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Wonderware Performance Software

Wonderware Performance Software. Dawid Sadie Wonderware SA. Introduction. Building the Foundation. Agenda. Wonderware Solution. Considerations. Summary. Introduction. The machine is producing at maximum – there is nothing more I can do … except

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Wonderware Performance Software

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  1. Wonderware Performance Software Dawid Sadie Wonderware SA

  2. Introduction Building the Foundation Agenda Wonderware Solution Considerations Summary

  3. Introduction The machine is producing at maximum – there is nothing more I can do … except if I could find a reliable replacement for Part-X … When will order X be Complete? Is the capex for the new line approved yet? We struggle to get orders out the door. Why should I be interested In performance management? My machines run just fine … Why does Line A always produce less scrap than Line B? The operator ensured me the setup is identical …

  4. Introduction Building the Foundation Agenda Wonderware Solution Considerations Summary

  5. Building the Foundation for Repeatable Process Improvement 1. Determining operational goals and requirements 2. Specifying business metrics and key performance indicators 3. Measuring, visualising, analysing and acting upon information

  6. Determining Operational Goals and Requirements • First step in improving ANY production process is to understand the Business Drivers • Improving Productivity andAsset Utilisation • Reduce capital expenditures • Get the most from your existing equipment • Get more from less  lower budgets, fewer personnel • Increase Efficiency to preserve (and even increase) bottom-line • Can’t make more  Capacity limited • Can’t increase prices  Price limited • So … Make it right the first time !!!

  7. Specifying Business Metrics and Key Performance Indicators (KPI’s) • Several KPI’s can provide substantial insight into improving operational results - • Overall Equipment Effectiveness (OEE) • Includes Availability, Performance and Quality • Equipment Uptime • Time running compared to scheduled time • Others, including TEEP, TAKT, MBTF • Key is having a consistent way to measure, visualise, analyse and act upon these metrics

  8. OEE = Availability * Performance * Quality Example: (.77)*(.65)*(.98)*100% = 49% OEE Overall Equipment Effectiveness (Key Efficiency Metric) Actual Output Good Output * 100 * 100 Quality = Performance = Target Output Actual Output Running Time * 100% Availability = Net Operating Time

  9. OEE Analysis is a Key Tool for Improving the Bottom Line • OEE – The percentage of time that equipment is actually producing quality goods • Improving OEE will directly lead in increased production, and can significantly impact thebottom line, especially in these cases - • High speed - (CPG, bulk products, electronic parts) • High value - (automotive, aerospace, electronics finished goods) • High capacity - (oil and gas, water and wastewater, mining & metals) • Most companies have far lower baseline OEE than accepted industry-standard • Improving OEE by even a small incremental amount can result in Big Bottom Line Impact

  10. Impact on Financials • Improving OEE by even a small incremental amount can result in Big Bottom Line Impact • 10% increase in OEE results in 38% increase in Operating Income

  11. Producing more product

  12. Production Cost (direct)

  13. Increase availability • Improving OEE by even a small incremental amount can result in Big Bottom Line Impact • 10% increase in OEE results in 38% increase in Operating Income

  14. Measuring, Visualising, Analysing and Acting upon Information • KPI’s and Business Metrics can be useful for improving a process, but only if they can be – • Measured and Recorded • Needs to be consistent and repeatable • Must take advantage of automatic data capturing rather than manual entry • Delivered in easy-to-understand visual format to all relevant personnel • Plant dashboards targeted to specific groups of users • Easily configurable and customisable • Analysed in real-time • Before bad products are made or production goals are missed • Made actionable • Allow users to drill down for more detail and to determine root cause

  15. Introduction Buildingthe Foundation Agenda Wonderware Solution Considerations Summary

  16. Wonderware MES & EMI Software Solutions Built on Strong Platform ERP (SAP, Oracle, Microsoft..) Database Applications System Platform LIM Systems Empowering All Roles in the Plant Devices, Applications, Enterprise Integration Asset Management Devices System Interoperability Information / Visibility Real-Time Manufacturing Operations Management Enterprise Integration Wonderware MES & EMI Software Solutions Food & Beverage Asset Monitoring Performance Quality Batch Operations Industry Applications & Industry Packs Clients Microsoft Technology & Industry Standards

  17. Adopting a Flexible Approach to Improving Your Manufacturing Operations Enable an incremental, low-risk deployment of increased application functionality, one step at a time.

  18. Get to the Bottom of your Unplanned Downtime Issues Wonderware Performance Software v3.5 • Leverages existing automation system • Provide more accurate, reliable & granular downtime data than manual systems • Highly flexible capture of downtime events with Unlimited downtime reasons per piece of equipment • Enhanced operator involvement with highly configurable .NET based Operator interface • Information delivery via standardised and pre-configured reports and KPI-displays

  19. Reduce Costs with Equipment Efficiency Tracking Wonderware Performance Software v3.5 • Real-time Overall Equipment Effectiveness (OEE) Monitoring • Monitor equipment, line or plant OEE • Compare machine to machine, line to line, plant to plant • Leverages existing automation system for accurate and timely OEE data • Unlimited number of OEE calculations • Include real-time OEE on Operator HMI screens and web-based plant information portals

  20. Wonderware Performance Software Monitors, analyses and reports on asset efficiency & equipment downtime - resulting in improved productivity and asset utilisation.

