Transcript Wonderware Presentation Template 2007

An Overview Of
Wonderware MES Products
Jan Rasmussen
Sales Director EMEA - MES
Wonderware Manufacturing Operations
Software Solution Offerings
Wonderware
QI Analyst
Wonderware
OPERATIONS 3.5
- PREMIUM
Enterprise
Integration
Wonderware
InBatch
Wonderware MES & EMI
Software Solutions
Batch
Operations
Asset
Monitoring
Local
Scheduling
Quality
Performance
System
Platform
Clients
Food &
Beverage
Industry
Wonderware
Applications
PERFORMANCE
&
Industry
Packs
Microsoft Technology & Industry Standards
Wonderware
OPERATIONS 3.5
- STANDARD
‘Mtelligence for
Wonderware’
Partner
Solution
Wonderware
EMI Offerings
3.5
Common Industrial IT Services for
Increased Sustainability
Wonderware System Platform
Platform

Native integration of plant model with MES
production model for low TCO

Superior reusability via object templates
and deployment with sharing of best
practices

Intuitive user interfaces for appropriate
operator involvement

Unparalleled data connectivity incl. leading
historian for process data, and advanced
security model
Enterprise
Integration
Wonderware MES & EMI
Software Solutions
Batch
Operations
System
Platform
Asset
Monitoring
Local
Scheduling
Quality
Performance
Clients
Food &
Beverage
Industry
Applications
&
Industry
Packs
Microsoft Technology & Industry Standards
Accurate Management of
Batch Processes
Wonderware Operations Software
Batch

Simple batch management with recipe
definitions using site specific processes

Accurate equipment setup with automatic
download of set points
Enterprise
Integration
Wonderware MES & EMI
Software Solutions
Batch
Operations
System
Platform
Asset
Monitoring
Local
Scheduling
Quality
Performance
Clients
Food &
Beverage
Industry
Applications
&
Industry
Packs
Microsoft Technology & Industry Standards
Wonderware InBatch

Powerful batch execution engine with
dynamic allocation of shared equipment for
even the most complex batch processes

Graphical recipe definitions according to
S88 with unit procedures, operations and
phases for equipment independent master
recipes
Improved Execution of Operational
Activities
Wonderware Operations Software
Operations
Enterprise
Integration
Wonderware MES & EMI
Software Solutions
Batch
Operations
System
Platform
Asset
Monitoring
Local
Scheduling
Quality
Performance
Clients

Dispatching and management of electronic
work orders, with multilevel BOM

Improved process and production
consistency and repeatability

Accurate inventory mgt and operational
enforcement through procedural steps
Food &
Beverage
Industry
Applications
&
Industry
Packs
Microsoft Technology & Industry Standards
Equipment Operations Modules

Non-model based approach for recording
of production events and ‘as-built’ records
as simple extension of supervisory system
Wonderware Operations Software…
Provides a scalable & configurable
Manufacturing Execution System
solution for a wide range of
industries
Background:
Core MES software capability (formerly
Factelligence) obtained from 2007 acquisition
of leading MES software provider, CIMNET
Product History
November 2008
February 2008
October 2007
July 2007
2002
EPM 2.0 = Factelligence 3.1 + QuickStart
Wonderware Factelligence 3.1
Wonderware Operations Software…
► Comprehensive MES Functionality
▪ Bill of Material, Work Orders, Events, Data Collection,
Specifications, Set Point Download, Inventory, Certifications,
Steps/Procedures, Labor Management, User Management,
Genealogy, Traceability, Web Reporting
► Fully Scalable
▪ Functionality – Standard & Premium Edition, Enterprise
Integration, MES Clients plus .net controls to embed in InTouch
▪ Physical Scalability – equipment, lines, plants
▪ Taking advantage of ArchestrA services
► Highly Configurable Application
Highly Configurable User Interface
Wonderware MES Features
Deliver planned vs. actual production
Improve process and production
consistency
Improve inventory velocity
Reduce order lead time
Monitor and analyze production
performance
using
using
using
using
using
•Electronic Work Order Management
•Recording of Production Events
•Centralized Manufacturing Model
•Production Rules
•Certifications
•Real time inventory management
•Detailed definition of materials, substitutes and
byproducts
•Bill of Materials
•Dynamic prioritization and sequencing
•Labor management
•Connection to HMI/SCADA
•Downtime
•Utilization
•OEE
General Overview
Wonderware Operations & Performance
Solutions “Powered By” MES Modules…
System Platform benefits on MES
► Track & Trace
► Error Proofing
► Electronic Batch
►
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►
►
Records (EBR)
Electronic Work
Instructions
Procedural Execution
Performance Mgt. (OEE)
Asset Utilization
Labor Mgt.
► Receiving
Lower Cost of IT in Industrial
► Applications
Order Management
for data collection
automated
transactions
► and
WIP
Management
andManagement
Collect : out of the
► Connect
Inventory
box connectivity to any
► Quality Data Collection
information source
► Weigh & Dispense
Reduce effort and cost on
► designing,
Batch Processing
building and
system
► maintaining
Recipe/Spec.
Mgt.
scalability,
► Complete
Master Data
Mgt.upscaling in
size and functionality without
impact to existing system
Building the Production Model
Highly configurable & customizable to ensure a complete & accurate
model of your production processes
Reduce Variances with
Specification and SPC
Wonderware Qi Analyst
Quality

