Solution for Manufacturing Flexibility and Efficiency. Business Intelligence. Chatchai Wajakiet / Chee Hoe Lee

Size: px

Start display at page:

Download "Solution for Manufacturing Flexibility and Efficiency. Business Intelligence. Chatchai Wajakiet / Chee Hoe Lee"

Dwight Eaton
5 years ago
Views:

2 Agenda 1. Basic Manufacturing Problem 2. The FactoryTalk VantagePoint Solution 3. Built-In Functionality for Plant Floor 4. FactoryTalk VantagePoint Advantages 5. Ordering, Training and More Information Copyright 2009 Rockwell Automation, Inc. All rights reserved. 2

3 Manufacturing: An Information Problem Material Time People Energy Product Waste Data: Control systems HMI systems Alarm and event systems Historians 3 Copyright 2009 Rockwell Automation, Inc. All rights reserved. 3

Universal Problem Manufacturing Production Testing Rework Control Systems Inventory HMI / Shipping SCADA

881 19 8 8 99 9 0 650 9 9 6 7 7 7 7 4 5 9 6 65 01 9?

9 5 4 4 4 0 650 9 5 6587 9 6 9 6 4 4 1 881 19 8 8 99 9 0 650 9 9 6 7 7 7 7 4 5 9 6 65 01 3 7 7 7 18 81 19 9

4 Universal Problem Manufacturing Production Testing Rework Control Systems Inventory HMI / Shipping SCADA Information Workers Co-workers Management Production Supervisor Quality Department Sales Marketing ?? Alarms & Event History Production HMI / Historians SCADA?? BAD INFORMATION POOR DECISIONS Copyright 2009 Rockwell Automation, Inc. All rights reserved. 4

5 Agenda 1. Basic Manufacturing Problem 2. The FactoryTalk VantagePoint Solution 3. Built-In Functionality for Plant Floor 4. FactoryTalk VantagePoint Advantages 5. Ordering, Training and More Information Copyright 2009 Rockwell Automation, Inc. All rights reserved. 5

8 Multiple Sources of Manufacturing Data RS Logix FactoryTalk FactoryTalk FactoryTalk OPC DA OPC HDA InTouch Proficy View Historian Alarms/Events SoCal OSI PI InSQL Suppliers Area 1 Area 2 Area 3 Customers Copyright 2009 Rockwell Automation, Inc. All rights reserved. 8

9 All Data in a Unified Production Model (UPM) RS Logix FactoryTalk FactoryTalk FactoryTalk OPC DA OPC HDA InTouch Proficy View Historian Alarms/Events SoCal OSI PI InSQL Suppliers Area 1 Area 2 Area 3 Customers Copyright 2009 Rockwell Automation, 9 Inc. All rights reserved. 9

10 A Realistic, Flexible Model Model Model Reflects Reflects The The Business ISA ISA 88/95 88/95 Open Open O&M O&M B2MML B2MML ProdML ProdML RS Logix FactoryTalk FactoryTalk FactoryTalk OPC DA OPC HDA InTouch Proficy View Historian Alarms/Events SoCal OSI PI InSQL Suppliers Area 1 Area 2 Area 3 Customers Copyright 2009 Rockwell Automation, 10 Inc. All rights reserved. 10

11 Built in Analytics, Extensibility Calculate Schedule React Aggregate Unified Production Model RS Logix FactoryTalk FactoryTalk FactoryTalk OPC DA OPC HDA InTouch Proficy View Historian Alarms/Events SoCal OSI PI InSQL Suppliers Area 1 Area 2 Area 3 Customers Copyright 2009 Rockwell Automation, 11 Inc. All rights reserved. 11

Rich Content, Easy to Use and View Excel Excel Trend Trend KPIs KPIs Portal Portal Analysis Unified Production Model Dashboards Reports Reports RS Logix FactoryTalk FactoryTalk

