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© Siemens AG 2015 All rights reserved.
Page 1
Company characteristics
SIDAT is one of the significant Czech companies
• (= System Integration & Deliveries of Automation Technology)
• Ltd. company (100% shared by Czech nationals)
• Automation of production processes and technologies
• Production information systems
mainly in the following branches
• Food & Beverages
• Production of building materials
• Oil & Gas industry
• Others (e.g. automotive, waste treatment, etc.)
Established: 1990
Number of employees: 80
© Siemens AG 2015 All rights reserved.
Page 2
SIDAT solutions and platforms
Industrial automation Industrial informatics
Real-time data archiving and processing
Energy monitoring and management
Labelling systems
OEE and maintenance monitoring and management
Control systems for mixing and dosing (solid and liquid)
Control systems for transport (solid and liquid)
Control systems for production and manipulation
machines
Control systems for compressors and cooling
Safety control systems
Integration of control systems and MIS/MES
LIMS
Design Production SW Installation Commissioning Training Support
© Siemens AG 2015 All rights reserved.
Page 3
25 years on the world market
1990 1995 2000 2005 2010
Oil & gas industry
Waste-treatment facilities
Production of food and beverage
Production of building materials
PLC + HMI/SCADA
NET
DCS
MIS
RTDB
Automotive industry
Activity fields
Branches
Chemical and pharmaceutical industry
Handling of nuclear fuel
Automation
Informatics
MES
Today
© Siemens AG 2015 All rights reserved.
Page 4
Training centre
Standard trainings, specific trainings, workshops
• Automation: PLC, HMI, communication...
• Standard Siemens courses (Siemens authorized training centre) concluded by issuing the
respective certificate – see www.sidat.cz
• Specific courses for customer specific needs.
• The training centre is entitled to provide also
education sponsored by EU funds.
• Courses may also be conducted outside of SIDAT
premises.
• Various languages (CZE, ENG, GER, RUS, ESP...).
• More than 3000 participants trained.
© Siemens AG 2015 All rights reserved.
Page 5
SIDAT solutions and platforms
Industrial automation Industrial informatics
Real-time data archiving and processing
Energy monitoring and management
Labelling systems
OEE and maintenance monitoring and management
Control systems for mixing and dosing (solid and liquid)
Control systems for transport (solid and liquid)
Control systems for production and manipulation
machines
Control systems for compressors and cooling
Safety control systems
Integration of control systems and MIS/MES
LIMS
Design Production SW Installation Commissioning Training Support
siemens.com/answers Restricted © Siemens AG 2013 All rights reserved.
Siemens AG, Digital Factory – Industry Software
SIMATIC IT Unilab
Your Next Generation LIMS
© Siemens AG 2015 All rights reserved.
Page 7
Digital Enterprise Realization
• R&D and Manufacturing
Operations Management brings
Realization to the Innovation
Platform
• Reducing Time-to-Market is the
combination of an efficient product
design and optimized
manufacturing
• Industry Software allows customers
to put their best laid plans to
practice :
• Execute product development
• Execute production
• Enforce quality
• Reduce waste
• Provide transparency
PLM
Core
Product
Formulation
Manufacturing
Engineering
Manufacturing
Execution
SCADA
Quality Mgt
Manufa
ctu
ring
Inte
lligence
The Customer’s Digital Enterprise
© Siemens AG 2015 All rights reserved.
Page 8
Siemens Industry Software Portfolio for Hybrid Industries
Quality offering with SIMATIC IT Unilab
ERP
Automation
Teamcenter
Electronic Lab
Notebook
Recipe
Transformation
Specification Mgt
Lab Exp.
LIMS
Formula Workbench General Recipe Mgt Dashboards
Scorecards
Analytics
Bench-marking
Reports Process Mgt &
Execution
Inventory Mgt &
Traceability
Quality Mgt
Asset Mgt &
Maintenance
Orders Mgt &
Scheduling Site Recipe Mgt
Primary Process Storage & Transfers Filling & Packaging
Ideation Planning Feasbility
Purchasing
Accounting
Planning
Finance
SIM
AT
IC I
T
Pro
du
cti
on
Su
ite
SIM
AT
IC I
T
R&
D S
uit
e
SIMATIC IT
Intelligence Suite Requirements Portfolio
© Siemens AG 2015 All rights reserved.
Page 10
ISA 95 In-line, at-line and off-line testing definitions
SIMATIC IT Unilab takes care of At-line and Off-line inspections
In-line At-line Off-line
Sampling No sample taking Sample taking Sample taking
Frequency
of quality control
Continuous measurement From every 15 minutes
to a few times per shift
From a few times per shift
to once a year
Level of implementation Plant level Plant level Plant level and/or enterprise level
Where Measurement point
at production line
Workstation at the production line Laboratory
Performed by Automatic Production operator or lab
technician
Lab technician
Exception handling by Shift leader
Production manager
Shift leader
Lab and/or production manager
Lab and/or production manager
Corrective action
taken when
During production During or after production After production
© Siemens AG 2015 All rights reserved.
