PlantConnect SFactory

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1 An ISO 9001:2008 company PlantConnect SFactory Smart Factory Solution

2 What is Smart Manufacturing PlantConnect SFactory About AIPL

3 Smart Manufacturing What? A manufacturing system that is optimised, demand driven, agile and sustainable Why? Produce more and better with less LET US EXPLORE HOW & WHY IN THIS PRESENTATION

4 Business Drivers Source : CII ARC Survey on Smart Manufacturing in India, 2015

5 Business Drivers Business drivers for manufacturing enterprises Productivity Quality Compliance Competitiveness PROFITS Downtime Energy Consumption Time to Market Finished Goods Inventory COSTS

6 Smart Manufacturing Landscape Smart manufacturing landscape encompasses several entities Smart Factory, Supply Chain, OEMs, Smart Grid and many more

7 Presenting PlantConnect SFactory A Smart Factory solution

8 PlantConnect SFactory Smart Factory solution for discreet manufacturing facilities Your tool to conquer the business drivers Data acquired from machines, utilities Easy to configure, deploy and use Can be integrated with ERP and other systems

9 SFactory Deliverables

10 Deployment PlantConnect DAM acquires data from machines, energy meters, utilities etc. in real time PlantConnect Server on customer premises / cloud Data from each DAM is sent to PlantConnect server over intranet / internet PlantConnect server processes the data tops it up with intelligence and presents it to different types of users like Supervisors, Engineers, Managers, Top Management Each user sees what is relevant to him/her

11 Functional Modules Data Acquisition Dashboards & Analytics OEE, Machine utilization etc. Asset Maintenance Energy Monitoring Reporting SFactory Setup Integration with enterprise systems

12 Data Acquisition Option I - Acquiring data from PLC PlantConnect Data Acquisition Module (DAM) collects data in real time from machine PLC / Controller Option II Acquiring data from sensors If machine does not have connectivity, required sensors are installed Minimum data acquired is 1 pulse for every production cycle. This is available in all machines and can provide critical outputs of production count, downtime etc. Energy data Energy data is collected from energy meters installed for each machine or as suitable Other utilities Data of other utilities like Chiller, Compressor etc. is also acquired

13 Dashboards Tree view of devices with current device status System level and device level dashboards Standard / custom widgets Widgets displayed based on user role Drill down to individual devices from the dashboard

14 SFactory System Dashboard System Dashboard shows performance at a glance for current day / shift updated in real time. Two levels Plant and Machine Only those machines accessible to user are included Plant level - data for entire plant OEE Energy Consumption Machine level, shows OEE Energy Consumption Product name Number of parts produced Machine status running / idle / off

15 SFactory Machine Dashboard Machine dashboard is related to one machine It has a number of widgets depending on machine type as well as role of logged in user Some widgets are OEE widget Standard cycle time Vs actual cycle time trend Downtime analysis by reason Machine utilization analysis Rejection analysis by reason Energy consumption Power factor trend

16 Condition Based Processing This is a powerful module that can be used in different ways Define conditions Based on multiple parameters Multiple conditions joined by AND / OR Attach periodicity / number of occurrences to the condition Examples - (Pressure1 < 68 AND Valve1 = OFF ) If this occurs 5 times in 30 minutes, then set condition true (Abs(Zone1Temp Zone1SetTemp) >= Zone1TempTolerence OR Abs(Zone2Temp Zone2SetTemp) >= Zone2TempTolerence ) If this condition occurs and stays for 10 seconds, set condition true

17 Condition Based Processing Condition Processing Attach condition to one of following Condition Based Alarms Generates an alarm when condition occurs Condition Based Maintenance Generates maintenance workflow State change Records a state change for device / process when condition occurs. Used for accurate analysis of machine utilization Execute logic Executes custom logic when condition occurs. Used for performance / efficiency calculations, control device etc.

18 Asset Maintenance Define asset health conditions Raise alerts when the condition occurs Send SMS / for each alert Asset Maintenance Maintenance scheduling condition based / running hours based / periodic Maintenance workflow Maintenance alerts Maintenance Reports Maintenance Due Report Maintenance Logs

19 Energy Monitoring Monitor energy consumption at different levels from machine to entire plant Establish correlation between machine performance and energy consumption Generate alerts if consumption above benchmarks Real time power factor trend Energy monitoring reports

20 Reporting Reports & Charts Standard (Standard reports & charts) Custom (Custom reports & charts developed for you) Report Builder (A powerful tool to create reports) Reports accessible to users based on their role Can be generated from any client machine in network Reports are generated on user demand Reports can be scheduled and distributed via , printed, stored

21 SFactory Standard Reports Production report Machine utilization report Rejection analysis report Production cycle detail report Alarm summary report Energy consumption report Define custom reports using our Report Builder

22 Mobile App for Operators Get alarm alerts on mobile app SFactory makes it easy for operators to provide inputs using a mobile app Various data entry forms Product change form Downtime reason form Rejection reason form Production remark form All these forms are available in browser client as well

23 Integration with Enterprise Systems Integration with ERP, CMMS, MES and other systems Standard integration using csv files which are exported based on a defined schedule Custom integration with SQL database, web service etc. is possible

24 SFactory Use Cases Use Cases: how you can get returns on investment SFactory Output Know exact downtime and idle time of machines and its reasons Get real time alerts for Cycle Time Variation beyond tolerance Rejection reason analysis Analyze reasons Take Action Reduce downtime Take immediate action on this critical input Stop further rejections Find root causes of rejections and fix them Improve quality

25 SFactory Use Cases Condition Based / Predictive Maintenance SFactory Output Material consumption forecast Real time OEE (Overall Equipment Effectiveness) Reduce cost by 50% compared to Preventive maint. 90% compared to Reactive maint. Helps in raw material inventory management Know pulse of the production Take informed decisions You can think of many more such areas

26 SFactory Case Study 1 - Plastics A plastics company in India Production Monitoring - 3 plants total 40 injection moulding machines - Plant / machine performance monitoring - Machine overview widget - Rejection widget - Machine level OEE widget - Condition based processing - Conditions for machine status - Rejected parts - Machine maintenance conditions - Reporting - Production report - Cycle time report - Rejection report - Machine utilization report

27 SFactory Case Study 2 - Energy Power Plant Sub-Station Energy Management - Energy consumption analysis - Peak load management - Circuit overload / trip alerts

28 What is Smart Manufacturing PlantConnect SFactory About AIPL

29 Ascent Intellimation Pvt. Ltd. Ascent Intellimation Pvt. Ltd. or AIPL is a Pune based boutique IT solutions company focused on Industrial Automation Thought leader in convergence of Industrial Automation & Information Technology Has provided solutions to several global customers like Siemens, Thermo Fisher, Newport, Honeywell etc.

30 Customers

31 Thank You! Dr. Arvind Tilak, CEO Mr. Anand Taparia, Manager Business Dev. Or call us at Ascent Intellimation Pvt. Ltd. Dnyanamayi, 1, Shreeniketan Society, Kothrud, Pune , India