Transcript PPT Template

Slide 1
WW OPS-05:
Achieve World-Class Manufacturing
with Wonderware Production and
Performance Applications
Tom Troy – Director, Ops & Execution Portfolio Segment
© 2012 Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are proprietary marks of
Invensys or its subsidiaries. All third party trademarks and service marks are the proprietary marks of their respective owners.
World-Class Manufacturing & Production
What Defines World-Class??
World-class firms are always examining their business
processes and continuously seeking solutions to improve
in key areas such as:
 Reducing Lead Times
 Shortening Time to Market
 Cost Cutting
 Exceeding Customer Expectations
 Streamlining Processes
 Managing the Global Operation
Slide 3
World-Class Manufacturing & Production
What’s the Journey??
Organization Design
 Align their organization to satisfy the needs and wants of
its customers in an effective, timely manner
 Eliminate organizational barriers to communication
Performance Measurement
 Recognize the importance of measurement in defining the
goals and performance expectations of their organization
 Relentless commitment to continuous improvement,
which cannot be achieved without measurement
Slide 4
World-Class Manufacturing & Production
What’s the Journey??
Information Systems
 Leverage world-class information systems for collecting,
processing and disseminating data
Operations Capabilities
 Capable of producing the right quantity, the right quality,
at the right time, and at the right price
 Highly available production assets
Quality
 All quality costs (prevention costs, cost of defects, etc.) are
evaluated and held to the lowest reasonable sum
 “Zero defects” is the goal
Slide 5
Embedded Operational Processes Maturity
Manual vs. Embedded Processes
World-Class
Organizations
Embedded
Business/Operational
Process
Followers in
the Industry
Value
Manual
Business
Process
Lean Process
Time
Begin
Analysis
Slide 6
Identify
Improvement
Change
Complete
Source ARC
The Supply Chain…
Let’s Explore How Wonderware Production and Performance
Offerings Enable Organizations to Achieve and Maintain
World-Class Manufacturing / Production Status!
Slide 7
Wonderware’s Operational Management
Approach
Enabling the Journey to Operational
Excellence Series of Functional Programs
• Asset, Safety, Env, Productivity, People
• Enable Horizontal Value Scenarios
• Across our Industrial Capability
• Acceleration to Result
• Foundation of Capability
for Solutions
• Enabling Sustainability
• Enabling Evolution on
Journey
Slide 8
Wonderware’s Operational Management
Approach
Production & Performance Offerings:
Asset
MES
Intelligence
Operations &
Performance
Mobile
Quality
Enterprise
Integration
Batch
Operations Management
• Enabling Decision Support
• Execution
• Intelligence
ArchestrA Workflow
Platform Application Offerings:
HMI
Information
Server
System Platform
Slide 9
Historian
Industrial Platform
• Unifying Asset Model
• Single Scalable Platform
• Supervisory Control
• Central Integration Point
A Platform to Help Drive Sustainable Process
Excellence & Results
• Inventory
Process
Data
Operations
Intelligence
• Work Orders
• Temperature
• Quality
• States
• Dashboards for
multi-site / db
• People & Systems
Work Process
Management
• Recipe
• Pressures
• Any SQL source
• Governance
• Maintenance
• Cycles
• KPI’s ,
Benchmarks &
analytics
• SoP’s, GMP’s
MES
• OEE
Collaboration
• Alerts, Escalations,
Approvals
• Audit
Slide 10
Wonderware’s Operational Management
Level 0, 1 & 2
Control
Level 3
Manufacturing Execution System
Level 4
Business
Planning
& Logistics
In Context with the Supply Chain & Automation
ERP
PLM
EAM
SCM
Wonderware Enterprise Integrator
Production &
Performance
Applications
Batch
Continuous
Discrete
3rd Party
Wonderware’s Operational Management
