Digital Manufacturing. FactoryLink. Tecnomatix SCADA. PRESENTED BY: KeeKwang, Lee FactoryLink Product Manager

Transcription

1 Digital Manufacturing FactoryLink Tecnomatix SCADA PRESENTED BY: KeeKwang, Lee FactoryLink Product Manager Copyright Siemens AG All rights reserved.

2 Shop Floor Production Production Counts Line Stop Alarm Equipment Status Process Parameters Line Speed Inventory Levels/Alarm s Page 2

3 Shop Floor is Unique 1000 s of variables No one can physically see all the values at the same time Machine status, line speed, inventory counts are all changes constantly Individual machine status for operator information is critical Efficiency and Quality are directly related to the visibility of the Shop Floor as a whole This world is happening in Page 3

4 Operators View Commonly 1 machine/operator Sometimes proprietary HMI screens from equipment vendor Machine Status Alarm and messages Process trends Real time feedback of machine activity Commonly known as, Islands of Automation Page 4

5 Managing Automation Today Managers need big picture view What is the status of all machines, all lines in real time What is the instant reading of production rates What alarms are affecting the production output Page 5

6 Visibility and Control Tools HMI = Human Machine Interface SCADA = Supervisory Control and Data Acquisition Support of UGS JT files for 3D Files from SolidEdge, Autocad, NX and others Full suite of 2D drawing tools Animations to reflect actual position, values and activity of Shop Floor devices and machines Ability to affect machines or process by sending new inputs to devices Page 6

7 Visibility and Control Page 7

8 Alarm Management Alarm on various conditions On/Off/Tgl, Hi and Low, Rate of Change, Time delayed Alarm message variable based on process values All client stations share common alarm list Can be filtered to local area or function of interest Sorted by group, priority, time and status Operator annotations for each alarm instance Alarm messages ed to cell phones or computers All history stored in database for advanced reporting and analysis Page 8

9 Alarms in Action Page 9

10 Trending Graphical analysis of time-based data Unlimited logged values can be mapped to 64 or more simultaneous pens Pan, zoom and statistical views of data Compressed logging techniques save disk space without loosing analytical information Page 10

11 Trending in Action Page 11

12 Other SCADA features Recipe management via standard databases Oracle, SQLServer, DB2 and others Native protocol drivers for major vendors Allen-Bradley, Siemens, Schneider, GE, others Connectivity via OPC, XML, OLE, DDE, and other standards Hot redundant servers, auto failover clients Traceability MES for automated environments Page 12

13 FactoryLink is Unique Patented event-drive architecture All real time data stored in RAM Each task is individual process Public API called PAK Highly scalable Multi-core/multi-CPU ready architecture Page 13

14 Data in action Change State Bits Change State Bits Change Wait Bits Change State Bits Page 14

15 Performance and Scalability Open Software Bus (aka: Kernel) Maximum: 40M t/s, Real-world 5.8M t/s (3GHz CPU) Limited by CPU and tasks managing the data Actual Applications: 4.5 Million tags Ford POSMON Planned 3.5 Million tags/200k alarms Heathrow Airport >1000 PLC/RTU, >1M tags Phillips Petroleum Page 15

16 Data Analysis Manufacturing Portal Web based reporting and analysis tools Expandable reports leveraging Portal tools and security User defined views and filters Predefined reports useful out of the box Page 16

17 Manufacturing Portal Page 17

18 Shop Floor is Real Time FactoryLink (Tecnomatix SCADA) provides real time solutions for monitoring and control of critical manufacturing processes and provides data to the MES system for Traceability. Siemens Manufacturing Portal provides data analysis tools to optimize plant operations Siemens Services can help you architect and design your worldclass Production Management solution. Page 18 <End of Introduce>

19 Production Management FactoryLink Case Studies PRESENTED BY: KeeKwang, Lee FactoryLink Product Manager Page 19 Copyright Siemens Product Siemens Lifecycle AG Management All Software rights Inc. reserved. All rights reserved

20 Seat Manufacturer JIT (just in time) storage and sequencing of seat set storage Seat sets delivered from manufacturing Seat sets stored (3 cranes, 875 positions) Data base information on part number, date, slot 42 count sequence electronically delivered from OEM Simultaneous picking of oldest seat sets to delivery sequence conveyor Page 20

21 Crane and Conveyor Controls Page 21

22 Current Inventory Reports Page 22

23 Heavy Equipment Manufacturer Diesel Injector manufacturing line Multiple customers including internal group sales Allen-Bradley PLC controls for tray movement and RFID reads Custom Robot driver (test station) 8 cells 2 are manned HMI plus data gathering 6 are without HMI, data gathering only All data saved via Oracle Page 23

24 Solution Architecture Page 24

25 Manufacturing Layout Final Assembly Armature Body Nozzle Base Rework Test Station Pallet 1 Pallet 2 Bar Code Page 25 Unload

26 Key Functions Conveyor control and alarming Multiple part numbers on same line RFID tracking of trays Component serial number and lot tracking Test data logging to Oracle Pass/fail based on customer specification Long-term spec report for each injector Page 26

27 Test Station Page 27

28 Final Test Page 28

29 Unload to Pallet Page 29

30 Steel Processing Facility Galvanize and galvanneal steel Process 482,000 tons of steel each year FactoryLink user since 1998 Capture data every 50 feet of coil 70 values from 20 process locations (total of 5500 values per coil) 185 process values recorded every 10 minutes Upload data to local SQL data base and then to Oracle Also download coil processing recipe from Oracle to PLC s Page 30

31 Solution Architecture Page 31

32 Line Overview Page 32

33 Coil Tracking Page 33

34 Page 34