Achieving Operational Excellence with a Connected Mill

Transcription

1 Achieving Operational Excellence with a Connected Mill Technical Session CT417 1

2 Agenda Macro Trends and Pressures Connected Mill Dashboarding and Production Reporting Analytics and Mobility TeamOne Productivity App 2

3 Macro Trends and PRESSURES Market Global Competitiveness Workforce Talent Shortages & Skills Gap Risks Changing Risk Patterns Technology Industrial Internet of Things Opportunities and challenges Global challenge Highly publicized and IoT value at stake and growth Workforce: The Changing Workforce changing global landscape hiring and retaining expensive incidents worldwide of internet enabled assets Retirements, economic expansion, and technology evolution are overwhelming companies ability to staff operations. Manufacturing and Industrial Operations IP and tribal knowledge are leaving with the workforce Incoming talent often lacks necessary technology skills. 220,000 New engineers every year 70% Suffered a security 11% Of worlds economy in 2025 until 2022 to connect the unconnected breach in the last year will be provided by IoT 2014 Ponemon Institute survey McKinsey & Co 2015 The World Bank Studies 3 3

4 City Populations are growing every year by 65M Emerging economies are becoming major forces That s equivalent to 7 new CHICAGOs every year M The rate emerging economies are 75% growing faster than developed nations By billion new middle class consumers will add $8T to consumer spending Increased SOURCE: Demand McKinsey on Industrial Production GLOBAL POPULATION TRENDS INCREASE DEMAND FOR Manufacturing Resources Infrastructure EMERGING MARKET CONSUMERISM 30% 100% More Water More Vehicles 80% More Steel 50% More Energy RESOURCE PRODUCTIVITY INVESTMENT $1T Annually Source: McKinsey 4

5 Business Risks & Drivers $65B ~ 75% $20B $30M <14 % 21% Automation systems reaching end of life U.S. plants are more than 20 years old Cost of unscheduled downtime 76% of recalls cost up to US Plants completely integrated Suffered a loss of IP in the past year SOURCE: ARC SOURCE: Industry Week SOURCE: ARC SOURCE: GMA SOURCE: Industry Week SOURCE: Kapersky (2014) Realizing Smart Manufacturing has become a business imperative 5

6 Agenda Macro Trends and Pressures Connected Mill Dashboarding and Production Reporting Analytics and Mobility TeamOne Productivity App 6

7 Challenges Forest Product Manufacturers $ Operational Readiness or OEE Access to Information Rising Operating Costs Production Targets Unplanned Downtime Workforce Skills Gaps 7

8 50B ALERT! NUMBER OF DEVICES ON THE INTERNET BY 2020 SAFE & COLLABORATIVE ROBOTS AI & MACHINE LEARNING PREDICT FAILURES AND REDUCE DOWNTIME WEARABLES & MOBILE DEVICES TRANSFORM WORK FLOWS 8

9 Manufacturing and Industrial Enterprises are becoming CONNECTED Intelligent devices that are able to: ANALYZE PREDICT ADAPT SMARTER OPERATIONS Leading companies are gaining business value today from IIoT strategies (new income streams, product and solution innovation, productivity, asset utilization). Where could you get the fastest ROI? 9

10 OUTCOMES-BASED DIGITAL TRANSFORMATION OF THE PLANT FLOOR PHASE 1 PHASE 2 PHASE 3 INTEROPERABLE LINE INTEGRATION LINE DIGITIZATION DIGITAL PLANT Smart Machines Predictive Maintenance Mobility Visibility Collaboration Efficiency Improved OEE Informed Decisions 10

11 THE COMPETITIVE CONNECTED ENTERPRISE Enhanced by Contemporary Technologies 11

12 Modernization The Need for Smart Machines Real-time Data Voltage,Kwh,Running Time, Temperature Security PROTECT Securing the data flow Information CONTEXTUALIZATION Energy/Product, OEE Knowledge ANALYTICS Predict bearing will fail in 10 hours Wisdom OPTIMIZE More efficient process workflows 12 12

13 Smarter Plants & Operations Yield will meet today s production needs ALERT Maintenance Line #1 7100KWh of energy used today Time to reach temperature is longer than normal 13

14 Connected Mill One Integrated Architecture Integrates Data from Multiple Sources. Process, Machine Control Safety Shares Power, Information Across Your & Enterprise From the Log Yard Condition Monitoring AC Drives Multidiscipline Control To the Lumber Yard Optimization systems Secure Network Infrastructure Mobile & Open Information Platform Manufacturing Intelligence Software 14