Level 0, 1 & 2
Control
Level 3
Manufacturing Execution System
Level 4
Business
Planning
& Logistics
In Context with the Supply Chain & Automation
ERP
PLM
EAM
SCM
Wonderware Enterprise Integrator
Production &
Performance
Applications
Batch
Continuous
Discrete
3rd Party
Wonderware
Batch
Effectively Manages Flexible Batching Processes
in Process & Hybrid Industries
Slide 13
Wonderware Batch
Overview
Business Value
• Increased Capacity through Optimal Utilization
of Equipment and Materials
• Effective and Consistent Management of
Complex Batch Processes
• Reduced Lifecycle Engineering
Key Capabilities
• Flexible Recipe Definition and Management
• Sophisticated Batch Execution and Control
• Comprehensive Batch Genealogy
• FDA / 21 CFR Compliance
Slide 14
Wonderware Batch
Features
RecipeExecution
Definition
and
Process
and
Validation
Recipe
Definition
&
Management
Management
 Batch Execution and Control
FDA
Recipe
Definition/S88
/ 21
CFR Process Management







Manages Process
Equipment
Arbitration
Process
Execution
and
Complete
ProcessFormulas
Management for Regulated Industries
Ability to Define
Orchestrates the Execution of the Phases
Validation
Electronic
Batch
RecordOperation
(EBR) Execution as Part of Recipe
Define Recipe
Process
History and Validation of Batch Execution
FDA
21 CFR
21
CFR/Flexible
Compliant
Enable
BatchProcess
Recipes
Captures Material Genealogy, Alarms and Batch Events
Management
 Golden Batch Analysis
Slide 15
Wonderware Batch
Seamless Integration to Automation
Extremely flexible and powerful batch
management capabilities
InBatch Server
MX communication
Phases modeled
within Control System
PHASE 4
PHASE 1
PHASE 5
Device Integration
PHASE 6
System
Platform
Phases modeled within
System Platform
Slide 16
Device
PHASE 2
PHASE 3
Extremely flexible and powerful
platform and plant model
Wonderware’s Operational Management
Level 0, 1 & 2
Control
Level 3
Manufacturing Execution System
Level 4
Business
Planning
& Logistics
In Context with the Supply Chain & Automation
ERP
PLM
EAM
SCM
Wonderware Enterprise Integrator
Production &
Performance
Applications
Batch
Continuous
Discrete
3rd Party
Wonderware
Operations
Improves Production Execution Consistency,
Visibility, and Agility
Slide 18
Wonderware MES Operations
Overview
Business Value
• Foundation for Agile Production Processes
• Improve Production Consistency
• Empower Supply Chain Applications
• Enforce Compliance & Governance
Key Capabilities
• Open, Modular, Scalable, Extensible
• Full-Featured MES Capability – “Dock-to-Dock”
• Real-Time Visibility to Production Activities
• Comprehensive Manufacturing Genealogy
Slide 19
Wonderware MES Operations
Features
Product
Definition
Order
Management
WIP
&
Inventory
Management
Step
Execution
Product
Definition
Instructions
Work
Create
Work
OrdersofManually
from an
External
Management
. or Import
Setpoint
Define
a
Hierarchy
Storage/Stock
Locations
to
Track
Order
Management
 Configure Steps (or Tasks) for each Operation within a Route










Import Electronic
Product
from
External Applications
Application
(e.g.Definitions
ERP)
Define
Folders
with
Associated
Documents and
Materials
–
Fixed
or
Moveable
Define
Values
(e.g.
Min.,
Max.,
Nominal),
Instructions,
Configure
and
Enforce
Step
Execution
Order
Multiple
BOMs
(e.g.
versioned)
for
each Finished
or
Work
Instructions
(Multiple
Versions)
Attach
Routing
Instructions,
BOMs,
BORs,
Setpoints,
SOPs,
WIP
&
Inventory
Management
Track
Comments
Materials
and Work
as BulkInstructions
and/or Lotfor
Based
each Setpoint
SemiData
Finished
Material
and
Attached
Work
Collection
Instructions
Requirements
to a Types
Step
to a(e.g.
Work
Order
View
Many
Different
Document
PDF,
MS
Assign
Associate
Configurable
Setpoints
with
“Grades”
a Particular
and “States”
Work to
Center/Machine,
all Materials a
Documents,
Web
Page,
etc.)
