AP11: Loram: Stays on Track with Mobile Data Collection and Reporting

®2014 Loram Maintenance of Way, All rights reserved Speed · Performance · Reliability

Loram: Stays on Track with Mobile Data Collection and Reporting

Eric Manninen

Principal Engineer Electrical


2. Machine Design System Layout

4. Rockwell Software Products Overview

5. FactoryTalk Solution Implementation

6. Loram’s VantagePoint Portal Demonstration

1. Loram Company Overview

3. Business Drivers for Information Enabled Solution

Agenda Overview

7. Related RSTechEd Sessions and QNA?


� Office Headquarters arelocated in Hamel, MN

� Employs over 850 people� Builds Leased and OEM

Machine Equipment� Outstanding Safety Record Provides Railway Maintenance Services

to Major Commercial Railroads and

Passenger Rail Markets across North

America and the World through:► Rail Grinders

► RailVacs

► Ditchers

► RailTrains

► Track Lifters

► Track Undercutters

► Rail Inspection Vehicles

► Shoulder Ballast Cleaners

Loram - Company Overview


For more information, visit us at:

www.loram.com

RailVac Light-Rail Grinder

Shoulder Ballast Cleaner Rail Grinder

Loram – Representative Machine Types


Loram Rail Grinder Video Demonstration


Physical Layout of typical Rail Grinder Machine

►Typical Length of 800 feet (244 m)

►43 Liter Diesel Engine Generator Set

►4920 KW Power Generated on Machine

►Power Bus draws up to 4000 Amps

►120 - 30 HP Grind Motors

►Travels up to 70 miles/hour (113 km/h)

►Operates at 20 miles/hour (32 km/h)

►10,300 Gallons of Diesel Fuel stored

►50,000 Gallons of Water stored on

Machine for Fire Suppression System

►26,400 feet (8047 m) of total wire used


Controls Layout of typical machine:RG400 Series Rail Grinder

►5 ControlLogix 1756-L73 Processors located in the Control Car & 4 Grind Cars

►5 ControlLogix (1756) Distributed Input/Output 17-Slot Remote Racks

►4 Flex (1794) Distributed Input/Output Remote Racks in the Control & Support Cars


Rail Grinder Rockwell System Architecture

Controller System

1,000,000 Controller Tags

145,000HMI Tags

2,100 Data Historian Tags

EtherNet/IP Network

HMI Communication

Data Collection

ControlNetNetwork

Distributed I/O

PLC Messaging

DeviceNetNetwork

Motor Protection


Machine Operators

– Crew is not technically trained with Automation skill-set

– Troubleshooting information from crew is not reliably Accurate

Mean Time to Repair

– Diagnosis of component failure was a slow multiple day process

– Failure analysis was not real-time capable

Historical Data Logging

– Legacy datalogs only stored locally on machine for 30 days

– Datalogs must be manually removed and sent to engineering

– Format is not easily readable, customizable, or searchable

Machine Diagnostic Logs

– Manual hand-written logs off Chart recorders, Metering, and Gauges

– Predictive Maintenance was not able to be implemented

Reliability Data and Remote Diagnostics are limited

– Most downtime situations require a remote site visit by field service personnel

Loram’s Business Challenges:Pre-Machine Historian implementation


Software Solution Needs OverviewWhat we needed to add to the architecture

EnterpriseData Historian

Server

Machine Historian Machine Historian Machine Historian Machine Historian Machine Historian

Web DashboardReporting Interfacefor Diverse Clients

Operations

Field Service

Controls

Engineering


Engineering and Controls:Information System Requirements

Engineering• Long-Term Corrective action planning for component failures

– Diagnosis of historical component product life

– Real-time failure analysis of current system

• Key Performance Indicator Data– Electronic Historical Datalogs provide machine performance data remotely

– Data that is easily accessible, sortable, and searchable in a variety of reports

– A system that can handle multiple months worth of local storage before upload

– Historical Trending verification of Machine Runtime Performance to Design

Controls• Controller Tag Data Reporting

– Electronic Historical Datalogs provide sequence of event data remotely

– Data is easily accessible, sortable, and searchable in a variety of reports

– Determination of root cause analysis of complex machine control faults

– Diagnostics reports determine operator, code, or machine component issues


Operations and Field Service:Information System Requirements

Operations

• Collection of Reliability Data and Remote Monitoring

– Electronic Datalogs of totalizer data on engine run hours, historical generator

loads, and other important KPIs.

