Manufacturing Informatics utilizing information technology to identify manufacturing opportunities and implement solutions Pete Larochelle NeoMatrix, Inc. Mark Fehlmann - Madico
Manufacturing Information Systems ERP MRP Quality Management Manufacturing Organization CRM E-mail Plant Floor Automation
Manufacturing Informatics Evolution 1 Plant Floor Automation 2 Analytics 3 Enterprise Integration
Automation Machine Control Manufacturing processes have hundreds to thousands of devices. PLC measures and controls inputs and outputs. Logic modifications can be made quickly and effectively. Critical system configuration is easily maintained and documented.
Automation Ethernet Adoption Pre-Ethernet required close proximity to the PLC and possibly proprietary hardware. Implementing Ethernet allows programming from anywhere on the network with a standard PC/Laptop. VPN solutions allow secure access is allowed from anywhere in the world.
Automation - HMI Intuitive graphical representation of the process reducing training time for new operators. Instantaneous notification of process issues. Historical analysis. Quick and accurate setup time with recipes.
Automation Vision System Automatic detection and alerting of visual quality details. Historical roll mapping with the ability to analyze by products and defect type. Availability of accurate first pass yield data.
Manufacturing Informatics Evolution 1 Plant Floor Automation 2 Analytics 3 Enterprise Integration
Analytics Data Collection Historian gathers information from PLC and or HMI. 1000 s Points/sec Years of storage PLC HMI Enterprise relational database provides ability to retrieve data with many different clients and other business systems. Historian Analytics
Analytics Ad-Hoc Data Analysis Maintenance, engineering and operations personnel can depend on accurate data taking the guesswork out of the process. Historian Export data to other analysis tools. Trending
Analytics Reporting/Web Automate report generation for critical business data. Alarm/Fault Analysis Raw Material Levels Production Data Roll Reports Plant Status Historian Web sites allows for availability of data on many devices.
Analytics - Alerts Exception reporting via e- mail and text messages provides immediate notification to key personnel of potential issues from the process: Critical Facilities Issues Raw Material Levels Production Quality Issues Process Alarms Historian
Analytics Automating KPI s Availability (Downtime) OEE Metric Performanc e = Automated data collection Provides accurate data. Reduces paperwork allowing operator s to focus on their process. Operators receive real-time feedback on their performance. Availabili ty = Run Hours Total Hours Average Machine Speed Machine Design Speed Total Good Production Quality = Total Production OEE = Availability*Production *Quality Data analysis tools provide root cause analysis.
Manufacturing Informatics Evolution 1 Plant Floor Automation 2 Analytics 3 Enterprise Integration
Enterprise Integration QMS/ERP Quality Management System documentation is embedded in the HMI. Instant access to important documentation relevant to the process. Reduces paper. Enforces revision control. HMI Roll Numbers in ERP triggered by machine start/turret index. QMS Specification ERP
Enterprise Integration - Scheduling Scheduling interface tied to the automation system. Modifications to the queue are instantly reflected on the plant floor. Recipes (specifications) are automatically loaded reducing data entry error. Paperless system. HMI
Enterprise Integration - Worfklow Business Process Management Recipe Change Management ERP BOM Automating Workflows Shorten process execution time. Enforce Standards. Automate mundane tasks. Reduce paper. Workflow QMS Specification HMI Recipe
Review Enhance the plant floor automation programming and troubleshooting processes. Provide plant floor operators access to real-time actionable information to enhance their productivity. Provide all members of the organization instant access to critical real-time and historical process data. Extend the data to implement metrics which enhance continuous improvement initiatives. Integrate business-critical information systems to enable a lean manufacturing environment.