Define
Multi-Level
BOMs
Capture
Assign
Work
Items
Order
to Events
a Step
(e.g. Status Change, Production,
StepBOM
Execution
Material
or
a
Procedural
Step
Calculate
and
Enforce
Expiry
Dates
Consumption)
at
each
Operation
on to
afor
Process
RouteItem
Link
Work
Instructions
and
Documents
toeach
Products,
Work
Define Machine
Multiple Substitute
Materials
BOM
Assign
and
BOM
Setpoints
a
Step
Download
Setpoints
to Automation
Devices
Capture
Complete
Genealogy
Trail
of
all WIP and
Inventory
Orders,
Operations,
Work
Centers
or
Procedural
Steps
Setpoint
Management
Sequence
Work
Orders
Manually
or
through
a
Finite
Capacity
Attach Work
Instructions
to Materials
Configure
Step
Activity
(e.g.
Collect
Data,
Consume
Material)
Activities
Scheduling (FCS) Application
Work Instructions
Slide 20
Wonderware MES Operations
Seamless Integration to Automation
Operations Capability Object (OCO)
Supports the following automated
transactions:
 Create & execute jobs/orders
 Record production &
consumption
 Create & transfer inventory
 Load specifications
 Record production events
Slide 21
© Invensys 17 July 2015
Wonderware
Performance
Improves Asset Utilization, Increases Capacity
and Empowers Operators
Slide 22
Wonderware MES Performance
Overview
Business Value
• Improve Asset Utilization (OEE)
• Reduces Capital Expenditures
• Increases the Capacity of Existing Assets
• Empowers Operators
Key Capabilities
• Detect, Capture & View Utilization Events
• Manual & Automated Data Collection
• Real-Time Visibility to Production Performance
• Bottleneck and Root-Cause Analysis
Slide 23
Wonderware MES Performance
Features
Equipment Utilization
Equipment
Utilization
Performance
Production
Progress
Equipment
Performance




Slide 24
Calculate
Detect
Capture
for
Equipment
Utilization
/ Line
Events
Provideand
a OEE
Clear
Indication
of Work
Order Progress to the
Production
Progress
Operator
in Real-Time
View
Trigger
Equipment
Events
and
Events
Display
Calculate
OEERecord
and
Other
Custom
KPIs
MonitorEvent
Analyze
and
Frequency
Equipment
and Duration
State
Estimate
Expected
Completion
Date
and Time
Automatically
Assign
What
States
or Manually
Affect OEE
Assign
Calculation
Reason
Codes
Wonderware MES Performance
Seamless Integration to Automation
Utilization Capability Object (UCO)
Provides the following capability:
 Configure utilization events to
collect for each asset
 Automatically captures event
data (start/stop time, etc.)
 Automatically collects
production performance data
Slide 25
© Invensys 17 July 2015
Wonderware’s Operational Management
Level 0, 1 & 2
Control
Level 3
Manufacturing Execution System
Level 4
Business
Planning
& Logistics
In Context with the Supply Chain & Automation
ERP
PLM
EAM
SCM
Wonderware Enterprise Integrator
Production &
Performance
Applications
Batch
Continuous
Discrete
3rd Party
Wonderware
Quality
Improves Product Quality and Consistency
Through Real-Time SPC and Analysis
Slide 27
Wonderware Quality
Overview
Business Value
• Improve Quality and Consistency, Reduce
Process Variation
• Identify, Correct Deviations in Real-Time
• Meet Regulatory, Customer Compliance
Key Capabilities
• SPC Alarms, Alerting and Charts
• Integrated Specification Management
• Sample Plan Definition, Execution
Slide 28
Wonderware Quality
Features
Specification Management
Sample
Plan
Definition
Management
Statistical
Process
Control
(SPC)
Specification
Management
Sample
PlanPlan
Execution
Management
Sample
Definition
Mgt.









Slide 29
Import
the
Sample
Plan
from
External
Source
(ERP/PLM)
Standard
Run
Rule Selection
Specifications
from
anan
External
Source
(ERP/PLM)
Sample Collection Notification
Configure
“What”
Characteristics
toMgt.
