Industrial Information Management Connecting people to information throughout the enterprise

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1 Industrial Information Management Connecting people to information throughout the enterprise Improve Your Business Performance

2 Sign up for your free monthly MyCitect News for the latest e-news on product and driver developments and application stories in your industry. Visit today! Disclaimer Citect Corporation makes no representations or warranties with respect to the contents or use of this brochure and, to the extent permitted by law, expressly limits its liability for breach of any warranty that may be implied to the replacement of this manual with another. Citect Corporation assumes no responsibility for any errors that may be in this document and reserves the right to revise this document at any time without incurring an obligation to notify any person of the revision. Copyright Copyright 2003, Citect Corporation. All rights reserved. No part of this document may be reproduced, photocopied, or transmitted in any form or by any means (electronic or mechanical), for any purpose, without the express written permission of Citect Corporation. Trademarks Citect, CitectHMI, CitectSCADA, Plant2Business, and Plant2NET are trademarks of Citect Corporation. All other brand or product names are trademarks or registered trademarks of their respective holders. CITECT CORPORATION LTD Citect is a worldwide leader in industrial automation and information management solutions. Its Citect and Plant2Business software are complemented by professional services, customer support and training. These solutions are enhanced by strong partner programs and are sold in numerous industries, including water and waste water, facilities monitoring, gas pipelines, mining, dairy, food processing, pharmaceutical, and power distribution. Citect is headquartered in Sydney Australia, has offices in Australia, USA, Europe, China and Africa, and its products are distributed in more than 40 countries worldwide. Industrial Information Management (IIM), is about transforming existing data into information that supports decision-making for plant and business managers ARC Advisory Group 2

3 IIM is Business Intelligence for Manufacturing Improve Your Business Performance Using a Citect IIM solution has brought substantial return on investment for TCA and Energy Australia David Jaques, Senior Project Manager, Testing & Certification Australia To gain a competitive edge in today s market, successful manufacturers are using Industrial Information Management (IIM) solutions to reveal opportunities for improved business performance and increased profit margins. In every manufacturing process, there are opportunities to refine the workflow and maximize asset utilization. By drilling down into the details behind plant Key Performance Indicators (KPIs), you can increase yield, minimize inventory shelf-life, improve quality, comply with regulations and reduce manual intervention and data entry. Return on Assets (ROA) can be maximized by eliminating downtime and unscheduled maintenance, speeding up response times, streamlining schedules and eliminating bottlenecks. IIM solutions deliver real-time access to plant and business information, enabling you to address these issues. Access to real-time information, enables you to take action to correct problems before they impact on supply chain, regulation compliance and production. Citect delivers high-quality, scalable, IIM solutions that enable executive, IT, plant and production managers, engineers and operators to make better decisions leading to minimized disruptions and maximized company competitiveness. By connecting, transforming and presenting information in real-time, throughout the enterprise, IIM solutions reveal opportunities which allow you to increase performance, efficiency and profitability. Significant value is added in a modular fashion, by addressing each business need independently and by tackling the greatest points of pain immediately. Each analysis module has a targeted purpose, with a focus on returning a measurable Return on Investment (ROI) to your business in key areas such as production, quality, tracking, downtime and plant performance KPIs. Citect Plant2Business is an easy-to-use platform that allows you to quickly build and deploy IIM solutions. By connecting to all your production control systems and business databases using non-invasive, open technologies, Plant2Business reduces training and deployment costs. This approach complements existing IT infrastructure to typically deliver ROI in 6-9 months. Citect is already delivering IIM solutions to hundreds of top international companies who benefit significantly from improvements in downtime, reporting and analysis. IIM solutions are delivered locally, through Citect s Professional Services; a team of highly trained and experienced engineers. Their technical knowledge and proven resources are transferred to you to ensure fast and effective benefits are obtained from the implementation of the IIM solutions. Choose Citect IIM solutions to improve your business performance management and benefit substantially from scalable solutions designed to optimize your productivity and efficiency and ultimately, increase your profit margins. 3

