Wonderware has joined forces with EmsPT to bring you a webinar that discusses how to make more of your Historian installation and DRIVE a Programme of Continuous Improvement. Wonderware recently surveyed a select number of Historian customers and there were some common themes that emerged. It is apparent that users want to: Understand their production process by using historical data to analyse process and production issues DRIVE Continuous Improvement activities and obtain data for production KPI's Expand their system to drive performance improvements Together Wonderware and EmsPT have already worked with many Wonderware Historian customers to ensure their goals were fully understood and beneficial use was realised. We would like to share these advantages of optimising a Historian installation to DRIVE Continuous Improvements with you. Webinar Content: Summary of Wonderware Customer Research The need for Manufacturing Information to enable Continuous Improvement Expanding on your Wonderware Historian Investment Who uses Manufacturing Information? Delivering Manufacturing Information for enhanced: -Efficiency -KPI's -Quality -Schedule Adherence -Yield -OEE A proven Methodology for Success
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1. Learning from History Unlock your Performance Potential
Richard Stone Lean Manufacturing Manager
2. Historian customer research 2 types of Historian user
Process trends, archives, reports (80%) Process trends are vital to
many companies for trouble shooting, batch production analysis, and
many other areas of insight Also Business benefits reporting KPI
(20%), doing more than trending, validation of process parameters
etc We wish to explore the second groups usage and discuss what is
required to deliver more from Historian data.
3. Quoted...1. The Historian is currently logging every bit of
PLC information from the 4 lines it is in operation on the data it
captures includes.. Time, Operators, Temps, Pressures, Speeds,
Alarms etc2. Historian is used to provide short term historical
data to the InTouch screens for Trends as the built in InTouch
trends are not capable of handling the volume of data, the solution
collects all data from 3 lines using InTouch the data includes...
Temps, Pressures, Signals, Speeds, Motors, Alarms3. currently
capture SPC data at the SCADA level identified through the Lasers
on the line which determine Diameter of the product (due to set
standards from the recipe) but this data is not looked at unless a
Non Conformance is raised by a customer after delivery, the QA team
may require more information...
4. And quoted...1. Historian is used in the Injection Moulding
department. It collects data from the drying process/injection
process/part counting process. It also collects data from resin
supply/handling system2. It is collecting information from 31
machines. We could/would not run without Historian. We would have
no reporting facility thus no KPI data. We would be producing
product but would have no method of recording how we were doing -
which is how we are compared to our European sister plants. We
would also be running blind - which would be going back to how we
ran 5+ years ago. We would also struggle to carry out root cause
analysis of complaints.3. If correctly deployed, Historian is a
veritable gold mine of information that can be very easily
accessed. If you have got used to Historian and it was taken away,
you could live without it but it would be like living without two
or three of your fingers
5. And quoted...1. It would make the job more laborious for
those that use it. At present faults can be identified from the
office. They would have to go out on to the plant to investigate
issues.2. Was purchased to validate the process in real-time they
use it as a validation aid to ensure that their operators have
processed a batch as intended3. ... dont directly report from
Historian, they export information into an excel spreadsheet and
use this information with data from other sources to compile a
production report.4. one practical example of how Historian has
helped is that using it they were able to notice that when the CHP
part of the plant was drawing water other processes within the
plant began to slow down. Without the Historian they never would
have known this but due to it being highlighted they installed an
extra water tank and this helped them make considerable performance
gains....
6. Where does Historian fit in thescheme?
http://www.wonderware.co.uk/products-and-technology/
7. The shape of the problem
8. Beyond the process The feedback tells us that our customers
have had significant benefit from their Historians, understanding
Process Data The need to understand Manufacturing Challenges
9. The need to deliver ManufacturingInformation Evidence that
Historian data does provide data for improvements for the
Engineers. The curve of improvements Request for information
Operational & Production Management It is the Engineers that
know what is going on. But others are reliant on engineering for
other production KPIs
10. Developing your investment Manufacturing Operational
Management (MOM) Information How is this achieved ? Your investment
in Historian could deliver more when used with associated
technologies Without accurate MOM information: Ask 20 people get 20
answers Needs to be in real-time to allow the shift to react It
needs to be in the right context for the right people Its also
important to understand the ROI of any investment current and
future.
11. Who uses MOM Information ?All your internal customers
Operation Manager Production Manager CI Manager Quality Manager
Plant Manager Works Manager Engineering Manager Business Unit
Manager How are we doing NOW !!