12 Rich Content, Easy to Use and View Excel Excel Trend Trend KPIs KPIs Portal Portal Analysis Unified Production Model Dashboards Reports Reports RS Logix FactoryTalk FactoryTalk FactoryTalk OPC DA OPC HDA InTouch Proficy View Historian Alarms/Events SoCal OSI PI InSQL Suppliers Area 1 Area 2 Area 3 Customers Copyright 2009 Rockwell Automation, 12 Inc. All rights reserved. 12

Information Business Context Knowledge Building and Sharing SoCal Suppliers Area 1

13 The VantagePoint Difference Increased IT Agility and Leverage Existing Information Assets Accommodate Change Extend Infrastructure Deeper Manufacturing Insight Unified Information Business Context Knowledge Building and Sharing SoCal Suppliers Area 1 Area 2 Area 3 Customers Copyright 2009 Rockwell Automation, Inc. All rights reserved. 13

14 Agenda 1. Basic Manufacturing Problem 2. The FactoryTalk VantagePoint Solution 3. Built-In Functionality for Plant Floor 4. FactoryTalk VantagePoint Advantages 5. Ordering, Training and More Information Copyright 2009 Rockwell Automation, Inc. All rights reserved. 14

Rich, Interactive Browser Experience Universal access via a browser No client

reports, client tools and help: VantagePoint Manager Trend XY Plot

Performance Performance Indicators Indicators Drill Drill Down Down to to

15 Rich, Interactive Browser Experience Universal access via a browser No client install necessary Role based reports and custom links for your users Links to reports, client tools and help: VantagePoint Manager Trend XY Plot Documentation Links to Help and Support Start Start with with Key Key Performance Performance Indicators Indicators Drill Drill Down Down to to Underlying Underlying Calculations Calculations Copyright 2009 Rockwell Automation, Inc. All rights reserved. 15

Excel Reports Available to Everyone Create powerful Excel reports Retrieve data from any supported data source Calculate, analyze and format reports

Pre-configured Excel reports in Sample Reports Retrieve Retrieve Data Data From From Any Any Source Source Calculate, Calculate, Analyze Analyze and

16 Excel Reports Available to Everyone Create powerful Excel reports Retrieve data from any supported data source Calculate, analyze and format reports using Excel functionality Publish reports via portal for viewing by anyone with access to a browser no client install Dynamically refresh data Pre-configured Excel reports in Sample Reports Retrieve Retrieve Data Data From From Any Any Source Source Calculate, Calculate, Analyze Analyze and and Format Format Publish Publish to to the the VantagePoint VantagePoint Portal Portal Copyright 2009 Rockwell Automation, Inc. All rights reserved. 16

Trending Made Easy Easy model navigation Diagnose and analyze data from any supported data source Access to real-time and historical data Powerful trend functionality- Pan,

17 Trending Made Easy Easy model navigation Diagnose and analyze data from any supported data source Access to real-time and historical data Powerful trend functionality- Pan, zoom, stack & synchronize Publish & share trends to the portal Pre-configured trends available in Sample Reports Copyright 2009 Rockwell Automation, Inc. All rights reserved. 17

Powerful Easy to Read Dashboards Create powerful dashboards that monitor real-time data and key manufacturing KPIs Dashboards can update dynamically and on demand

18 Powerful Easy to Read Dashboards Create powerful dashboards that monitor real-time data and key manufacturing KPIs Dashboards can update dynamically and on demand Easy access to all dashboards via a browser Pre-configured dashboards available in Sample Reports Copyright 2009 Rockwell Automation, Inc. All rights reserved. 18

19 FactoryTalk Vantage Point XY Plot Create XY Plots using the XY Plotter Tool Analyze one value with respect to another over time Publish and share XY Plots to the Portal Pre-configured XY plot available in Sample Reports Copyright 2009 Rockwell Automation, Inc. All rights reserved. 19

21 Agenda 1. Basic Manufacturing Problem 2. The FactoryTalk VantagePoint Solution 3. Built-In Functionality for Plant Floor 4. FactoryTalk VantagePoint Advantages 5. Ordering, Training and More Information Copyright 2009 Rockwell Automation, Inc. All rights reserved. 21