4 Revealing Opportunities Industrial Information Management solutions reveal opportunities which allow you to improve business performance by providing vital plant information to key personnel. IIM solutions not only bridge the communication gap between systems, but also between people in different parts of the enterprise. In this way, better decisions can be made and actions taken, which results in immediate benefits to your company through improved efficiency, production and performance. With IIM, you can take data from multiple disparate sources then aggregate and transform it into manageable information for productivity analysis, data mining, querying and reporting. The information is presented in business context, comprehendible to everyone in the company, and allows you to dynamically select the groups of information you need in order to make better business decisions. Personalized or role-based monitoring of production metrics reveal operational performance in real-time, allowing more immediate and responsive decisions to be made throughout the enterprise and supply chain. Optimize production process efficiencies By drilling down into the detail of plant KPIs, you can make informed intelligent decisions which will increase yield, improve quality and reduce manual intervention and data entry. Access to real-time information, enables you to take action to correct problems before they impact on supply chain, regulation compliance and production. Maximize Return on Assets (ROA) ROA can be maximized by eliminating equipment downtime, unscheduled maintenance and bottle-necks and by improving operation equipment efficiency, speeding up time-to-market and by streamlining schedules. Lower Total Cost of Ownership (TCO) Citect s IIM solutions are deployed in a modular fashion, where each analysis module delivers fast, incremental and measurable benefits, with a long-term vision of an integrated architecture that will allow sustainable and continuous improvement as and when you need it. Open technologies allow your IIM solution to scale easily with your requirements, whilst upgrades are available between versions ensuring you stay up to date with new features. ERP Enterprise Resource Planning MES Manufacturing Execution System LIMS Laboratory Information Management System DCS Distributed Control System SCADA Supervisory Control and Data Acquisition HMI Human-Machine Interface Fast and substantial Return on Investment (ROI) Citect s non-invasive, modular approach, complements existing automation and IT infrastructure, providing you with a low risk solution. With higher visibility of operations throughout the enterprise, Executive and Plant managers can make decisions which will increase productivity and quality as well as decrease costs of maintenance and energy consumption. Used efficiently, your company can expect to achieve significant ROI in less than 6-9 months. 4

5 IIM Connecting people to information throughout the enterprise Executive Managers With real-time enterprise-wide information at their fingertips, CEOs, CFOs and business managers can confidently take prioritized action leading to increased profit margins and optimized quality, based on KPIs such as Operational Equipment Efficiency, Return on Assets, energy utilization, production performance and quality trends. Executives can also compare information between different production lines or plants, be they in different towns or countries, and make changes which will optimize business performance. Plant Managers Plant managers can easily integrate business information with plant KPIs to maximize asset utilization and quickly measure yield, downtime, quality or material waste and determine a course of action to improve performance. IT Managers An easy-to-use interface gives IT managers point and click access to all plant data as well as low installation and training costs. Reports can be automated in minutes using standard Microsoft SQL or Oracle database client tools. Process Engineers Engineers can use standard tools like Excel to analyze plant information and identify areas that require improvement such as increasing response time, streamlining scheduling, analyzing equipment failures and inventory shelf-life. Maintenance Engineers Maintenance engineers can increase asset effectiveness, track equipment statistics, such as run hours and number of overloads, optimize service intervals and reduce bottlenecks and unscheduled stoppages. Quality Assurance Managers Quality Assurance personnel can easily compare plant production outputs against specifications and environmental regulations, analyze quality implications and automate record keeping and reports. Suppliers Suppliers will benefit from access to online inventory and equipment information allowing them to proactively prepare and deliver orders on time. Customers Customers will enjoy improved customer service, product quality and speed of delivery due to operational performance improvements. 5

6 Connect >> Transform >> Present IIM solutions use Citect Plant2Business to provide a range of services facilitating data integration, event management, information abstraction and publication. This model can be described in three layers: Present Layer A presentation layer makes the information available to key personnel anytime, anywhere, for analysis and extraction using common tools such as Internet Explorer, Crystal Reports or other Business Intelligence tools including Citect s IIM Metrics application. Clients Transform Layer A transformation layer captures and transforms this data into information using predetermined business rules. These rules use object-based models of your plant processes, equipment, products or specifications. Manual data entry can be used to complement automated data captures, providing a rich repository of information for productivity analysis. Modules Engine Connect Layer The connect layer provides the connectivity and aggregation of data from multiple disparate systems (which is then stored in Microsoft SQL or Oracle databases), enabling high-level macro decision-making to be performed seamlessly throughout the enterprise. Storage Acquisition 6