15 Information Solutions - CUSTOMER USE CASES $ Productivity and Optimization Asset Management & Reliability Enterprise Risk INFORMATION SOLUTIONS CAPABILITIES CLOUD ON-PREMISE EDGE SCALABLE MES SCALABLE ANALYTICS MOBILITY & COLLABORATION CONNECTED SERVICES RA IIoT INFRASTRUCTURE Auto Discovery & Configure Zero Config Devices Zero Config Dashboards People in the IIoT FactoryTalk Cloud Platform SMART CONNECTED ASSETS EtherNet/IP Enabled Network Infrastructure SENSORS & ACTUATORS INTELLIGENT MOTOR CONTROL CONTROLLERS TERMINALS MACHINES & EQUIPMENT REMOTE ASSETS Enabling the Industrial Internet of Things (IIoT) 15

16 Strategic Partnerships Full Suite of Industry-Focused Solutions Transactional information: orders, supply network, product design ERP FINANCIALS HR LOGISTICS QUALITY WAREHOUSE IT COMMON SECURE NETWORK INFRASTRUCTURE OT Real-time data: alarms, events, states, energy, diagnostics, INDUSTRIAL THINGS PLCS & SCANNERS MATERIAL & TRANSPORT MACHINES & TESTERS SHOP FLOOR PERSONNEL PRINTERS & LABEL SERVICES 16

17 Journey to a Connected Enterprise Business Impact EVALUATE CONNECT COLLECT PRESENT OPTIMIZE What are the most significant challenges in my organization? What KPI s are used to measure performance? What data is needed, from which systems, and define how it could help improve KPI s? Assess current infrastructure for readiness Modernize infrastructure Connect plant equipment & people Must be scalable and flexible Do it securely Data from assets and organize to improve business processes Leverage information from across the plant and enterprise Contextualize it against other data Make it actionable & to make smarter decisions Put it in terminology that s right for the user Correlation & qualitative analysis of the information for process improvement Maximize plant workflow in a coordinated way Make the plant integral to B2B partners 17

18 Today s Digital Mill BIG DATA SILOS OF INFORMATION 18

19 Agenda Macro Trends and Pressures Connected Mill Dashboarding and Production Reporting Analytics and Mobility TeamOne Productivity App 19

20 How Do You Provide Reports Today Information is gathered manually from various plant systems and reports are generated in excel spreadsheets then distributed in paper form. The issues are: Gathering data is tedious and time consuming Data is stale at time of reporting Reports live in a specific person s file not shared 20

21 CONNECTED Mill Solution Fully Integrated & Scalable Collect. Make Contextualize. Informed Decisions Analyze. 21

22 A1 Dashboarding and Analytics Product Overview Enables real-time and historical connectivity to your Logix based data with trending, KPIs, and reporting that can be created and viewed from your PC or mobile device. Connect to your real time or historical Logix based systems. Third party connectivity also exists. Data stays in it s source. Just connect and analyze! Organize data logically in a manner that makes sense to you! View the data you ve connected to on your mobile device or PC. Create a range of simple to more complex role displays ensuring users have access to the information they need, when they need it. 22

23 Slide 22 A1 Can we use a single slide to talk about VP in general? I've asked our slide designer to convert this to look like the single slide for FTAD and FTAM. Author, 1/24/2017

24 Dashboarding & Reporting Overview CONNECT Premier Integration with Rockwell Data Sources 3 rd Party Historians, 3 rd Party Systems via OPC / OPC DA Database Connectivity (Oracle and SQL) ORGANIZE Organize the data in a way that makes the most sense for your users Combine multiple data sources into one logical unit Reuse model content for increased productivity VISUALIZE Ad Hoc / Self Service Tools: Excel, Trend, XY Plotter Enterprise Reporting Tools: SQL Server Reporting Services and Sharepoint Web Parts Mobile: Mobile First Design Model Browser and Display Creation 23

25 Time Series vs. Relational Data Storage Plant wide Data Storage Solution Time Series Database HISTORIAN Store process data over a period of time Pressure, temperature, speed, etc. Stores events with value and timestamp E-Stop, Part jam, etc. Optimized data storage to handle large amounts of data over long period of time Efficient data retrieval of large amounts of data that may span weeks/months/years Relational Database SQL Store process and production data as records and relationships: Products, recipes, units, orders, batches, etc. Add Context To Time Series Data (UPM) Moving away from a flat data structure to an organizational structure Event Framing Store event data associated with a batch (S88 model), work shift, material flow, alarms & events 24