22 A Rockwell Solution for Rockwell Products User Defined Data Types Save engineering time creating data structures Make it easier to design and maintain programs Copyright 2009 Rockwell Automation, Inc. All rights reserved. 22

Make it easier to create, manage, view reports

23 Create Tank Reports, Trends, Dashboards VantagePoint Types Save engineering time mapping to data sources Make it easier to create, manage, view reports Copyright 2009 Rockwell Automation, Inc. All rights reserved. 23

24 Map Logix UDTs to VantagePoint Types VantagePoint The Logix tank UDT is mapped to the VantagePoint tank type. Tank UDT members are mapped to tank type properties. Logix Copyright 2009 Rockwell Automation, Inc. All rights reserved. 24

Users can now easily find tanks and associated tags, and can see the real time value of

25 Import Logix Configuration into VantagePoint VantagePoint Instances of the tank UDT are imported as items of type tank into the VantagePoint Unified Production Model Logix Users can now easily find tanks and associated tags, and can see the real time value of these tags (via LiveData) Copyright 2009 Rockwell Automation, Inc. All rights reserved. 25

Correlate Logix Tags with FT Historian Tags VantagePoint FT Live Data tags are associated with FT Historian tags in the VantagePoint Unified Production Model.

26 Correlate Logix Tags with FT Historian Tags VantagePoint FT Live Data tags are associated with FT Historian tags in the VantagePoint Unified Production Model. VantagePoint can now retrieve the history of a tank from FT Historian, and the real time values of tank tags from Live Data. Users don t need to know where the data is coming from. FT Historian Logix Copyright 2009 Rockwell Automation, Inc. All rights reserved. 26

View Tank Reports, Trends and Dashboards Tank

Authorized users can access tank information by

27 View Tank Reports, Trends and Dashboards Tank reports, trends and dashboards work automatically against tank items imported from Logix. Authorized users can access tank information by browsing to the VantagePoint portal. Copyright 2009 Rockwell Automation, Inc. All rights reserved. 27

Real World Model For Information the Way You Need It Process Control Engineer Pressure Flow Speed Live Data: Control System/HMI Maintenance Management System Maintenance Manager Running hours

29 Real World Model For Information the Way You Need It Process Control Engineer Pressure Flow Speed Live Data: Control System/HMI Maintenance Management System Maintenance Manager Running hours Performance spec Manufacturer data Spares on hand Maintenance date ERP, LMS, SQL Database Quality Assurance Batch record Leak test data Lab sample Production Manager Volume pumped Product throughput Operation history Power consumed Historian Process Engineer Related equipment Rating Vibration data Asset Database Asset Manager Purchase date Cost Warranty Manufacturer Engineering Specs Copyright 2009 Rockwell Automation, Inc. All rights reserved. 29

Single Point of Access, One Version of the Truth Access to ALL plant floor, production and business systems Integrate and organize time series and

30 Single Point of Access, One Version of the Truth Access to ALL plant floor, production and business systems Integrate and organize time series and transactional data Users at all levels of enterprise can view role-based KPIs, reports and dashboards Copyright 2009 Rockwell Automation, Inc. All rights reserved. 30

31 All You Need is a Browser No client install is needed to view trends, reports and dashboards Simply publish reports in the portal to allow access Copyright 2009 Rockwell Automation, Inc. All rights reserved. 31

32 Non-programmers Can Create and Publish Reports, Trends and Dashboards Build ad-hoc reports and publish to the model Reports can be saved and modified easily as needed Reduces the marginal cost of curiosity Copyright 2009 Rockwell Automation, Inc. All rights reserved. 32

33 Agenda 1. Basic Manufacturing Problem 2. The FactoryTalk VantagePoint Solution 3. Built-In Functionality for Plant Floor 4. FactoryTalk VantagePoint Advantages 5. Ordering, Training and More Information Copyright 2009 Rockwell Automation, Inc. All rights reserved. 33

How would you answer these questions? What types of control systems do you have? What types of Historians do you have? What types of HMI systems do you have?