7 IIM takes the data that already resides within your organization, and transforms it into enterprise-wide information for improved decision-making. Link production orders from the business database directly to the control system to streamline production scheduling Compare production statistics from the control system with production shifts, as defined in the business database, to identify trends by various work groups Link equipment runtimes, operating environment and other details directly to the maintenance database to prioritize maintenance and reduce parts costs Compare the production performance for different products in multiple plants around the state, country or world! Corporate Dashboard Analytics Product Visualisation Production OLAP Citect Data Citect Data Citect Data Citect Data Downtime Data Start Date/Time End Date/Time Duration Downtime Event Production Dashboard KPIs Citect Plant2NET Production Tracking Downtime Quality Metrics Production Performance Analysis OLAP Online Analytical Processing (OLAP) provides sorting by different dimensions allowing Plant and Business managers to view and compare plant information. Information transformed through IIM analysis modules and stored in Microsoft SQL or Oracle tables, can be loaded into OLAP cubes and integrated into business intelligence solutions. IIM Clients IIM analysis and data entry is performed via a standard web browser, using purpose-built interfaces that are specific to each module. This allows analysis across your entire organization via a single portal and allows customers and suppliers to view personalized account information. Data Aggregation 7

8 IIM Analysis Modules To continually and sustainably improve business performance, successful manufacturing companies need to use modular solutions which give fast, incremental and measurable benefits, with a long-term vision of an integrated architecture. IIM solutions are designed to be deployed in a modular fashion, where each module delivers those benefits to aid in improving each business need independently. Each module has a targeted purpose, with a focus on returning a measurable ROI to your business in key areas such as production, quality, tracking and downtime. Production Automatic capture and single point of entry for manually entered production values, progressively minimizes time, errors and costs associated with manual and duplicate data entry and provides a far more accurate picture of production. Data is aggregated to summary information with full drill-down capabilities for detailed analysis. Business managers can now reliably report on KPIs such as raw feed inputs, production or batch consumables, output and waste, as well as mass balance. Citect s Professional Services work strategically with you to provide the best solution for your requirements. Their technical knowledge and proven resources are transferred to your company to ensure fast and effective benefits are obtained. Citect is continuously striving to exceed customers expectations and is committed to producing software that takes away your pain whilst revealing opportunities for business improvements. A number of modules are currently being developed and deployed, which tackle your specific areas of interest. Citect is currently working with real customers to build new modules such as production, quality, tracking, downtime and metrics. Quality Automatic identification and modification of out-of-spec values during production facilitates fast operations activities to bring the product back into specification and prevent wastage. Automatic capture and logging is mandatory in most fields to meet both regulatory and customer requirements. Production Managers can now reliably report on in-spec and out-of-spec production runs, including variance from specification. The non-conformance log report allows production quality management to continuously improve. 8

9 Downtime Automatic capture of both production downtime and virtual downtime, (producing below target rate), provides total visibility into your facility s asset utilization such as under-performing equipment and allows you to break down seemingly complex issues to common causes. Powerful analysis helps identify cause and effect of the production process allowing you to prioritize maintenance and maximize uptime. Measurable increase in profit is delivered through optimized uptime, improved efficiency and lower TCO. Production Managers can now intelligently prioritize maintenance to streamline operations, maximize asset utilization and increase profits. Tracking Automatic tracking of lots provides detailed traceability of products, satisfying both regulatory and customer requirements. Lots are automatically linked and split to suit multiparent lots and multi-child lots. Business Managers can now reliably trace every aspect of a product from raw material suppliers, supplier specifications, production data and packaging information to ensure maximum visibility and traceability in every aspect of the manufacturing process. Metrics By bringing together information from all of the IIM modules, Key Performance Indicators for the entire production system can be produced. For example, Overall Equipment Effectiveness (OEE) requires time-usage models and statistics from Downtime, Production data and Quality. Normalized yield requires Production statistics to be combined with Quality information. Production and Business Managers can now view a snapshot of their production system with all KPI indicators and trends available at a glance. 9