– Predictive maintenance using remote diagnostics (MTTF)

• Historical Machine Efficiency available for comparison study

• Real-time feedback using Ad-Hoc tag reporting on current machine issues

Field Service

• Collection of Reliability Data and Remote Monitoring

– Machine Location tracking for travel and component replacement scheduling

– Real-time failure analysis through Web Portal

– Remote Diagnosis time reduction from 1 or 2 days to hours improving MTTR

– Remote Real-time failure analysis to replace field service travel

– Predictive Maintenance improvement to reduce downtime, save expensive

component failure, and decrease field service call volume needs


What Rockwell Software can be used to meet all these diverse application needs?

Factorytalk® Historian Site Edition

FactoryTalk® VantagePoint

Factorytalk® Historian Machine Edition


FactoryTalk Historian Machine EditionIn-rack On Machine Historian

Data collection at the machine level � More granular data

� Data at higher speeds

� Single machine historian

� Reduce network dependency

Improved Reliability� Solid-state data collection

� No computer / OS to maintain

� No moving parts

Remote data capture� Collect data where a computer is not

available or desired

Distributed / modular configuration� Configure one machine at a time


FactoryTalk Historian Site EditionEnterprise Level Historian Server

15

� Market Leading Historian Technology – Optimized time series data storage and retrieval

– Advance Calculations & Data Access capabilities

� Quick to Deploy and Easy to Own

– Integrated with Logix and FactoryTalk Technology

– Auto Discovery & Configuration

– Low Total Cost of Ownership

� Rich Set of Clients

– FactoryTalk View Site Edition – HMI trending integration with Historian

– VantagePoint EMI – bundled with Historian SE Package

� Distributed Historian Architecture

– Includes a 1756 chassis based Historian

– Data can be aggregated at the site and Enterprise level

– Seamless integration and common client access throughout the portfolio


� FactoryTalk VantagePoint a

powerful client interface for

Factorytalk Historian:

– Advanced trend tool

– XY Plotter

– Excel Add-in

– Advanced Dashboards

– Portal for thin client access

� Provides Client Access to

Historical, Real-time and Alarm

& Events Data. Aggregating

and Correlating Data Sources

with Common Reporting Tools

FactoryTalk VantagePointWeb-based Client Report Server


FactoryTalk VantagePoint:Notifications and Reporting on Mobile platforms

� Reporting available on mobile devices:

– Enterprise Reports

– Charts

– Status Indicators

– Grid Reports

� Report Notification

– Event Triggers Email or Text Message

� with Event Data

� with Pre-Built Report

Loram has tested Microsoft Surface Pro Tablets on machine to view data using the FT VantagePoint Mobile Client Application


Putting it all Together:Loram’s FactoryTalk Implementation

FactoryTalkHistorian Site Edition Server

FT Historian ME FT Historian ME FT Historian ME FT Historian ME FT Historian ME

FactoryTalkVantagePoint

Web Reporting Server

Operations

Field Service

Controls

Engineering

FT Historian ME Modules added to Rail Grinders

FactoryTalk Historian SE Server

Consolidates Historical Tag Data

FactoryTalk

VantagePoint

Turns Historical

Tag Data into

Actionable Reports

Each Group uses

Web Interface to

View their Unique

Report Tool Set


In-Rack Machine Historian logs data locally even when network is not available. Historian Server provides centralized long term data storage when network becomes available.

Historical Database

Collection Server

and Remote Data

Machine Edition

Historian ModuleIn-Rack Historian:

A FactoryTalk Historian Machine

Edition module collects data from a

PLC using compression and exception

algorithm storage. It collects data from

the controls system even when

network is not available.

Store and Forward:

Collected Data in Historian ME module

is Uploaded to FT Historian Site Edition

Server when network is available for

long-term storage and reporting.


FactoryTalk VantagePoint visualizes the data from the Historian Server and provides a Web Portal Reporting Interface

Reporting Server

The data collected by

FactoryTalk Historian System is

reported upon through Excel

and Trending Tools. These

reports are then published to

and visualized by FactoryTalk

VantagePoint Web Portal.

Reporting Clients

FactoryTalk VantagePoint makes

these reports available via

a web client dash-board

interface. Allowing a range

of reporting client user groups

to have their different data

wants and needs met.