34 How would you answer these questions? What types of control systems do you have? What types of Historians do you have? What types of HMI systems do you have? Who has access to the information from these systems? Would your engineering / maintenance / quality / supervisory staff benefit from access to this information? Would it help to have a common set of tools to report against all of these data sources? Would a web based reporting solution help? How much time do you spend creating production / quality / maintenance reports? What happens if the owner of the reports is not available? Would you benefit from reports being generated from the structure data types in ControlLogix (UDT)? Copyright 2009 Rockwell Automation, Inc. All rights reserved. 34

FactoryTalk VantagePoint EMI Contact your local Information Solutions Regional Manager (ISRM) to receive

35 Additional Connectivity via FactoryTalk VantagePoint EMI For connectivity to FactoryTalk Metrics, Transaction Manager, Batch or other manufacturing data sources utilizing a SQL database, a connector is available with FactoryTalk VantagePoint EMI Contact your local Information Solutions Regional Manager (ISRM) to receive additional information on ordering and configuring Copyright 2009 Rockwell Automation, Inc. All rights reserved. 35

com/mi Includes Product Demo / Videos Discover Webcast Recordings Product

37 Where to Find Additional Information Discover Rockwell Automation Portal Includes Product Demo / Videos Discover Webcast Recordings Product Profiles Ordering Information System Requirements Case Studies Copyright 2009 Rockwell Automation, Inc. All rights reserved. 37

Training Training is available for FT VantagePoint and FT VantagePoint EMI through Rockwell Automation s training site at:

39 Customer Value Food & Beverage SCOPE 69 plants 140+ data sources SCADA, control, MES, LIMs, Asset Management, SAP, ORACLE & SQL databases, InSQL historian Many legacy systems and in-house designed MES 2.5 MM 10 MM objects in the database (FactoryTalk VantagePoint model) Corporate portal system TV (One plant) available to 28,000 employees TV monitor above every production line Dashboard tracking the following for each line Production target Results so far Current projection against target Targets Cost MTBF/MTTR Downtime cause RESULTS Improved throughput by 8% Reduced waste by 3% Copyright 2009 Rockwell Automation, Inc. All rights reserved. 39

40 Customer Value Chemical SCOPE/OBJECTIVE A global fortune 500 manufacturing company Objectives Increase production due to higher demand Without adding new capital or resources Replace antiquated batch reporting No rip-replace of other legacy systems Rational for EMI Integrated easily with existing production control systems Provided deep insight into our batch processes Reports available to production and management to monitor production in context of individual s role Future expansion capabilities for integration with our ERP RESULTS Changeover time reduction Control Loops optimized One of the main benefits of using FactoryTalk VantagePoint was greater Schedule improvements performance. We have better insight into how we perform, how long More product produced in 2 processes take and how fast we can make our products. We ve reduced shifts than previously done in 9 our production cycle times by 90% already. Manager Copyright 2009 Rockwell Automation, Inc. All rights reserved. 40

41 Customer Value Energy Management SCOPE Small university 70 buildings Central plant to manage: electricity, heat and cooling Cogeneration of electricity and heat from fuel oil Buildings metered / data stored in historian and control OBJECTIVE Manage/reduce energy consumption Make vs. Buy SOLUTION Track and accurately predict electricity and oil consumption Reduce impact of high cost peak-demand energy Calculate / predict individual building demands Integrate islands of information from water treatment, HVAC, co-generation and weather reports RESULTS Reduced overall energy consumption by 23% Lowered total energy bill by $3M / year Copyright 2009 Rockwell Automation, Inc. All rights reserved. 41