10 Measure Your Success By providing instant access to realtime production information from every corner of your enterprise, IIM solutions enable key personnel to make better decisions leading to increased company competitiveness. The resulting improvements can be calculated using production metrics from information within plant systems such as: Production schedules and orders from the ERP; Quality from the LIMS; time-usage model and asset efficiency from Downtime; real-time Production statistics from the control systems; Lot statistics from Tracking, etc. To create metrics that can be used as indicators of production performance, all of this information needs to be consolidated for use in KPI algorithms. This allows you to measure the instantaneous state and trend of your business at a single glance. Customers are investing to achieve more collaborative supply chains improved operating efficiencies, product quality and plant throughput. To achieve this, they are looking for a collaborative solution, aligned with business processes and strategies that leverage real-time plant data in business context, to support decisionmaking. ARC Advisory Group KPI Metrics Production Key Performance Indicators will vary from business to business depending on variations within each enterprise for model definitions. For example, Available Time may ignore Unplanned Maintenance time for some businesses, while other businesses will include it. Therefore it is important that an IIM solution can be tailored to suit your definitions, rather than forcing pre-determined definitions upon your organization. Each 0.1% increase in quality or yield could equate to thousands of dollars in incremental profits. 10

11 In the same way that Microsoft and partners have revolutionized business intelligence in the finance, supply chain and customer relationship sectors, so do we see the potential, with Citect IIM solutions, to revolutionize business performance throughout the manufacturing industry. Joe Crisologo, Business Development Manager, Business Intelligence, Microsoft, Australia Case Studies Tomago Aluminium Production Reporting solution improves efficiency Tomago Aluminium competes globally in one of the world s most demanding international markets where quality supply and continuous improvement are paramount. The company produces quality, value-added aluminium products for the highly competitive export market and is the largest consumer of electricity in New South Wales. It is imperative that extended plant stoppages do not occur, as the repercussions would be considerable in terms of cost. To better manage their facility, Tomago needed a realtime production monitoring & reporting solution that was independent of their SCADA system. This would allow them to keep the facility running smoothly without requiring constant modifications to their production control system, as well as enhancing their ability to comply with environment regulations. Solution Citect provided a production reporting solution with Historian capabilities that allowed the separation of the control functions from that of monitoring and reporting. This allows these specific environments to be managed independently, vastly reducing the level of manual intervention required for continuous customization of reports and data delivery to the business database. Information is presented to key personnel throughout the enterprise via Crystal Reports and ASP pages developed by Tomago and delivered via a web browser. Conclusion The production reporting system has added considerable value to Tomago, saving labor costs for report implementation and maintenance, as well as streamlining operations and enhancing emissions reporting compliance. BHP Billiton Downtime Monitoring solution helps BHP Billiton save AUD$1 million over 2 year period The BHP Billiton owned and operated Cannington mine in Queensland, Australia, is the world s largest tonnage producer of both silver and lead. With such a massive investment to protect, and long-term smelter contracts in place, the company sought to reduce unscheduled stoppages of their processing plant and achieve savings of AUD$1 million over a 2 year period. Solution Citect used the Plant2Business framework as the basis of the Downtime Monitoring solution, leveraging Plant2Business connectivity to publish information, and Citect s Downtime module to identify downtime. This framework helped overcome the usability problems Cannington had experienced with their legacy system, and provided the power to model the plant hierarchy and drilldown into the downtime causes for detailed analysis. Conclusion Citect provided the methodology for analyzing the plant s downtime, for connecting the plant s multiple servers, and for collecting and analyzing information and making it available in a simple easy-to-use format, thus allowing managers to view the plant s availability, prioritize maintenance and optimize uptime. While achieving initial savings of AUD$1 million over a 2 year period, Cannington is realizing continuous improvement that will yield ever greater savings in operations and maintenance, and see steadily increasing throughput of their facility. 11

12 Make an informed and intelligent decision today and contact your nearest Citect representative to learn more about how you can improve business performance with IIM solutions. AMERICAS Tel AUSTRALIA Tel EUROPE Tel CHINA Tel SOUTH AFRICA Tel Product of Australia PR Citect Corporation Ltd. All rights reserved. Citect and Plant2Business are registered trademarks of Citect Corporation Ltd. All other brands or names are property of their respective holders.