2 GE Fanuc ©2008 GE Fanuc Intelligent Platforms All Rights Reserved Agenda Proficy Plant...

2GE Fanuc ©2008 GE Fanuc Intelligent Platforms

All Rights Reserved

Agenda

• Proficy Plant Applications

• What it is

• What it gives you

• Why customers are using it

• Solution Walk-Through


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Proficy Plant Applications is a suite of powerful application modules that allows manufacturers to make business sense out of plant data in real-time.


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Plant ManagerProduction Finance QualityMaterialsLean/6 SigmaOperator Maintenance

Plant Reporting/Intelligence – Compliance – Continuous Improvement – Supply Chain Integration/EAI

Production Data with Context

Reporting, Visibility& Analytics

OperationalExcellence

Real-TimeExecution

True Capabilities Demand VisibilityAccess to accurate, timely production data is no longer optional.It’s essential.


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Utilization of plant assets

Quality of products produced

Agility of production processes

Integration between production and business systems

Manufacturing costs and productivity

Proficy Plant Apps is…Focused on improving:


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Proficy Plant Apps is…

• Configured to match your manufacturing and business processes

• Extensible using standard tools

• Easier to use, maintain and evolve than custom solutions

• Easier to train users for larger-scale adoption– implementation, roll-outs

and support• Continually enhanced

through input from global users across multiple industries

Configurable, off-the-shelf, packaged solutions


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Universally applicable

Proficy Plant Apps is…

• Our unique architecture supports a wide variety of discrete, batch, continuous and hybrid manufacturing processes – Mixing, forming, processing,

assembly, painting / coating, packaging, etc…

• and supports the production of many different types of products– Foods, beverages, paper,

chemicals, plastics, components, assemblies, etc…

• This ability to support all production environments is essential when driving a standard solution and is a key reason Proficy has been chosen by many customers

Material Handling

AutomotiveForestProducts

Water/Wastewater

Power Generation

Metals MachineTool

Pharmaceuticals/Life Sciences

Food &Beverage

PackagedGoods

Oil & Gas/HPI PackagingApplications

Process

DiscreteContinuous Hybrid


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Proficy Plant Apps delivers results on the shop floor and in the business office and gives you a powerful, reliable system to tackle today’s challenges and stay ahead of tomorrow’s.


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Proficy Plant Apps gives you…

• Knowing your Objectives– Production, Quality and Cost

Targets– Specifications, Recipes,

Schedules, Orders– Materials, Methods

• Tracking your Status– Event Detection with Reason

Code capture– Automated and Manual Data

Collection– Non-conformance Alerting;

Enunciation

• Analyzing your Performance– Automated Reporting &

Analysis

• Giving you the Information to Take Action

Real-time information and control of your plant’s performance by:

Objectives

Analysis

StatusAction

Real-Time

His

torica

l


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Proficy Plant Apps gives you…The context needed to interpret what’s happening on the shop floor


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Universal Web Information Client

Proficy Plant AppsModules

Historian

HMI / SCADA Other

OtherCtrls & I/O

PLM/EAMPAM/RM&DAnd Other

Other

Other

GE Fanuc Solutions

An Open & Layered system architecture

Complete, open offering works in harmony with all GE Fanuc products or when integrating other products

– Preserves customers’ existing automation infrastructure

– Reduces system costs

Non-intrusive to controls layer systems


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Proficy Plant Apps gives you…A single, integrated data model for all applications

All applications utilize the same data model

– No customer database development

All installations utilize the same data model

– Reusable from plant to plant

Scalable implementations– Small to large-scale

systems– Few to many Proficy

Plant Applications


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Plant Apps’ ability to interpret happenings on the shop floor and translate them into specific, meaningful information delivers value to many different users throughout your organization.


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VP Manufacturing

• Control and visibility to all aspects production for all plants globally

• Use common KPIs to benchmark plants to drive performance improvement & productivity

• Control and visibility to all aspects production for all plants globally

• Use common KPIs to benchmark plants to drive performance improvement & productivity

Production and Line

Supervisors

LeanSixSigma

& Quality Teams

•Reduce & track scrap thru early warning• Selectively handle quarantine of finished goods thru multilevel genealogy access•Foundation for CI projects

•Reduce & track scrap thru early warning• Selectively handle quarantine of finished goods thru multilevel genealogy access•Foundation for CI projects

•Production & Quality reporting by shift and crew•Production & process data

•Production & Quality reporting by shift and crew•Production & process data

Value across your organization


Finance /Controller Maintenan

ce

IT Team (Plant & Corp) Plant

Management

• Control and visibility to all aspects of production environment

• Increase collaboration between departments

• Reduce and better control of costs (mfg, labor, maintenance, & inventory)

• Control and visibility to all aspects of production environment

• Increase collaboration between departments

• Reduce and better control of costs (mfg, labor, maintenance, & inventory)

• Increase user satisfaction

• Application consolidation and re-plat-forming

• Integrated production environment with enterprise

• Supportable and maintainable solution

• Decrease shadow IT projects

• Increase user satisfaction

• Application consolidation and re-plat-forming

• Integrated production environment with enterprise

• Supportable and maintainable solution

• Decrease shadow IT projects

• Use collected information to invest on high ROI CAP X projects

• Measure results of CAP X projects

• Use collected information to invest on high ROI CAP X projects

• Measure results of CAP X projects

•Use MTTR & MTBF to improve operations•Top ten hitter report on demand•Foundation for TPM initiatives

•Use MTTR & MTBF to improve operations•Top ten hitter report on demand•Foundation for TPM initiatives


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Plant Apps’ modular design and scaleable architecture allow users to tailor a solution to their environment and easily expand as needed.