42 Customer Value Water Management SCOPE/ENVIRONMENT Mid-size city municipality Multi-vendors SCADA and Control Many disparate data sources Facing severe environmental issues with storm run-off OBJECTIVES Consistent reporting Yield Quicker leak detection Reduce contamination Improve water quality Reduce energy RESULTS consumption Remediated detection, quality and energy issues Reduced operating cost (dbl digits) We re taking business intelligence to the next level because our departmental staff recognize opportunities earlier, react more swiftly to them, more easily communicate the issues involved, and make better decisions. Manager Copyright 2009 Rockwell Automation, Inc. All rights reserved. 42

44 How do you manage your challenges? Reduced Mfg Cost Improve Mfg Agility Improve Quality Reduce Mfg Lead Time Reduce FG Inventory Improve Schedule Compliance Improve Throughput BEST IN CLASS TOP THREE OTHERS Reduce Raw Material Inventory Reduce WIP Inventory Source: Aberdeen Group, Mfg Perf Mgt2, 2006 SYSTEMATIC DATA COLLECTION A MUST Copyright 2009 Rockwell Automation, Inc. All rights reserved

Applications for Manufacturing Historians Historians are utilized across many industries and applications: Consumer Products, Food and Beverage, Automotive, Life Sciences Continuous Process,

45 Applications for Manufacturing Historians Historians are utilized across many industries and applications: Consumer Products, Food and Beverage, Automotive, Life Sciences Continuous Process, Packaging, Material Routing, etc. Key benefit of a Historian: Capture and process high-speed, time-series data Store in a central (Site or Enterprise) data repository for future analysis Historical data is used for: Analysis through calculations, statistical processes, quality controls, etc. Supports business and operational analysis: Trends and graphs of data Turns Data into Information! Copyright 2009 Rockwell Automation, Inc. All rights reserved

46 Value of a Data Historian Helps improve overall operations through analysis of manufacturing, process and production data. Accelerate Six Sigma and Lean initiatives Identify under-performing production areas Increase quality Identify the root causes of process variability Improve processes Analyze complex process data easily Capture non-relational data very efficiently Extreme capture speed and compressed storage Reduce variability Verify production parameters versus targets/norms Capture critical performance and quality data in real-time Decrease overhead costs Save time in collecting data and preparing reports Centralized storage repository Enables a platform for standardization of data collection and reporting of key performance indicators (KPIs) Copyright 2009 Rockwell Automation, Inc. All rights reserved

Strategic Partnership Leadership in Automation

Automation and Controls Expertise Solution

Software Products Technology Provider Data

Market leaders joining together to provide

50 Strategic Partnership Leadership in Automation and Information Solutions Solution Provider Automation and Controls Expertise Solution Platform Real-time Performance Management Software Products Technology Provider Data Historian and Context Experts Product Platform Market leaders joining together to provide winning solutions Copyright 2009 Rockwell Automation, Inc. All rights reserved

FactoryTalk Historian Machine Edition FactoryTalk Historian Machine Edition

backplane More granular data Solid-state data storage Part of the Distributed

Auto-discover sources downward Auto configure tags Performance and scalability

51 FactoryTalk Historian Machine Edition FactoryTalk Historian Machine Edition Based on FactoryTalk Historian SE Module-based historian Data Collection over backplane More granular data Solid-state data storage Part of the Distributed Historian Strategy Three-tiered historian Aggregating data upward Auto-discover sources downward Auto configure tags Performance and scalability 3 rd -party connectivity Copyright Rockwell Automation, Inc. All rights reserved. 51

Platform Architecture Trend KPIs KPIs Portal Reports Excel Excel Dashboard EAI, SOA Data Rollup FactoryTalk Platform Production Data Process Data Single Operator Interface OPC Alarm & Events UDT

52 Platform Architecture Trend KPIs KPIs Portal Reports Excel Excel Dashboard EAI, SOA Data Rollup FactoryTalk Platform Production Data Process Data Single Operator Interface OPC Alarm & Events UDT Definitions* Structured Data* Alarm & Events Self Discovery Self Discovery* Mobile HMI 3 rd Party Controllers Control Logix Historian ME* Copyright Rockwell Automation, Inc. All rights reserved. 52