Collect
SPC
Charts
–Plan
Xbar
andSpecifications
Sigma,
Moving
X of
Define
Product
andRange
Process
in Average,
the Context
Sample
Execution
View Sample Details & Recorded Data
Individual,
p/np/c/u/DPMO
Materials, “When”
Equipment,
OperationsShould be Collected
Configure
the and
Characteristics
Additional Sample Request Generation
Statistical
Process
Control
Feedback
Control
Rule
Violations
Define
andofAttach
Characteristics
(Variable
& Qty,
Attribute)
Select
from
Multiple
Frequency
Types:
Time,
Event, etc.
Manual
or Automatic Sample Collection
(SPC)
Additional
Operator
Data Collection
Comments)
Define Multiple
Specification
Overrides
Attach
Frequency
Types to a(e.g.
Sample
Plan
Wonderware’s Operational Management
Level 0, 1 & 2
Control
Level 3
Manufacturing Execution System
Level 4
Business
Planning
& Logistics
In Context with the Supply Chain & Automation
ERP
PLM
EAM
SCM
Wonderware Enterprise Integrator
Production &
Performance
Applications
Batch
Continuous
Discrete
3rd Party
Wonderware
Mobile
Accelerates & Sustains Operations
Improvements Through Mobile Work
Task Management
Slide 31
Wonderware Mobile (IntelaTrac)
Overview
Business Value
• Improve Uptime, Safety & Reliability
• Accelerate & Sustain Process Improvements
• Reduce Maintenance Costs for Instrumented &
Non-Instrumented Equipment
Key Capabilities
• Work Task Management & Workforce Scheduling
Optimization
• Paperless Work Management
• Plant Maintenance & Turnaround Management
• Dynamic Rounds, “System of Mobile Execution”
Slide 32
Wonderware Mobile (IntelaTrac)
Features
Procedure/Work
Task
Procedure/Work
Task
Execution







Slide 33
Configuration and Scheduling
Operator Rounds
Equipment
Inspection Task Execution
Procedure/Work
Health, Safety and Environmental Rounds
Audit Rounds
Reporting, Exception Mgt.,
Security
Performance
Mobile
On-The-Job KPIs
Learning
Quality
Data Collection
rd
3 Party Integration (e.g. EAM,
Etc.
Historian, etc.)
Wonderware Mobile (IntelaTrac)
Content Management
Traditional
Approach
Procedure Builder
Database
Server
External Systems
(Historian, InFusion,
LIMM, etc.)
Synchronization
Server
• Configuration
• Scheduling
• Execution
Schedule Manager
• Storage
– IntelaTrac
– Other Systems
Mobile IntelaTrac
Slide 34
Wonderware’s Operational Management
Level 0, 1 & 2
Control
Level 3
Manufacturing Execution System
Level 4
Business
Planning
& Logistics
In Context with the Supply Chain & Automation
ERP
PLM
EAM
SCM
Wonderware Enterprise Integrator
Production &
Performance
Applications
Batch
Continuous
Discrete
3rd Party
Wonderware
Intelligence
Access, Aggregate, Contextualize and
Visualize Operations Metrics
Slide 36
Wonderware Intelligence
Overview
Business Value
• Strategic manufacturing decision support
platform
• Synthesizes and transforms disparate data
into “contextual information”
• Enables continuous improvement across the
manufacturing enterprise
Key Capabilities
• Visualization through an easy to configure
dashboard – self service access
• Model KPIs to meet specific business
objectives
• Collaborate and share metrics through a
web-based dashboard
Slide 37
Wonderware Intelligence
The Strategy…
User-friendly
Configuration &
Administration
Production/Process
Information Platform
Wonderware &
Non-Wonderware
Data sources
Slide 38
Share content
& Collaborate
Incremental approach
Self-service access
to information
& content authoring
Wonderware Intelligence
The “Consumers”…
∑
Put in context
data from
various
sources and
compute
metrics
Flexible,
near-real time
dashboards
Ad-hoc
analysis,
drill-down,
drill-through
Consolidated
reports,
comparison
across sites
Plant Manager
Process Engr.