Realtime and historical SPC with
comprehensive charts and custom run
rules with alarm generation upon violations

Minimize costly scrap and rework through
detection of process variations better
understanding of actual process
capabilities
Enterprise
Integration
Wonderware MES & EMI
Software Solutions
Batch
Operations
System
Platform
Asset
Monitoring
Local
Scheduling
Quality
Performance
Clients
Food &
Beverage
Industry
Applications
&
Industry
Packs
Microsoft Technology & Industry Standards
Wonderware Operations Software

Central administration of process and
product specifications with versions and
min/max limits per BOM entity
Using Standard Deviation
► Cream Cheese
▪ Online Controlling Water percentage
▪ Operators only allowed to adjust paramaters
based on rule violations from QIAnalyst
▪ Water is cheaper than milk 
► Mozarella
▪ Planning production based on the orders solid
material requirements in the cheese
► Cream Cheese
▪ On line Weight control in filling line
► Butter
▪ On line controlling fat and water
Using standard deviation
Rapid and Accurate Decision
Making via Realtime Visibility
Wonderware Performance Software
Performance

Improve asset utilization by automated
data collection and selective involvement of
operators

Consistently monitor and compare
equipment performance and OEE.
Enterprise
Integration
Wonderware MES & EMI
Software Solutions
Batch
Operations
System
Platform
Asset
Monitoring
Local
Scheduling
Quality
Performance
Clients
Food &
Beverage
Industry
Applications
&
Industry
Packs
Microsoft Technology & Industry Standards
Wonderware System Platform

Powerful reporting infrastructure through
Information Server
Improve Asset Utilization and OEE
Operations / Mgt
Engineering
IT & Infrastructure
Productivity gains drop straight to bottom line
Engineering Efficiency
Operations / Mngt
Engineering
IT & Infrastructure
IT Environment Consistency
Operations / Mngt
Engineering
IT & Infrastructure
Increase Capacity
► Reduce unplanned equipment downtime
▪ By tracking and analyzing equipment downtime
► Improve the output of existing equipment
▪ Track and analyze equipment output (performance)
► Reduce quality related losses (scrap)
▪ Track and analyze first pass yield
All require detailed equipment
performance information
Empower Operators
► Leverage existing automation system
▪ Provide more accurate, reliable and granular
downtime data than manual systems
► Flexible capture of downtime events with
unlimited downtime reasons per equipment
► Enhanced operator
involvement with
highly configurable
.NET based
Operator interface
Real-time Graphics
► OEE KPI Control
▪ Displays OEE value and/or the
OEE components (Availability,
Performance, Quality)
► Count/Duration KPI Control
▪ Displays the number and
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
Drill Down to Root Cause
Tight Alignment with
Business Processes
Enterprise Integration
Enterprise
Integration

Out-of-the-box integration using predefined mappings.

