Using Manufacturing Intelligence to Provide … Manufacturing Intelligence to Provide Information...

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Using Manufacturing Intelligence to Provide Information for Better Business Decisions

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Agenda

Mobility / Portability

FactoryTalk® VantagePoint EMI Solutions

Manufacturing Intelligence Overview

Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.PUBLICPUBLIC INFORMATION

Manufacturing Intelligence Defined

• Software used to bring a corporation’s production data together from many sources for the purpose of reporting, analysis, and visualization.

• As data is combined from multiple sources, it can be given context that will help users find what they need regardless of where it came from.

• The primary goal is to turn data into real knowledge (information), and drive business results based on that knowledge.

+ = IMPROVEDDecision Making


Manufacturing Landscape

4

Productivity

• Unplanned Downtime

• Equipment Efficiency / OEE

Quality & Operations

• Compliance Tracking

• Improved First Pass Quality /

Process Consistency

Network Convergence & Security

• Infrastructure Modernization

• Security & Anti-Virus / Anti-Tampering

Protection – Top Floor to Shop Floor

Virtualization & Thin Clients

• Reduction in Physical Servers

• Shop Floor Thin Clients

Common Issues

• Manual Data Collection

• Data consistency / Standardization

• Energy Usage / Optimization

Asset Management

• Preventative / Predictive Maintenance

• Reduced MTTR


Pro

du

cti

on

Pla

nt

Quality & Operations Maintenance

Plant Manager

Engineer Operator

Production Manager

Manufacturing IntelligenceDifferent Users, Different Needs, Right Time

Ma

ch

ine

Are

aL

ine

Define Corporate objectives &

observe actively

Costs, production output, overall

efficiency

Financial indicators, capacity

Production output,

achieving targets

Efficiency of production

Ways to improve production and yield

Minimize scrap & rework

Monitor process, help ensure

compliance

Reducing downtime

Preventive maintenance

Monitoring process to keep production running

Identifying problems in real time

Improvement activities

Keeping plant running

Predictive maintenance

Optimize asset availability

Document effects of

improvement activities


What Keeps You Up At Night?

Plant Management

Maintenance

Control Engineering

Quality

Machine Builder

Scheduling

Information Technology

Planning and Logistics

Operator

Knowledge Worker

How are wedoing against

plan?

How is my process

performing?

What is capacity for new order?

What is my equipment utilization?

What is my first pass quality?

What are downtime causes?


Would having all the information you need accessible from one portal help?


What if you could see this information on your tablet?

8


Would you want to drill down to see more?

9


FactoryTalk® VantagePoint EMIDelivering on the Connected Enterprise

1010

Performance/

OEEQuality

Systems/LIMS

Control

SystemsHMI/

Alarm/Events Historians

Other Systems/

Databases

VantagePoint EMI Portal Mobile ClientsSharePoint Portal

Maintenance

Mgmt Systems Energy HSE

Quality & OperationsPlant Manager Engineer Operator MaintenanceProduction Manager

MES


What results can you expect?Leveraging Manufacturing Intelligence

Actionable Information rather than data – Advanced portal, reporting, and analytics

– Increased productivity, revenue, and profit

Decrease in production costs– Better understand your process, then

optimize it

– Reduced materials, labor, and energy

Improved quality– Higher accuracy and agility via process

control

– Less waste and material losses

Decreased Total Cost of Ownership– Reduction in data collection and information

transformation (data prep)

– Increased utilization of fixed assets

Increased productivity by 10 percent in less than one year, resulting in more product at a lower price getting to the market for a competitive edge - CPG

With real-time visibility into batch comparisons and the capability to make inline corrections, throughput increased by 60%+ (from 4 batches every 12-14 hour shift to 5 batches in a 10 hour shift) - Brewery

720 man-hours saved annually in generation of regulatory reports. Estimated savings of one man-year in automation of billing process - Water Wastewater


FactoryTalk® VantagePoint EMIBuilding a Reporting and Analytics System

Connect to Data Sources

Seamlessly integrate to Rockwell Automation® devices

Connect to 3rd Party Sources via OPC / OPC-HDA

Build a Logical Model

Organize information so anyone can understand

Combines multiple data sources into a logical unit

References data directly from its source

Visualize & Analyze Data

Creating reporting content to meet customer needs

Leverage a variety of reporting options including Excel,

Advanced Trending tools and SSRS

View information in your favorite web browser including

mobile device support

Connect to Data

Build Logical

Model

Visualize Data


Start with Connecting To Data SourcesGood Data Is Key To Any Reporting System!

Define a Physical model

Identify what data is available

Connect to the Data Sources

Premier integration with Rockwell

Automation® devices and data

sources

Connect to 3rd Party Historians

Connect to 3rd Party Data Sources

via OPC-DA / OPC-HDA

Connect to databases

Data stays with the source

Reduced loading on network –

only accessed when needed

No replication of data necessary

Connect to Data

Build Logical

Model

Visualize Data


Premier Integration with FactoryTalk® products

FactoryTalk® Historian SE and ME for

monitoring process parameters

FactoryTalk® Metrics for machine

performance and downtime events

FactoryTalk® View SE for embedded reporting

and advanced trending

FactoryTalk® Alarm and Events for alarm reporting

FactoryTalk® EnergyMetrix™ for correlation of energy data

FactoryTalk® ProductionCentre® for Manufacturing Execution Systems (MES) connectivity

Logix and Process Solutions Automatically ‘discover’ known User-defined Data Type (UDT) structures in Logix

Predefined type packages & dashboards aligning with the PlantPAx® process library

3rd Party Plant Systems Connectivity (Real-time, Historian, Databases)

FactoryTalk® VantagePoint EMIWhat data sources can I connect to?