Let’s walk through the modules…


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Proficy Architecture


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Proficy Plant Applications Architecture

Business Operations (ERP)SAP ORACLEPRISMMFG-Pro JDE IFS

Plant Operations

Real Time Data Historian

PLC DCS SCADA Wi-Fi RF-IDBar Code

InterfaceHistorians with

Plant FloorData Sources

Enterprise Systems

IntegrationISA 95 B2MML,

ODBC

Proficy OSI-PI IP21 HPD InSQL SQL

Proficy Plant Applications

MES &Production Management


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Plant Operations



InterfaceHistorians with

Plant FloorData Sources

Enterprise Systems

IntegrationISA 95 B2MML,

ODBC




Business Operations (SAP)PP-PI MM QM PM XmII APO


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Business Operations

Plant Operations




Execution Model

Defines:Business Rules

That Control The Flow Of

Materials Through The Plant

Event Model

Relates:Plant Floor

Eventsto the Plant

Model(by Time &

Event)

Plant Model

Defines:Plant

Equipment & How it’s

Organized

Product Model

Defines:Materials, Products,

Specifications, Recipes &

Procedures


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Business Operations (ERP)

Event Model

Plant Model

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Product Model

Execution Model

Plant Operations


Overall Equipment

Effectiveness for

Plant & Equipment

(OEE)In-Process &Finished Product

Quality Control,SPC/SQC

ProductionScheduling,

Material Tracking &

ConsumptionBatch

Execution, Recipe &

Specification Management

Batch Process Optimization& Analysis

A Number of Manual or

Machine Steps with a Logical Execution Path

Use Of Real-Time

Information for Predictive & Preventative

Maint. Real-TimeOperating Reports &

Management Level Reporting


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Business Operations (SAP)Batch Process Optimization& Analysis

Use Of Real-Time

Information for Predictive & Preventative

Maint. Real-TimeOperating Reports &

Management Level Reporting

In-Process &Finished Product

Quality Control,SPC/SQC

Overall Equipment

Effectiveness for

Plant & Equipment

(OEE)

ProductionScheduling,

Material Tracking &

ConsumptionBatch

Execution, Recipe &

Specification Management

Event Model

Plant Model

Eff

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Product Model

Execution Model

PLC DCS SCADA WiFi RF-IDBar Code

SAP ORACLEPRISMMFG-Pro JDE IFS

PP-PI MM QM PM XmII APO

Plant Operations




A Number of Manual or

Machine Steps with a Logical Execution Path

Ba

tch

Ex

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Ba

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An

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Business Operations (SAP)

Event Model

Plant Model

Eff

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Product Model

Execution Model

PLC DCS SCADA WiFi RF-IDBar Code

SAP ORACLEPRISMMFG-Pro JDE IFS

PP-PI MM QM PM XmII APO

Plant Operations




Data

Mart

Rep

ort

ing

Port

al

MS

Excel

Re

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Proficy Plant Apps

• Application Modules:– Efficiency Management– Quality Management– Production Management– Batch Management

A suite of powerful application modules that allows manufacturersto make business sense out of plant data in real-time.


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Proficy Efficiency

Track and monitor production and your manufacturing efficiency

• Track downtime, waste, production counts, user-defined events, OEE (Overall Equipment Effectiveness)

• Automatically or manually associate events with a specific cause on a real-time basis

Analyze production history and solve root cause problems

• Summarize and analyze data in the context of production events such as by equipment, by product, or by personnel (hour, shift and day) for improvement

• Correlate events and reasons to actual production operations (historical process data)

• Capture Actions taken to resolve issues from operators to have complete picture

Support real-time decision-making with web-based dashboards and reports.• Web-based analysis and visualization – real-time decisions• Powerful extensions to Microsoft Excel• Report scheduling and viewing capabilities• Detailed Production data for long term analysis


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The Value of Efficiency ManagementOptimize Utilization of plant equipment, people, and materials through a comprehensive manufacturing driven KPI’s

• Efficiency/OEE identifies the true potential of existing plant and machinery.

• Efficiency/OEE helps understand link between money and machines!!• Efficiency/OEE can track the performance of investments from

commissioning into steady state of operation.

Identify and Improve areas that are causing operational inefficiencies

• Minimize scheduled and unscheduled downtime events• Reduce waste and rework• Improve machine run-time effectiveness• Efficiency/OEE measure can be used to make sure that the

performance of the equipment satisfies the original business case for purchase.

Make data-driven decisions on best practices, capital expenditures, and process improvement initiatives

• Gain insight into production operations by shift, equipment or product• Evaluate operations over any period of time• Efficiency/OEE can be used to save companies from making

inappropriate purchases, and help them focus on improving the performance of machinery they already own.