Page 12
The Answer ...
SIMATIC IT Unilab 7
Single Page
Application
Responsive Web
Design
© Siemens AG 2015 All rights reserved.
Page 13
SIMATIC IT Unilab
User Interface & User Experience
New, state of the art
look & feel
Integrating applications in a
single Web environment
Designed for web, multiple
devices, browsers &
platforms
Support of multi touch and
gestures
Created by designers
Future proof to SCADA &
MES UI integration
© Siemens AG 2015 All rights reserved.
Page 15
SIMATIC IT Unilab
Powerful functionality at your fingertips
Trending & Analysis Sample Management
Request Handling Work Lists
© Siemens AG 2015 All rights reserved.
Page 16
Use Case – Lab Management
Reports and Graphs
Sample
overview
Management
reports
© Siemens AG 2015 All rights reserved.
Page 17
SIMATIC IT Unilab
Business Benefits
SIMATIC IT Unilab provides competitive advantages and cost savings within quality
management and production
Worklists and easy configuration – improve lab efficiency
Integration between lab and production – shorter lead-time for samples and analyses
Lab automation and instrument connection – reduce administrative tasks and errors
Immediate feedback on quality exceptions – reduce scrap and rework
Workflow management – enforce QA/QC procedures throughout the entire organization
Communication of quality data – unified overview of all quality measures
Enterprise architecture for centralized LIMS – accommodates both QC & R&D labs
Standard and modular software product – easy roll-outs to other plants, reduced TCO
Audit trail and flexible reporting – reduced cost of regulatory compliance
What is the cost of “Non-Quality”?
© Siemens AG 2015 All rights reserved.
Page 18
SIMATIC IT Unilab
Proven solution
Industry branches
• Food & Beverage
• CPG
• Chemicals
• Pharma & Biotech
• Metals & Mining
• ...
Laboratory types
• Production (QC)
• Environmental
• Development
• Service
• Regulated
• Water treatment
• …
Thousands of users
• From single-site version with a
few users
• To multi-site multi-language
licenses for Fortune 500
companies with thousands of
users across 50+ sites
© Siemens AG 2015 All rights reserved.
Page 19
SIMATIC IT Unilab
Customers in Food & Beverage and CPG
siemens.com/answers © Siemens AG 2015 All rights reserved.
SIMATIC IT
Line Monitoring System
siemens.com/simatic-it
© Siemens AG 2015 All rights reserved.
Page 21
Overall Equipment Effectiveness (OEE) is a Key First Step to Continuous
Improvement
• The KPIs generated by an OEE package
deliver a wealth of actionable information
with minimal effort
Machine Performance Quality Rate Machine Availability
Good indication of resource
scheduling & logistics in the
plant
Good indication of how well
maintenance & operational
procedures are coordinated
Good indicator of how well
operational & quality
procedures are coordinated
© Siemens AG 2015 All rights reserved.
Page 22
By Measuring Overall Equipment Effectiveness
Machine Performance Quality Rate Machine Availability
Total Production Target Production Scrap Produced Total Production Operating Time Planned
Production Time
Good Counter Bad Counter Status Time Model Reason Codes Production
Context
© Siemens AG 2015 All rights reserved.
Page 23
By Measuring Overall Equipment Effectiveness
Meantim
e
Betw
een
Failu
res
Meantim
e to
Repair
Meantim
e
Betw
een
Changeo
vers
Changeo
ver
Dura
tion
Meantim
e
Betw
een
Mate
rial S
top
s
Tim
e lost D
ue to
Mate
rial
Sto
ppages
Spee
d lost due
to U
nd
er
Utiliz
ation
Guilt
y M
achin
e
Fre
quencie
s
Good Counter Bad Counter Status Time Model Reason Codes Production
Context
Machine Performance Quality Rate Machine Availability
Total Production Target Production Scrap Produced Total Production Operating Time Planned
Production Time
© Siemens AG 2015 All rights reserved.
Page 24
Scalability over Functional Scope
LMS
Equipment scalability
Multiple users
Station 1 Station 2 Station ... n
Equipment 10 Equipment 20 Equipment n Equipment 50 Equipment 100 ....
Equipment scalability SIMATIC IT LMS 2.2 licensing starts from 5 Equipment items up to 3.000
Equipment 1 .... Equipment 2 Equipment 5
SIMATIC IT
Reporting Framework
SIMATIC
WinCC SIMATIC IT LMS
PLC Interface
© Siemens AG 2015 All rights reserved.