FactoryTalkVantagePointWeb Reporting

Server

Operations

Field Service

Controls

Engineering

Web-based Dashboard

Reporting Server and

Client User Groups


History and Progress of this Rockwell Solution

GPS Dashboard Map for Machine Reporting and Tracking in 2011


What we learned and where we’re going

The Results of this solution implementation today:

– Faster troubleshooting resulting in:

• Shorter downtime

• Increased productivity

• Real-time diagnostics

– Able to decrease field service deployment of technicians

– Implement pro-active maintenance procedure timelines

• Before critical component failures occur

• Saving downtime and decreasing replacement costs

– Provide built-in warranty / legal protection through reporting of machine service record

We are continuing to invest in this technology with its proven results:

– We’ve increased our reporting tag usage as we have identified new KPI data

– Expanded our fleet install to retrofit existing machines and deploy on new start-ups

– We are designing this system into new machine types for the latest generation builds

– Exploring building a customer reporting cloud portal for future OEM machines

Productivity

Downtime


This unique GPS enabled google maps interface allows tracking of machine progress at a glance and drill-down to machine reports

Since implementing the first

machine historian in 2011,

more information-enabled

machines have been retro-

fitted or started up with this

solution and new machine

types plan to upgrade.

RG402 - 01/19/2012

RG403 - 02/27/2013

RG406 - 03/03/2013

RG405 - 04/04/2013

RG404 - 04/20/2013

RG401 - 06/11/2013

RG408 - 11/15/2013

RG410 - 05/05/2014

RG409 - Planned

RG411 - Future


Web Dashboard and Reporting DemonstrationLoram’s VantagePoint Web Portal Home Page

Each Machine has

a set of pre-built

reports based on

troubleshooting

experience

Each Machine has

a set of pre-built

reports based on

troubleshooting

experience


Loram’s Machine Reporting Dashboard

Machine Selection

Machine Overview

Grind Diagnostics

Power Generation

Traction Data

Dust Collection

Hydraulic System


Machine Efficiency Data Reports – Proactive Improvement Tracking and Comparison


Framing Historical Data into Event-based Reports provides Warranty / Legal Protection


Report Tracking Ambient Machine Temperatures can Correlate Potential Heat-related Component Failure


AdHoc Report created to Troubleshoot Machine and Solve Field Issue Remotely


Excel Report to Track Fuel Consumption


Related Sessions at RSTechEd 2014

Introduction to FactoryTalk VantagePoint 1 hour

You’ve heard about Manufacturing Intelligence, but do you have a good base understanding for

what the FactoryTalk VantagePoint EMI reporting and analytics product can really do? Come

take a quick tour of FactoryTalk VantagePoint EMI and learn more about what it has to offer.

FactoryTalk VantagePoint EMI: 50 Minutes to Value 1 hour

If you had 50 minutes, a computer running FactoryTalk VantagePoint, and an information

engineer, what could you do? In this session, the instructor will lead you through solution creation

on the fly. What types of ad-hoc analysis can you do? What types of content are easiest to

develop? Could you really do a full report-package solution with FactoryTalk VantagePoint in the

allotted time? Come see.

Mobility and Portability with Today’s Rockwell Software 1 hour

Bring your own device to work? Need to support mobile workers? Production and operations

management solutions today require various forms of access to their Manufacturing Intelligence

systems including mobile devices and web clients. In this session, see how Rockwell Software

can begin to accomplish these goals with access to FactoryTalk View Site Ediction, FactoryTalk

VantagePoint EMI and eventing on any mobile platform.


Related Sessions at RSTechEd 2014

Introduction to FactoryTalk Historian 1 hour

A distributed historian strategy produces strong advantages. Learn how FactoryTalk Historian

delivers a scalable, modular, synchronized methodology for collecting, maintaining and analyzing

process data at each level of manufacturing operations. New features and functionality will be

highlighted and compared to similar products in the marketplace.

FactoryTalk Historian Machine Edition 2 hours

Hands-on lab with FactoryTalk Historian Machine Edition covers typical configuration and data

collection in a ControlLogix chassis. The lab will cover the web configuration of the module,

simple web reporting, and the use of thick clients for reporting and analysis of the data in the

historian module. You will also learn about store and forward architecture between Historian

Machine Edition and Historian Site Edition and integration with Rockwell Software Studio 5000

through Add-On Profiles.

FactoryTalk Historian Siting Edition: Data Collection and Reporting Lab 2 hours

Introductory FactoryTalk Historian Site Edition lab covers basic elements of system confi

guration, data collection and reporting tools. Learn how FactoryTalk Historian Site Edition

provides an engine of unmatched performance and scalability. See the power of

autoconfiguration and diverse control system/HMI connectivity.

®2014 Loram Maintenance of Way, All rights reserved Speed · Performance · Reliability 33

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For more information, visit us at: www.loram.com


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