Simple, yet powerful integration capabilities
in a standardized formats
Enterprise
Integration
Wonderware MES & EMI
Software Solutions
Batch
Operations
System
Platform
Asset
Monitoring
Local
Scheduling
Quality
Performance
Clients
Food &
Beverage
Industry
Applications
&
Industry
Packs
Microsoft Technology & Industry Standards
Master/Static Data (30+ templates):
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Attributes
BOM Item / Oper. Links
BOM Item / Oper. Step Links
BOM Item Substitutes
BOM Items
Data Log 16 and 48
Folders & Files
Operation Routes
Operation Step Entity Excl.
Operation Steps
Operations
Operations Step Groups
Operation / BOM Spec Links
Operation / Entity Links
Operation / Entity Spec Links
Operation Attributes
Process / Item Links
Process Attributes
Processes
Rework Process Usage
Specifications
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Item Attributes
Item Classes
Item Folders
Item Reasons
Item Substitutes
Items
Standard Operations
Standard Operations Entity Links
Standard Operations Attributes
Utilization Reasons
Dynamic Data (20+ templates):
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Customer
Inventory Items
Job Attributes
Job BOM
Job Step Links
Job BOM Substitutes
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Job Routes
Job Specifications
Job Step Groups
Job Steps
Jobs
Lot Attributes
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Sales Order
Sales Order Items
Work Order Attributes
Work Order Folders
Work Orders (with Process)
Work Orders (without Process)
Enterprise Integration
Basic Features
► Provides standard mechanism to import and export data
►
►
►
►
►
►
from WW Ops & Perf Database
Provides a set of data import and export templates
Integrate with ERP, SCM, LIMS and other business level
or plant level systems
Used to synchronize BOM, orders, WIP, items, specs,
certifications, attributes, etc.
Configurable data formats including XML, flat file, and
Database table transfers
Configurable triggers including period, weekly, data
changes, table data exists, file exists
Delivers standard production reports, exception reports
and email alerts
Comprehensive Application for
Packaging Lines
Vertically oriented Packaging Solution
Industry App
for Packaging

Leverage System Platform, InTouch,
Performance Module and Information
Server

Provides a window for Planners (job
sequencing and dispatching), Operators
and Supervisors (line and machine state,
status, yield, Performance, Events and
alarms)

Generates and distributes reports via
Wonderware Information Server

State Model Compliant with OMAC and
PackML

Food& Beverage, Tobacco, Consumer
Packaged Goods (CPG)

Easy setup via Excel Utility

Alternative to traditional MES/Performance
project
Enterprise
Integration
Wonderware MES & EMI
Software Solutions
Batch
Operations
System
Platform
Asset
Monitoring
Local
Scheduling
Quality
Performance
Clients
Food &
Beverage
Industry
Applications
&
Industry
Packs
Microsoft Technology & Industry Standards
Improved Maintenance Strategy
with Condition Based Monitoring
Condition Based Monitoring Mtelligence
Asset
Monitoring

Endorsed Partner Solution

Equipment run-time hours fed to
maintenance system with automatic
generation of work orders

Detect health degradation and prevent
equipment failures

Open Standards eliminate Upgrade and
Migration Risk (MIMOSA, ISA-95)
Enterprise
Integration
Wonderware MES & EMI
Software Solutions
Batch
Operations
System
Platform
Asset
Monitoring
Local
Scheduling
Quality
Performance
Clients
Food &
Beverage
Industry
Applications
&
Industry
Packs
Microsoft Technology & Industry Standards
Improved Maintenance Strategy
with Condition Based Monitoring
Preactor Finite Scheduling
Local
Scheduling

Wonderware offers you a world class MES
solution

Preactor offers the best available finite
scheduling tool available on the market
today

The two have been integrated to offer both
scheduling and manufacturing shop floor
control

With a record that shows a ROI which is
unsurpassed

Largest installed base of any independent
planning & scheduling software company
for the manufacturing sector