26 Why do you need a Data Historian? Optimize Production Processes Reduce process variability from run to run Monitor and improve asset utilization Increase yield / decrease downtime / improve actual availability Improving Product Quality Determine root causes for variability Decrease scrap and rework Regulatory Compliance / Genealogy (tracking) Regulatory reporting requirements (EPA, DEP, FDA, etc.) Satisfying customer requirements and limiting liabilities Monitoring, Optimizing, and Reducing Energy Consumption You can t improve what you don t measure

27 Manual Entry

28 Do You Know the Answers? Plant Management How can we reduce costs? What is my first pass quality? Where are bottlenecks? Scheduling Knowledge Worker Do we have enough capacity? What are downtime causes? Machine Builder What is my equipment Quality utilization? Information Technology Control Engineering Operator Planning and Logistics Maintenance 27

29 Forget the Terminology You may call it: Efficiency Monitoring Machine Monitoring Downtime Tracking Process Improvement OEE (Overall Equipment Efficiency) Analysis LEAN All of the above or none of the above What you really want to know is: Are your machines producing as much as they can? How can you make them produce more? 28

30 Managing OEE Means Managing Cost There are 3 general ways to reduce costs in an automated process: 1. Reduce unproductive machine time 2. Reduce cycle times 3. Reduce waste / scrap OEE measures these same 3 components: Productive time = Availability - Are the machines running when expected? Cycle times = Performance - Are they running as fast as expected? Good vs. scrap = Quality - Are they wasting cycles and material producing scrap? Higher OEE results in Lower Costs Cost 29

31 Performance By Asset

32 Production By Board Length by Log Size

33 Visualize MANAGEMENT SUPERVISOR OPERATOR The Right Information, at the Right Time, with the Right Fidelity

34 Agenda Macro Trends and Pressures Connected Mill Dashboarding and Production Reporting Analytics and Mobility TeamOne Productivity App

35 MONITOR & INTERACT WITH IIoT DEVICES, IMPROVE PLANT HEALTH DETECT your smart devices, automatically DIGITIZE the data, allowing work to be done ANALYZE the data perform calculations, transform the data ACT on information, get to the right people, on the right device Immediate value delivered as an Industrial Appliance; Self-contained and FactoryTalk Cloud aggregation options

36 FactoryTalk Analytics for Devices What Does It Do? Optional Monitors and improves MTTR (Mean Time to Repair) Detects Ethernet/IP devices automatically Performs analysis on device data If there is any issue with a device, notifies customers Provides simple and immediate instructions for how to correct the issue Learns what devices are important for a specific customer Performs system level health & diagnostics to solve hard-todiscover issues Analytics Appliance Browser + Mobile Access Automation Devices

37 ALL DONE AUTOMATICALLY! DASHBOARDS PEFORMS DIAGNOSITIC ASSESSMENT IDENTIFIES THE DEVICE IMPORTANT SUPPORTING DATA SIGNIFICANT DIAGNOSTICS

38 Agenda Macro Trends and Pressures Connected Mill Dashboarding and Production Reporting Analytics and Mobility TeamOne Productivity App

39 Copyright 2015 Rockwell Automation, Inc. All Rights Reserved. 38

40 The app for team productivity Why? Reduce mean time to repair (MTTR) How? Enable every industrial worker to investigate, collaborate and troubleshoot plant floor issues faster (when they are at work in the plant) instantly with no setup with very little changes to their infrastructure. What? A team based ios and Android App that integrates worker knowledge and automation data. An app platform for Rockwell Automation to continue to build more modular content into and deliver connected enterprise solutions to customers.

41 App Platform Modules What they do now? 1. Knowledge base: Access within without a separate login. 2. Incident: Allows users of the app to capture information about a problem. The user can enter a name, description and other similar fields. In addition, photos can be attached to an incident. 3. Pinboard: Allows a customer to pin items from within modules and it to be accessed later as a favorite link. Future state for this module is to snapshot data from live connected modules for use in offline situations or sharing with others that are not connected to the device. 4. Chat: 1 to 1 with a team member, module items can be send/shared. Has notifications. 5. Team Board: A group board (1 to all) that allows users of the team to post to the team members. Adding notifications shortly after the preview release

42 App Platform Modules cont 6. Connect: This module stores IP s of devices & system login information. Currently supports PF755 & 525 drives. 7. Device Health: module allows the user to view basic status information for the devices. This information is only retrieved once and subsequent request are user initiated. 8. Instant Trend: Read parameter values from a supported device and plot up to 60 seconds of those data values. 9. Alarms details coming soon

43 When your ready to expand your system 5 Easy Steps to Ensure Success Source: LNS Research Step 1: Don t go at it alone Step 2: Clearly define the objectives of a pilot Step 3: Define clear short term scope of 1-3 months Step 4: Show success and more ideas will be generated. Step 5: Select the right implementation partners.