Leverage Rockwell Automation s industry expertise

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Clifford Douglas
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Discrete Machine Performance Solution Computer and Software bundled for Continuous Solution Improvement Technical Data Leverage Rockwell Automation s industry expertise through packaged solutions

1 Discrete Machine Performance Solution Computer and Software bundled for Continuous Solution Improvement Technical Data Leverage Rockwell Automation s industry expertise through packaged solutions powered by RSBizWare. Discrete Machine Performance Solution (Discrete MPS) provides real time information for optimizing machine operations in your production facilities. Performance metrics and OEE (Overall Equipment Effectiveness) data provide the necessary information for improving plant uptime and optimizing manufacturing. Overview Rockwell Automation has pre-developed and packaged this solution to reduce the complexity typically involved in the setup and configuration of these types of systems. The Discrete MPS offering is built on other successful Rockwell Automation software components, while being deployed at a fixed price. The Rockwell Automation Discrete MPS offering captures, analyzes and displays key operating data associated with a machine or work cell to provide: Operating Efficiencies and Effectiveness Current Process Status Process Event and Process Variable Tracking Downtime Durations and Reasons Information supplied by Discrete MPS can be used by all levels of management and maintenance to: Monitor Key Performance Indicators (KPIs) and understand their impact Supply metrics for continuous improvement Help justify line improvements from a cost v. productivity basis Features Single catalog number - Easy to order and deploy - On-site configuration and training included in the package Modular and expandable - Building block for Line Performance and Plant Performance Solutions Web based reporting - View reports from any PC with Internet Explorer Central configuration - A single location to configure both operator interface and reporting Standard compliance with S95 Standard from ANSI/ISA Dedicated Operator Interface for performance monitoring and machine management - Industrial PC with touch screen interface Machine reporting - 48 standard reports per machine Web-based reporting - View Reports from any PC with Internet Explorer

Configurator Application The Discrete MPS Configurator application has been developed to Choose automated or manual data acquisitions for the provide a user-friendly graphical interface for

2 Configurator Application The Discrete MPS Configurator application has been developed to Choose automated or manual data acquisitions for the provide a user-friendly graphical interface for configuring the following parameters operating parameters for the Discrete MPS system. - Ideal cycle time Configurator application functionality includes: - Availability status - Running status Discrete MPS data collection, including data addresses - Breakdown justification used to automatically retrieve data from a PLC. - Summarization events Configure the machine specific text used for the display The Configurator is proprietary to Rockwell Automation and only provided as part of the Discrete MPS system. fields in the HMI and reports. Save a configuration export file that can be reloaded by the Discrete MPS Configurator at a later time. Generate all the operating parameters for the Discrete MPS based on the configuration information specified in the Discrete MPS Configurator application. 2

Operator Interface The Discrete MPS screens have been designed to provide the operator,

View the current state of values monitored by the Discrete MPS.

Start/Stop data collection or Stop the application.

3 Operator Interface The Discrete MPS screens have been designed to provide the operator, plant engineering and maintenance staff a view of equipment status and information on its operating efficiency. Functionality includes: View the current OEE for each work cell. View the current state of values monitored by the Discrete MPS. Process value trend displays (Limit 5 per work cell) Secure maintenance functions to Start/Stop data collection or Stop the application. Configure users who have access to maintenance functions. Screens will reflect configuration preference (i.e. Manual, Automated, Constant) Includes faceplates for manual data entry Reflects machine specific text specified in the configuator 3

Reports Based on the information stored in the Discrete MPS database, the Discrete MPS reporting engine provides several pre-defined reports for production and performance data.

Licensing for report access is limited to a single user. The Discrete MPS provides 48 standard reports. Report formats include Text, Bar Chart, Pie Chart and Trend.