Page 25
Scalability on Visibility Levels and
Data Management
Scalability:
from Line-Level LMS Reporting ... Scalability:
... up to Plant-Level Integrated MES Reporting ...
Scalability:
... up to Enterprise-Level Manufacturing Intelligence
LMS on OEE/Downtime
and Energy
Real Time Line
Reporting
Manufacturing
Intelligence
Global
Dashboards
and
Scorecards
Equipment 1 .... Equipment 2 Equipment n
SIMATIC IT
Reporting Framework
SIMATIC
WinCC SIMATIC IT LMS
PLC Interface
MES
Integrated Reporting
Reporting
on Multiple
ISA 95
Functionality
ERP Interface
SIMATIC IT Platform
Load-In Warehouse
Mgt
Primary
Production Mgt
Tank Farm
Mgt
Secondary
Production Mgt
SIT Reporting
Framework
Integrated
Quality Mgt
© Siemens AG 2015 All rights reserved.
Page 26
Manufacturing Information System:
Main Functions
Visual representation of manufacturing plant status in real time
(WinCC 7.3SE and WinCC Web Navigator)
Fat and web clients are supported for SCADA/MIS information
OEE KPIs for individual machines or larger lines
Shift Calendar integration
Reporting functionalities done using Microsoft standard products
Key Benefits:
Increase production plant availability
View the status of the entire production plant
Identify weak spots in the production system
Availability of detailed pre configured graphical pages, KPI’s and reports about the production plant
Dramatically reduce effort and risks in MIS projects
© Siemens AG 2015 All rights reserved.
Page 27
Line monitoring and controlling – with CAB Portal screens
Main Functionalities:
Calculation of standard and custom KPIs
Downtime Management and analysis support
Integration with LMS Message management
Key Benefits:
Decision support system based on real time information
Operational cost improvement thanks to high plant reliability,
equipment utilization optimization
Improved ROI
© Siemens AG 2015 All rights reserved.
Page 28
Easy and flexible engineering phases
Overall Equipment Effectiveness:
Configuration
Equipment Model Definition
Time Model Declaration
Machine State List
States & Levels
Reason Tree
Counters / Design Speed
Standard and Custom KPIs algorithms
Equipment Attributes Management:
Counters Acquisition
© Siemens AG 2015 All rights reserved.
Page 29
Production monitoring with dedicated graphical components
Overall Equipment Effectiveness:
Monitoring and Management
Out of the box web operator screens
Touch Screen interface
Short term performance check
State declaration
Unknown stoppage justification
Production control compared with targets and actual state
visualization
Plant / Line / Equipment navigation
Equipment runtime status
© Siemens AG 2015 All rights reserved.
Page 30
A contextualized analysis against manufacturing events
Overall Equipment Effectiveness:
Analysis
Downtime Management
detailed information about equipment states can be
displayed and updated
Downtime Analysis
exploring the causes that have generated a production
breakdown
Production Counter Analysis
current production can be compared with theoretical
production
On-the-fly OEE calculation
line or equipment OEE calculation for hour, shift, or daily
analysis
© Siemens AG 2015 All rights reserved.
Page 31
Reporting Framework:
Data Model views
Scalability:
from Line-Level LMS Reporting ...
Scalability:
... up to Plant-Level Integrated MES Reporting ... Personalized Reports for all users in the Plant
The Report Parts, already organized
and structured in specific entities
(Downtime info, algorithm, shifts, etc.), can
be used to create custom reports with a
standard Drag & Drop action and quickly
parameterized
Different levels( Production Manager,
Maintenance manager, Plant Managers, etc.)
can easily generate different reports
based on different analysis
requirements
© Siemens AG 2015 All rights reserved.
Page 32
Manufacturing Intelligence
Scorecards & Dashboards
Functionality:
Collects data from the plant in real-time and integrates it with
business and financials
KPI calculation, rollup and drilldown
Covers all portfolio elements (Production, Quality, Assets, Inventory,
Utilities, etc)
Provides several levels of reporting:
Analytics
Excel Export
Operators, team leaders,
production managers
Business Benefits
Scalability from the Single Site to the Enterprise
Access to corporate data, reports and KPIs via various devices
Enables Continuous Improvement in the plant
Provides rollup and benchmarking capabilities
SIMATIC IT Intelligence Suite provides to End Users simple
but powerful views on their domain of responsibility
© Siemens AG 2015 All rights reserved.
Page 33
Alarms & Production Messages:
Management and Monitoring
Key Benefits:
Empowered root cause analysis extended to equipment subcomponents
Centralized Alarms Reporting
Easily configuration of machine state calculation logics
Association of Alarms & Production Messages with
machines status
Support for root cause analysis
Down Time justification extended to root cause alarm
Graphical user interface for Alarm statistical analysis
Centralized monitoring of active Alarms