Building the Logical ModelI’ve connected to the data, now what?

Define organizational model

to present to users

Combines multiple data

sources into a logical unit

Typically includes

organizational hierarchy

References data directly from

its source

Present information in context

that anyone can understand

Connect to Data

Build Logical

Model

Visualize Data


Building a Logical ModelHow does it work?

17

UPM

Data Sources

KPIs, Reports, Applications

Chaos vs. Structure

By creating template data structures called 'models‘, you can organize data the way you want to use it, instead of by how it is stored or how it is exposed


Building a Logical ModelThe power of a Unified Production Model

Physical ModelConnect data sources

Logical ModelOrganize for Presentation


Visualizing the DataCreate meaningful content, role specific

Determine what information you want to

present to users

Add computation or analytics when data is

required in a different form

Build report content

Leverage built in capability to configure reporting

content

Use predefined or ad hoc Trending or XY Plots

Create Excel Reports leveraging built in capability

Create dashboard or advanced reports leveraging

reporting integration built into the model

Connect to Data

Build Logical

Model

Visualize Data


Many Reporting Tools Available Get the information you want, the way you want

20

Create a wide range of reports from dashboards to tabular data using SQL access to the model

VantagePoint Client Tools

Excel, Trend / XY Plotter, HTML

Dashboard Builder

Model-Based Report Elements

Charts & Grids

Status Indicators

SharePoint

Excel Services and Web Parts

VantagePoint Portal

SharePoint Portal


Excel - The Most Common Reporting ToolShared reports save time and money

Create powerful Excel reports

leveraging the VantagePoint

Excel Add-In

Retrieve data from any

connected data source (Real-time

or Historical values)

Calculate, analyze and format data

using Excel functionality

Publish reports for sharing /

collaborating with others

Restore Excel workbook from the

VantagePoint model to the same

or different PC for editing

Single version of the truth

Retrieve

Data From Any

Source

Calculate,

Analyze

and Format

Publish to the

VantagePoint

Portal


Advanced ReportingInformation access across the enterprise

22

Power to create a wide range of

enterprise reports from

dashboards to tabular data

Query the VantagePoint model

(UPM) and create reports using

Reporting Services (SSRS) or

other Business Intelligence tools

Author and publish reports to the

VantagePoint EMI Portal

Leverage the VantagePoint

model and create Report

templates for re-use

Reporting Services


Advanced Trending ToolReporting that empowers action

23

Create Trend templates for re-use

or ad-hoc trends to analyze

impromptu situations

Publish trends for sharing /


Diagnose and analyze data from

any connected data source

Powerful trend functionality – Pan,

zoom, stack and synchronize

Display multiple time period at the

same time to determine batch

variations

Pre-configured trends available in

Sample Reports


Why FactoryTalk VantagePoint?Trend Anywhere – PC, HMI, Tablet, or Phone

24

Create Trend templates for re-use

or ad-hoc trends to analyze

impromptu situations

Publish trends for sharing /


Diagnose and analyze data from

any connected data source

Powerful trend functionality – Pan,

zoom, stack and synchronize

Display multiple time period at the

same time to determine batch

variations


FactoryTalk® VantagePoint EnergyMonitor energy usage in production to save

Connect to a wide variety of Energy

Data sources and Power Monitors

Allen-Bradley® and 3rd Party

Power Monitors

Intelligent Motor Control

products

Other Energy Data Sources

Use the predefined type package to

create an energy specific logical

model.

Out of the box dashboards for

reporting.

Combine energy data with production

data to determine energy intensity and

drive actionable decisions.

Demand vs. consumption charts

48hr dashboard


Mobile Capabilities


FactoryTalk® VantagePoint KPIAutomatically Display & Share KPIs!

27

A native Windows 8.1 application that visually shows off your

FactoryTalk® VantagePoint® system in a simple but powerful way

It uses KPIs (Key Performance Indicators) to focus your attention

With your KPI’s you can:

Visually represent your data as a gauge,

bar graph or indicator

Collaborate by sending an e-mail with

instructions and attaching a KPI

Drill down to more specific detail

Leverage Live Tiles to provide continuous

updates by pinning a KPI on the Start page

See a map view of your KPI’s based on

geographic location

Available for download from the Microsoft Store


FactoryTalk® VantagePoint EMI MobilityProviding Information When and Where you need It

28

Mobile Landing Page

Responsive User Interface

Support for all major mobile platforms (iOS, Android)

Mobile Model Browser

Mobile Favorites – personalized, available on any device

Ad Hoc dashboard or trend creation

Mobile Content

Excel Reports, Advanced Reports

Trend, XY Plot charts

New Composer – Drag and Drop Dashboard Creation

Mobile First Design – Optimized for your browsing

experience


ComposerCreate Displays Quickly and Easily

29

Create new displays on a Tablet or PC Device

Drag and Drop Canvas for Display Creation

Library of Widgets (Gauges, Indicators, Trends, Text)

Save displays as favorites

Simplified single click functionality for display creation from mobile phones


FactoryTalk® VantagePointMobile Capabilities Demo

30


Eventing / NotificationReceive Notifications for Increased Efficiencies

An Event / Notification is comprised

of a Trigger and associated Actions

A Trigger can be

Any tag with historical values

Based on Time / Schedule

An Action can be (one or more)

Generate a published report

Send an e-mail

Attach a generated report

Embed an item value from the

model in body of message

Send SMS to a mobile phone

48% of Execs plan to reduce their total cost

of operations in the coming year

Are you ready?


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Using Manufacturing Intelligence to Provide … Manufacturing Intelligence to Provide Information...

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