Event by Work cell State Tracking - Duration in State - Total Duration by Summarization Value Counters - Totals - Total by Summarization Value Breakdowns - Totals - Total by Summarization Value

4 Reports Based on the information stored in the Discrete MPS database, the Discrete MPS reporting engine provides several pre-defined reports for production and performance data. A standard Microsoft Internet Explorer browser is the only tool required to display the reports from any computer that can obtain network access to the Discrete MPS Industrial Computer. Licensing for report access is limited to a single user. The Discrete MPS provides 48 standard reports. Report formats include Text, Bar Chart, Pie Chart and Trend. Information available in reports includes: Performance Analysis - OEE Overview - Historical OEE Trend - Production by Shift - Overall Production Event Tracking - Event Count - Event Duration - Top Event by Work cell State Tracking - Duration in State - Total Duration by Summarization Value Counters - Totals - Total by Summarization Value Breakdowns - Totals - Total by Summarization Value Process Variables - Historical Trends Data refresh rates are a function of data collection and data retrieval, which is dependant on many factors including: the number of concurrent data transactions, network loading, the amount of data being retrieved, and the report complexity. 4

Solution Architecture The Discrete MPS offering is an Industrial PC loaded with application software that has been pre-configured to deliver production analysis functionality.

Production and process data is obtained automatically from a PLC or manually via the Discrete MPS operator interface. Discrete MPS Data is stored in the Discrete MPS local database.

5 Solution Architecture The Discrete MPS offering is an Industrial PC loaded with application software that has been pre-configured to deliver production analysis functionality. Site-specific configuration information is added. The interface to the Discrete MPS Industrial PC is via an integrated Ethernet network card. Production and process data is obtained automatically from a PLC or manually via the Discrete MPS operator interface. Discrete MPS Data is stored in the Discrete MPS local database. Current status information is displayed to an operator on the Discrete MPS operator interface. The Discrete MPS reporting software engine allows data from the local database to be accessed via several standard reports which are displayed using a Web Browser. Technical Specifications Hardware The Discrete MPS includes an Allen-Bradley VersaView 1500P Industrial Computer, packaged for use on the factory floor. Some key attributes of this computer are: 15" Touch Screen Display 2 GHz Pentium IV processor 1 GB RAM 40 GB Hard Drive 10/100 Ethernet NIC (integrated) NOTE: No mouse or keyboard is supplied. The hardware provided with this system is delivered pre-configured and tested for this product. PLC Office Computer Ethernet Plant Network Ethernet Control Network PLC Web Reports Software The Discrete MPS Industrial Computer comes pre-loaded with several software applications: Microsoft Windows 2000 Professional operating system software Rockwell Software RSView 32 HMI software Rockwell Software RSBizWare PlantMetrics software Rockwell Software Discrete MPS Configurator application software Microsoft SQL Server 2000 Desktop Engine database software Rockwell Software RSSql data transaction software Rockwell Software RSLinx communication software Several of the standard Rockwell Software products supplied have been pre-configured with Discrete MPS application code. Additions or modifications to the supplied software may adversely affect Discrete MPS operation and invalidates the product warranty. Please discuss desired changes with your local Rockwell Automation Sales or Services representative. 5

6 Database Details The Discrete MPS Microsoft SQLServer Desktop Engine database has been designed using the FactoryTalk Data Model to support the standard Discrete MPS functionality and to automatically manage accumulated data. Database size is controlled by periodically condensing activity data into summary tables in the database. Controlling database size helps maintain data collection and reporting response times. Data for a limited time period (180 days [6 months]) remains in the active data tables and can be recalled for inclusion in the Discrete MPS Reports. Configuration and Training Services Up to 16 hours of services are included as part of the product offering. Services may include: Input of data source addresses for configuration Input of Time Patterns Customer standardized naming convention Training user on system NOTE: Other services can be provided at an additional cost Catalog Numbers 9368-MP5SDENE Rockwell Software For more information on the latest pricing or a demonstration of any Rockwell Software package, please contact your local Rockwell Automation sales office or Allen-Bradley distributor. For the very latest on Rockwell Software products, visit us at: Doc ID MPSD-TD001A-EN-D Copyright 2004 Rockwell Automation, Inc. All rights reserved. Printed in USA.