  21. Capabilities • Equipment Utilisation • Real-time Tracking/Display/Analysis of Unplanned Equipment Downtime What is Equipment Performance? • Equipment Utilisation • Equipment Efficiency • Reporting

  22. Drive Better Equipment Utilisation…through Operator Awareness

  23. State Reason Customisable Operator Interface • User definable utilisation states • Define an unlimited number of reason codes to establish the utilisation state • Reason code triggered automatically from I/O or manually input by operator • Define a target Utilisation & OEE for each asset • Configure if utilization reasons affect OEE values

  24. Powerful Utilisation ControlReal-time Visualisation & Input

  25. Equipment Utilisation • Real-time Tracking/Display/Analysis of Unplanned Equipment Downtime Capabilities What is Equipment Performance? • Equipment Efficiency • Real-time Tracking/Display/Analysis of Equipment Efficiency • Equipment Utilisation • Equipment Efficiency • Reporting

  26. Higher Equipment Efficiencies with Operator Involvement

  27. Equipment Utilisation • Real-time Tracking/Display/Analysis of Unplanned Equipment Downtime • Equipment Efficiency • Real-time Tracking/Display/Analysis of Equipment Efficiency Capabilities What is Equipment Performance? • Equipment Utilisation • Equipment Efficiency • Reporting • Reporting • Real-time Web Reports or Paper Reports

  28. “Zero Footprint” Web-Based Reporting • Flexible Report Templates • OEE & Downtime • Production Event Summary • Extensible • Easily create report instances for specific users • Wired for Analysis • Drill through by passing parameters • Determine root cause of production problems

  29. Web-Based ReportingDrill Down to Root Cause

  30. What’s in Performance 3.5? • Simplified Configuration • New Utilization Capability Object • New Performance Configuration Client • Improved Visualisation • New ArchestrA Graphic Templates • OEE, Downtime & Production Progress • Improved Operator Interface • New Utilisation Grid .NET Control • Enhanced Reporting • New Web based ArchestrA reports • New Migration Utility • Easier upgrades

  31. Object Based Configuration • New Utilization Capability Object • Configure downtime events & OEE calculations • Define production attributes for production progress tracking • Associate with ArchestrA Graphic templates • Extend with custom scripts • Benefits • Facilitates corporate standards • Template approach promotes engineering reuse • Faster configuration & reduced maintenance

  32. New Performance Configuration Client • Helps configure: • Users & Groups • Utilisation States, Reason Groups & Reasons • Shifts & Shift Schedules • General System Parameters • Helps simplify system configuration

  33. New Performance Graphics Templates • OEE KPI Control • Displays OEE value and/or the OEE components (Availability, Performance, Quality • Count/Duration KPI Control • Displays the number & duration of events for the current entity • Production Progress Control • Displays the current progress of production for the current shift compared to a provided target

  34. OEE KPI Control • Shows OEE or OEE components • Dial or Bar chart • Configure • All standard graphic properties are available for setup.

  35. Counts and Duration Control • The control will display either counts or duration for Utilisation States, Reason Groups, or Reasons on the graph • Filtered for the time period specified by the Filter properties for the current entity

  36. Production Progress Control • Used to display progress towards a production target for the current shift • The projected production is based on the current rate of production for the current job running on the current machine

  37. New .NET Control – Utilisation Grid • Allows enhanced operator displays • Employs advanced filtering capabilities • Time based • Last N events, this/last shift, last N hours • State based • Unacknowledged • Minimum Duration • Status based • Utilization state • Any combination of filters

  38. Reporting • New ArchestrA Utilisation Reports

  39. Information at your fingertips Web based or Paper Reports, You choose

  40. Efficiency Information for Decision Makers

  41. Introduction Building the Foundation Agenda Wonderware Solution Considerations Summary

  42. Considerations • Wonderware Performance Software is the key to achieving consistency in equipment performance • Consistently measure and record • Single or multiple “lines” • Modular solution for adding functionality • Grow towards Operational Excellence (start with Performance) • Start small, get benefit, and grow bigger • Eliminates the “big-bang” approach • Can integrate with your existing investment … co-exist

  43. Introduction Building the Foundation Agenda Wonderware Solution Considerations Summary

  44. Summary • Business Benefit – • Reduce operational costs • Delay the need for investing in new equipment • Business metrics and KPI’s • Required to track and measure performance • Measure (consistently) to improve • Wonderware builds the foundation • Modular functionality • Re-usable, repeatable, consistency • Making the “1st time right” approach not just a vision but a reality!

  45. Wonderware Ease of Use • Single development environment • Wonderware Integrated Development Environment (IDE) • Single configuration object • Utilization Capability Object • Pre-built visualization graphics • Downtime, OEE, Production Progress • ArchestrA graphic template technology • Pre-configured Web Reports • Out of the box value

  46. Powering intelligent plant decisions in real time.

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