VP of Ops
Wonderware’s Operational Management
Level 0, 1 & 2
Control
Level 3
Manufacturing Execution System
Level 4
Business
Planning
& Logistics
In Context with the Supply Chain & Automation
ERP
PLM
EAM
SCM
Wonderware Enterprise Integrator
Production &
Performance
Applications
Batch
Continuous
Discrete
3rd Party
ArchestrA
Workflow
Framework for Modeling, Executing and
Measuring World-Class Processes
Slide 41
ArchestrA Workflow
Overview
Business Value
• Enable Change, Improve Process Agility
• Improve Procedural Quality & Consistency
• Adhere To and Enforce Regulatory Compliance
• Increase Collaboration Across People & Systems
Key Capabilities
• Digitally Capture, Institutionalize Best Practices
• Sophisticated Human Workflow Management,
Calendar Management and Task Escalation
• Seamlessly Embedded into Invensys
Applications and 3rd Party Applications
Slide 42
ArchestrA Workflow
Features
Model: Create Processes,
Analyze:
Find
Bottlenecks,
Get
Alerts
Forms
& Reports
Model:
Create
Processes,
Forms
& Reports
Execute:
Manage
&
Escalate
Tasks
Connectivity
 Out-of-the-Box
Activity
and
Monitoring
Views
Intuitive, Visual
Modeling
Environment
Seamless
Workflow
TaskReporting
Execution
with
Invensys Applications
 Wonderware
–Manage
System Platform
(Application Server and
Execute:
&
Escalate
Workflows
with
BAM Events
Configurable
Workflow
Activities
for
Common Workflow
 Associate
Multiple
Task
Execution
Channels:
Wonderware
InTouch,
Historian),
MES
and
IntelaTrac
Tasks,
Coordinate
Resources
Tasks
 Customizable
Web
Browser, Key
Smartphones,
Performance
PDA,
Indicators
Email and
(KPIs)
IM
 Microsoft – BizTalk, SharePoint, Office, and Outlook
 Extensibility
for Creating
Custom
Activities
Human
Standard
Workflow
Out-of-the-Box
Management,
Performance
Calendar
Analysis
Management and
Analyze:
Find
Bottlenecks,
 SAP
(RFCs and BAPIs)
Task
Escalation
 Model
Complex
FormsInstances
to Collectand
or Visualize
Data
Visibility
to Workflow
Genealogy
Get
Alerts
 Extensibility for Creating Custom Connectors
 Comprehensive
Microsoft
Integration
Forms canAlerts
be Linked
to, or Outlook
Initiate,
Workflows
Proactive
of Business
Exceptions
and KPIs
Connectivity
Slide 43
ArchestrA Workflow
Delivering Effective & Sustainable Processes
Value Proposition:
 Process Governance
 Knowledge Management
 Process Agility
 Dynamic Change Mgt.
 Process Responsiveness
 Rapid Innovation
 Continuous Improvement
 People & System-Centric
Collaboration
 Real-time Decision-Support
Slide 44
Wonderware’s Operational Management
Level 0, 1 & 2
Control
Level 3
Manufacturing Execution System
Level 4
Business
Planning
& Logistics
In Context with the Supply Chain & Automation
ERP
PLM
EAM
SCM
Wonderware Enterprise Integrator
Production &
Performance
Applications
Batch
Continuous
Discrete
3rd Party
Wonderware
Enterprise
Integrator
Facilitates Integration of Plant Floor
Applications to Enterprise Solutions
Slide 46
Wonderware Enterprise Integrator
Overview
Business Value
• Reduces Integration Cost via Standards
Based Integration (e.g. B2MML, etc.)
• Increases Inter-Operability Between
Disparate Applications
• Enables Business Continuity
Key Capabilities
• Configurable and Extensible Messaging
Framework
• Guaranteed Message Delivery
• Advanced Message Management &
Administration
Slide 47
Wonderware Enterprise Integrator
Features
Configurable and Extensible
Messaging Framework
Transforms & Delivers Messages
to Multiple Applications
Out-of-the-Box Message “Plugins” Reduce Integration Effort
Mediates and Guarantees Data
Exchange – Store & Forward
Slide 48
Wonderware Enterprise Integrator
Architecture
Slide 49
Thank You!
© 2012 Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are proprietary marks of
Invensys or its subsidiaries. All third party trademarks and service marks are the proprietary marks of their respective owners.