• Link capital expenditures to expected profitability improvements


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Efficiency example


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Proficy Quality

Control your product quality and improve your process capability • Apply product specifications and recipes to production

processes• Create intelligent alarms for abnormal conditions• Integrate with Production Management

Ensure that only quality materials are consumed Ensure only quality products are shipped

Analyze data to solve root cause problems • Correlate quality data from across the process • Integrate process data and laboratory data• Capture, summarize and analyze manufacturing and

quality data in the context of production events such as batch, lot, item, serial number, time period and more

• Develop reports and dashboards for real-time decision making

Meet Regulatory Requirements • Secure Audited Product Specification Management• Secure Audited Data Management • Configurable Electronic Signature Capabilities


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The Value of Quality Management

Improve first pass quality • Improve real-time visibility and alarming• Reduce rejects / downgrades• Reduce customer complaints / returns• Avoid major quality “upsets”• Avoid and/or contain costly product recalls

Lower the cost of quality• Verify quality standards of raw materials and suppliers• Reduce effort and time to collect quality data• Reduce effort to research complaints and quality “upsets”

Optimize your processes • Integrate process data and quality data in real-time

Increase manufacturing agility• Automate New Product Introduction (NPI) processed down to plant floor• Reduce time-to-market for new products


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Proficy ProductionControl your Production Schedule and Optimize Material Flow in real-time

• Ideal touch point for ERP Integration• Track progress against production schedules• View Production and Inventory Levels in real-time • Enable intelligent alarming

schedule deviation, inventory levels, and raw material consumption.• Control material staging and the flow of in-process products

based on product specific routings, inventory, quality, and process information

Provide Comprehensive Product Genealogy Tracking• Track “as-built” specifications, materials, quality, routing, and process data. • Enable upstream and downstream traceability across any process type

Continuous, Discrete, Batch, Hybrid

Provide Comprehensive Product Genealogy Tracking• Track “as-built” specifications, materials, quality, routing, and process data. • Enable upstream and downstream traceability across any process type

Continuous, Discrete, Batch, Hybrid

Support real-time decision-making with web-based dashboards and reports.

• Provide comprehensive view of schedule, genealogy, specifications, and materials over the web

• Detailed data available for long term analysis Birth History Product Recall


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Improve Agility and Predictability Of Production Processes• Integrate quality, materials, inventory, and schedules

• Respond to changing production conditions in real-time with intelligent alarming

• Close loop with control systems for automated product changeover, routing, and production reporting

Lower Manufacturing Costs• Provide real-time visibility to schedules and material requirements

• Reduce material consumption

• Reduce order overruns and shortages

• Reduce raw material and in-process inventory requirements

Reduce Latency Between Plant Systems and Business Systems• Integrate Production Schedule, BOM, and Quality Specifications with Business Systems

• Close loop with Business Systems to improve responsiveness to production order changes and special customer requests

• Communicate production status to Business Systems in real-time

Prevent Customer Complaints and Contain Product Recalls• Prevent sub-standard raw materials from being consumed

• Prevent sub-standard products from being shipped

• Respond to customer complaints quickly and reliably

• Limit the scope of recalls with detailed and accurate genealogy data

The Value of Production Management


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Proficy Batch Analysis• Track Independent Batch as Prescribed By ISA

S88 Standards– Operation– Procedure– Phase

• Extract and Analyze Relevant data in context– Context of Crew, Batch, Schedule– Context of Extended core Proficy Solutions

– Efficiency, Quality, Production– Specifications

• Visualize and Report on results– Reports

– Summary, Batch Time Line– Trending and Analysis

– Cycle Time Analysis, Batch Trending / Comparisons

• Interfaces with commercially available S88 Batch Execution systems


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Understand and control batch variances• Integrate quality, materials, inventory, and schedules• Respond to changing production conditions in real-time with intelligent alarming• Close loop with control systems for automated product changeover, routing, and production

reporting

Lower Manufacturing Costs• Provide real-time visibility to schedules and material requirements• Reduce material consumption• Reduce order overruns and shortages• Reduce raw material and in-process inventory requirements

Reduce reporting administration time • Powerful analytical tools, reports, and a generic interface to several commercially available

batch execution systems. • Extend typical batch execution systems with powerful off-the-shelf reporting and analysis

capabilities

Prevent Customer Complaints and Contain Product Recalls• Prevent sub-standard raw materials from being consumed• Prevent sub-standard products from being shipped• Respond to customer complaints quickly and reliably • Limit the scope of recalls with detailed and accurate genealogy data

The Value of batch analysis


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Plant ManagerProduction Finance QualityMaterialsLean/6 SigmaOperator Maintenance

Plant Reporting/Intelligence – Compliance – Continuous Improvement – Supply Chain Integration/EAI

Plant Applications

Maintenance Gateway

Data MartEnterpriseConnector

Plant ApplicationsThe Foundation for Enterprise Application Solutions

2 GE Fanuc ©2008 GE Fanuc Intelligent Platforms All Rights Reserved Agenda Proficy Plant...

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