulated industries such as Food & Bever-

age or Pharmaceutical. The users have flexible ac-

cess to reports from any workplace in the network.

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Struggling with volatile raw material prices? Why not include price information from external

sources into your production reports? Close the gap between production and business reporting!

“ “

Fast Facts

zenon Analyzer is a web-based tool for dynamic production report-

ing. It can operate completely independently or be fully integrated

into the zenon product family.

zenonanalyzer improves your production by increasing production effectiveness

supports monitoring, measurement and analysis of energy data

(like the ISO 50001 standard)

eliminates waste by optimizing energy and material consumption

enables up-to-date benchmarks with historical production data

supports quality control

supports daily activity of production teams with reports

focused on production entities (batch, articles, shifts, etc.)

supports “continuous improvement” processes

easeofuse easy-to-use reports

easy access to sophisticated production information

interactive reports with “drill through” capabilities

modern and clear report layouts

integrationandsetup unintrusive installation

easy integration of different data sources

convenient design and update of new reports etc.

built-in Microsoft SQL Server 2012

connectivityandintegration integration of offline and online data sources

high connectivity to many different kinds of

machines and hardware

easy integration of new equipment

direct connection to automation infrastructure

integration of meta-data from HMI/SCADA Systems

possibility of manual data input





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from sensor to erp I food & beverage

One consistent Product Family from Sensor to ERP.

















Platform-independent Dynamic Production

Reporting tool, which processes and presents

data from the process to the ERP in real time.

Full visualization and control of complex

equipment with a connection to other systems

like SAP ERP.

Specialized simple and ergonomic machine

and equipment control.

zenon integrated PLC system with IEC 61131-3

programming environment.

Four products for creating top-of-the-line automati-

on solutions. All products work seamlessly together,

covering everything from sensors to ERP.

The entire Product Family is built around the

zenon philosophy of providing perfect ergonomics

through:

integrated, native networking

horizontal and vertical connectivity

hardware independence

automatic engineering

individualization of user interfaces

and interaction

setting parameters instead of programming

zenonissettingindustrystandardsinergonomics.

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zenon has been used for over 25 years by many

companies worldwide and in various industries.

zenon is firmly positioned in automation, particu-

larly in the Automotive, Food & Beverage, Energy

and Pharmaceutical industries.

globalpresence-localsupportWith nine subsidiaries in Europe, North America

and Asia and an international network of around

15 distributors and over 100 partners, COPA-DATA

is active in more than 40 countries.

completeautomationsolutionsTogether with the competent partners of the

COPA-DATA Partner Community, COPA-DATA

offers tailor-made solutions for your complete

automation.

zenon

zenon shines with excellent performance and comfortable maintenance, even in a project

with over 6,000 process screens.“ “

partnersfromvariousindustries

© Copyright 2013, Ing. Punzenberger COPA-DATA GmbH. All rights re-served. This document may not be reproduced or photocopied in any form (electronically or mechanically) without a prior permission in writ-ing from Ing. Punzenberger COPA-DATA GmbH. The technical data con-tained herein have been provided solely for informational purposes and are not legally binding. Subject to change, technical or otherwise. Reg-istered trademarks zenon® and zenon Analyzer ® are both trademarks registered by Ing. Punzenberger COPA-DATA GmbH. All other brands or product names are trademarks or registered trademarks of the re-spective owner and have not been specifically earmarked. We thank our partners for their friendly support and the pictures they provided.

Publication number: CD-ZAF-13-10-02

COPA-DATA Headquarters

Ing. Punzenberger COPA-DATA GmbHKarolingerstraße 7B, 5020 SalzburgAustria

t +43 (0) 662 43 10 02-0f +43 (0) 662 43 10 02-33

[email protected]

Find your regional contact at: www.copadata.com/contact

dynamic process solutions

Even though we have generated more fills and could increase our turnover in the last year, we have

managed to achieve a large savings in individual consumption through our Energy Management

System with the support of zenon.

“ “

rudolfkropfhead of eet

adelholzener alpenquellen gmbh

zenon analyzer

Documents

uptodate production

production facility

production entities

process data

realtime production

sources of data

data inter

historical data