12. Delivering MOM InformationLooking around the room
13. Delivering MOM InformationLooking around the room ?Looking
at your data from the factory ?The same data for different uses:
Manufacturing Efficiency Quality OEE Manufacturing KPIs Schedule
Adherence Yield Production Progress Utilisation EnergyMOM
information delivers information that is used as a measurementand
helps maintain sustainability
14. Integrating your Historian System Information /
Interoperability Real-Time Manufacturing Operations Management
VisibilityDevices, Applications, Enterprise Integration Empowering
All Roles in the Plant ERP (SAP, Oracle, Microsoft..) Enterprise
Wonderware MES & EMI Software Solutions Integration CEM
Intelligence Database Energy Applications Asset Operations
Performance Quality Batch Asset Monitoring Management Wonderware
System Platform Wonderware Wonderware Wonderware Application
Historian Information Server Server LIM Systems Device Integration
Devices
15. Manufacturing Performance Software needs to be Proven
Mature a Future Historian is proven for logging data against a time
line Users need to be able to be self sufficient: Complex reports
and queries from non-process data Mixed with information such as
shifts, batch number, product type Interactive drill down reports
Root cause analysis Historian is major component of System Platform
which is part of a Manufacturing Operations Management solution An
example - Wonderware Performance Module provides: Real time KPIs
Reports Operator / Supervisor interfaces Real-time data collection
Production Dashboards Management KPIs Links to Scheduling
Systems
16. Empowering OperatorsDaily & Shift Focus Real - Time
Daily Production Plans Line bottle neck identification Shift OEE
information Product and Batch performance Shift Downtimes
Integration with planning systems Daily KPI Displays Empower
operational staff
17. Online meetings Online Production Meeting Point Hourly
Short Interval Control Operations Maintenance point Driving on time
delivery Promotes operational collaboration Real time
management
18. A picture of ?
19. Plant Intelligence
20. Hierarchy Of Information Solutions Intelligence HMI Reports
Server Information ActiveFactory / Historian Client Multi-site Site
InTouch & Build on your existing InTouch & System
information infrastructure Historian Platform Multi-node
InTouchSingle-node InTouch
21. Wonderware Intelligence For your multi-site or
multi-database deployments Build KPIs (Key Performance Indicators)
to view your critical manufacturing metrics in near real-time Site
Leverage data that exists in your automation, MES, business
systems, or legacy applications View rich dashboards with drill
down capabilities into analytics and source data for better cause
and effect analysis Multi-site Dashboards Analytics Reports
22. Culture & Change We are all involved in change and
effected by culture Focus on the Positives Important to use proven
Methodology Software Products alone dont deliver they must be
supported to deliver the value identified in by a ROI statement.
Goals ROI Success Training Enable DRIVE - emsPT
23. A Proven Methodology forSuccess At emsPT we use DRIVE
Starts with a Discovery phase and stays engaged to deliver the
manufacturing benefits. Understanding your challenges and what
success looks like A Proven Program
24. Delivering Success of our customersGoals Efficiency Easy
access to the information To provide a day-to-day performance
measure To be able to identify 3% production efficiency gains To
understand our Downtimes on our whole site as this is affecting
overall OEE A Solution offering accurate understanding of
bottlenecks Providing real-time information to analyse downtimes
and causes Supporting efficiency improvement initiatives with
detailed reports & analysis Understanding the real effect of
minor stoppages Detecting reduced performance early, based on
historical data Capacity To be able to understand where we are
today with a view to looking at spare capacity available Support
the desire to improve asset utilisation (production downtime &
performance) and improve the OEE Releasing additional production
capacity through better understanding of our processes To see how
different products effect our line output and effect overall
capacity
25. Delivering Success of our customersGoals Time & Culture
Spend less time on paper work and more time in the production area.
A system that assists with the evolution of the productivity and
improvement culture within the business Allowing more effective
capital budget planning Daily Production KPIs & Quality Have
access to information to drive a CMMS solution. A system that is
used by the business To deploy a unified solution across all lines
to ensure like for like comparison and Benchmarking for
improvements in line with KPIs Improve Quality and ensure
consistency To understand how process variables effect production
quality Improvement of product yield Reduced energy
consumption
26. Delivering Success of our customersGoals MES Have an
ongoing initiative to work towards a paperless environment as
currently there is wasted time within the process to collate
information from the shop floor and feed this into SAP and other
systems Reduce your labour costs and improve quality of information
by moving towards full Automation & MES Standards Ability to
deliver the requirements of such a system, faster, more flexibly,
in a more standard way across sites A system that enables a lower
TCO (as there are ever-changing requirements) A solution that is
maintainable and configurable Using existing factory automation
infrastructure to reduce time and cost of implementation
27. Discovery & ROI
28. Discovery & ROIGoals Value Benefits SOE
29. Conclusion Many software products are a solution looking
for a problem Customers have been tempted to buy for instant result
and from the heart You need a combination of powerful products and
a proven methodology with demonstrable benefits
30. What next What next Call EmsPT Take a DRIVE Audit or
Workshop Register your interest in further events Bringing the
information to you Regional breakfast seminars
31. See you in 2011?Breakfast seminars coming to alocation near
you.1. DRIVE Manufacturing Performance2. DRIVE Manufacturing
Operations3. DRIVE the SAP ERP Connection
32. Powering intelligent plant decisions in real time.