>2,300 companies in almost every
manufacturing sector

Discrete/process/hybrid

>10,000 licenses Users in 64 countries

Translated into 30 languages
Enterprise
Integration
Wonderware MES & EMI
Software Solutions
Batch
Operations
System
Platform
Asset
Monitoring
Local
Scheduling
Quality
Performance
Clients
Food &
Beverage
Industry
Applications
&
Industry
Packs
Microsoft Technology & Industry Standards
Adopting a Flexible Approach to
Improve Your Manufacturing Operations
Enable an incremental,
low-risk deployment of
increased application
functionality, one step
at a time.
Milkshake Manufacturer
– Scenario #1
► Three Lines Produce Milkshakes
► Two Manufacturing Sites
► Currently, no MES
► Goal: Monitor/Improve equipment
performance
▪ Answer the question, “How are we doing?”
• Overall Equipment Effectiveness (OEE)
• Downtime
• Asset Utilization
Manufacturing ‘Pains’
► Fillers not running at designated capacity
▪ Output & profits lower than forecast
► Not meeting daily schedule
► Pasteurization process blocked
▪ Production storage is full
► No information about filler stops
► Operators often wait around
▪ Don’t knowing how to resolve issues
Scenario #1: Performance
Initial Deployment of
Performance
Line 2 Clients
Line 1 Clients
Install
Install
InTouch,
InTouch
‘WW
license
Op’s & Perf’
Install
InTouch,
Install
InTouch

‘WW
Op’s
license & Perf’
Line 3 Clients
Install
InstallInTouch,
InTouch

‘WW
license
Op’s & Perf’

Production Server
System Platform
Install
Install System
System
Platform
Platform license

Install
Install Historian,
Historian,
‘WW
Op’s
‘WW Op’s &
& Perf’,
Perf’,
WIS
licenses
Info Server

MES database
Historian
Info Server
Manufacturing Scenario #1
Solution Diagram
Reports
Machine Utilization
MES Configuration
Scenario 1:
Machine Utilization
Reports
► Scenario #1 – Asset Utilization
▪ Downtime
▪ OEE
▪ Utilization
Milkshake Mfgr – Scenario #2
► Mfgr now has visibility to performance
▪ OEE & Downtime
▪ Asset Utilization
► Goals (one or more):
▪ Increase consistency using electronic work
orders for line management
▪ ‘Track & Trace’
▪ Consistent data model
Manufacturing ‘Pains’
►
►
Possible pains
▪
▪
▪
▪
▪
▪
▪
▪
▪
Can’t correlate process conditions with WOs or batches when issue detected
Small issues become big problems because impacts can’t be easily assessed.
Mistakes are made repeatedly
Major concerns about recalls
Operators waste time figuring out what to produce next
Differences in time to complete jobs between lines, shifts, operators
Different definitions of product formulas / recipes
Introducing new product variants causes issues
Too much time spent compiling manual reports
Potential Self-Diagnosis
▪ Increased requests for additional / special reports
▪ ‘Firefighting’ since information not shared across
▪
▪
▪
▪
shifts and departments
Reduction in customer service due to delays in
response time
Rework has increased
Production costs have increased
Changeovers take too long
Scenario #2: Op’s Standard
Deployment of Operations
(Standard)
Line 1 Clients
Line 2 Clients
Line 3 Clients
Production Server
System Platform
Install Op’s
Standard license
MES database
Historian
Info Server
Manufacturing Scenario #2
Solution Diagram
Solution Diagram
Reports
Reports
Machine Utilization
Machine Utilization
Work Order
Execution
MES Configuration
MES Configuration
Scenario 1:
Machine Utilization
Scenario 2:
Work Order Execution
Reports
► Scenario #2 – Track
and Trace, Execution
▪ Consumption and
▪
Waste
Production and
Rejects
Genealogy
Traceability
Yield
▪
▪
▪
► Scenario #1 – Asset
Utilization
▪ Additional domains
▪ By item, work order
Milkshake Mfgr Scenario #3
► Mfgr now has…
▪ Visibility to equipment performance
▪ Increased consistency w/electronic work
orders
▪ ‘Track & Trace’
► Goal #3: Add more MES capabilities…
▪ Inventory tracking capability
▪ Reduce WIP inventory
▪ Manage expiration of WIP
▪ Improve inventory turns
▪ Reduce inventory costs
▪ Reduce order lead time
Manufacturing ‘Pains’
► Excessive Scrap
► Too Much Inventory
► Inventory Costs Too High
► No Traceability To Quality Check
► Accurate Labor Costs Unknown
► No enforcement of business rules for
intermediate WIP
► Starved processes
Scenario #3: Full MES
Deployment of Operations
(Premium)
Line 1 Clients
Line 2 Clients
Line 3 Clients
Production Server
System Platform
Install Op’s
Premium license
MES database
Historian
Info Server
Manufacturing Scenario #3
Solution Diagram
Solution Diagram
Solution Diagram
Reports
Reports
Reports
Machine Utilization
Machine Utilization
Machine Utilization
Work Order
Execution
Work Order
Execution
WIP Inventory
Tracking
MES Configuration
MES Configuration
MES Configuration
Scenario 1:
Machine Utilization
Scenario 2:
Work Order Execution
Scenario 3:
WIP Inventory Tracking
Reports
► Scenario #3 – Inventory Tracking
▪ Additional reports available
► Scenario #2 – Track and Trace, Execution
▪ Additional information provided to previously
available reports
More Manufacturing Scenarios
► Example 1: Scalability
▪ … from a Small System to Large System
• Scale from a pilot to a larger system with ease
▪ Procedure to scale:
• Start with a pilot system
• Add clients and servers without re-engineering the applications
• Reuse library of templates for multisite rollouts
Scalability
Line 1 Clients
Line 2 Clients
Line 3 Clients
Line 4 Clients
Production Server
System Platform
MES database
Historian
Info Server
Line 5 Clients
More Manufacturing Scenarios
► Example 2: Incremental Growth
▪ … from One Application to Multiple
Applications
▪ Scale to address additional functional
requirements
▪ Procedure to grow ’incrementally’
• Start with Performance
• Add Operations Standard
• Add Operations Premium
… all by simply changing the license file!!!
Incremental Growth
Line 1 Clients
Line 2 Clients
Line 3 Clients
Production Server
System Platform
MES database
Historian
Info Server
Differentiators
► Standard application content out of the box
► Single comprehensive database for all
MES capabilities – not disparate solutions
► Modular operator interface concept
► Support for mixed manufacturing modes
► Data master flexibility
► True integrated SCADA through MES
capability
► Modern Microsoft-based architecture
Additional Benefits
of Wonderware MES
► Integrated use of System Platform + MES
► Templates for MES User Interfaces
► The Value of a consistent data model
▪ Templates
▪ Deployment
In Conclusion…
► Wonderware Operations and Performance
Software offers:
▪ Rich MES functionality that can be deployed
▪
▪
incrementally
Maximizing effectiveness
While reducing risk and time to value
Wonderware Workshops
Operations Management - Monday
Time
Topic
Zunkles Room
10.00-10.50
An Overview of Wonderware MES
Products
Jan Rasmussen
11.00-11.50
NEW! - Wonderware Performance
Software - Real-time equipment
downtime and performance tracking
Dawid Sadie
14.00-14.50
Manage and maintain your assets
utilising Wonderware's condition based
monitoring (CBM)
Tim Sowell
15.20-16.10
NEW! - Wonderware Industry Application Andrea Sartori
for Packaging
Wonderware Workshops
Operations Management - Tuesday
Time
Topic
Zunkles Room
10.00-10.50
Manage and maintain your assets
utilising Wonderware's condition based
monitoring (CBM)
Tim Sowell
11.00-11.50
NEW! - Wonderware Operations
Software - improve production
consistency, visibility and agility
Andrea Sartori
14.00-14.50
NEW! - InBatch 9.0 - Flexible
management for batch processes
Jos Peters
15.20-16.10
Advanced Scheduler for
Wonderware MES
Chris Mollison Preactor
Time
Topic
Injasuti Room
11.00-11.50
NEW! - Wonderware Performance
Software - Real-time equipment
downtime and performance tracking
Dawid Sadie
14.00-14.50
NEW! - Wonderware Industry Application Andrea Sartori
for Packaging
Questions
Thank You
[email protected]