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Wonderware Operations Software “Improving Manufacturing Operations”

Terence Tan

General Manager

MES

Definition according to MESA International:

Manufacturing Execution Systems (MES) deliver information that enables the optimization of production activities from order launch to finished goods.

Definition according to ISA:

The MES layer focus in a group of activities (operations, inventory, quality and maintenance activities) corresponding to Level 3 in the Functional Hierarchy model.

ISA Model

Level 4 Business Planning & Logistics Plant Production Scheduling, Operational Management, etc Level 3 Manufacturing Operations & Control Dispatching Production, Detailed Production Scheduling, Reliability Assurance, ...

Levels 2,1,0 Batch Control Continuous Control Discrete Control

Purdue CIM Model

Level 4: Enterprise Resource Planning System Level 3: Manufacturing Execution System Level 2: Process Supervisory System(s) Level 1: Real time Controllers Level 0: Instruments and Actuators

The MESA model

Sales & Service Management Operations/ Detailed Scheduling MES Resource Allocation & Status Dispatching Production Units Product Tracking & Genealogy Performance Analysis Enterprise Resource Planning Document Control Labor Management Maintenance Management Process Management Quality Management Data Collection Acquisition Supply Chain Management Control

What is Wonderware MES?

Wonderware MES

Wonderware MES is an out-of-the box, configurable, modular Manufacturing Execution System (MES) software focused on production execution, shop floor data collection and analysis.

Product History

March 2009 February 2008

Wonderware Operations and Performance 3.5

Wonderware Operations and Performance 3.4

October 2007 July 2007

EPM 2.0 = Factelligence 3.1 + QuickStart Wonderware Factelligence 3.1

2002

First version of Factelligence by CIMNET

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

Licensing

Operations Premium Wonderware MES

Utilization and Downtime

Performance

Work Order Execution Bill of Materials Parameters Download Data Collection OEE Production Events Tracking

Operations Standard

Inventory Labor Management Certifications Steps

Wonderware MES Architecture

Clients Configurator Supervisor Operator Manager IIS Custom .NET App Middleware Wonderware MES Service Database Server COM+ Package Factory Connector

Production DB

Wonderware MES Middleware

Wonderware MES Client

System Requirement - Software

System Requirements Hardware

Operations Software… Functional Overview

Operations Standard Operations Premium

Work Order Execution Specifications Bill of Materials Parameters Download Data Collection Inventory Certifications Labor Management Steps ► ► ► ► Improve Inventory Turns and Reduce Inventory Cost ▪ Accurate recordkeeping, visibility Reduce Order Lead Time ▪ Dynamic allocation of production assets ▪ Enforcement of production rules / steps Reduced Time-to-volume for New Products ▪ Map entity model, product / process context Improved Compliance & Governance ▪ Electronic system records, history

Operations Software – Standard Edition

Improve Productivity

via

faster

‘Changeovers’ product or line

Central administration of process and product parameters

  Maintain Bills of Material (w/ version mgt) Product & material specs w/ min/max limits per BOM entity  General recipe definitions using site specific processes

Accurate equipment setup

 Site specific product specifications  Automatic download of set points

User-based parameter management

 Operator visibility of set point values (.NET Controls)  Associate drawing, multimedia file or documents to specifications  Build Operator dashboards tailored to specific operation (InTouch, .NET controls)

Faster Changeovers – One Version of the Truth

► Electronic Bills of Material & Specifications ► Centralized administration with version control

Faster Changeovers – Accurate Equipment Setup

► Site Specific Product Specs ► Auto Download of Set Points

Faster Changeovers… Better Operator Visibility

►

Powerful Set of .NET Controls for Building Operator Displays

►

Flexible Display Options

▪

InTouch

▪

Operator

▪ ▪

Third Party HMI Web

Respond Faster to Production Issues

via Planned vs. Actual Production Values

Electronic management of Work Orders

 Ability to change job prioritization & sequencing via Operator displays & job summary .NET Control

Recording of production events

  Material consumptions Complete “as built” records per work order

Immediate detection of deviations

  Specification or plan deviations Real-time database captures full production data record  Active alarm management system • Equipment & material

Planned vs. Actual Production

►

Online Work Order Management

▪ .NET Controls used in Operator Displays ►

Visibility to Planned Values

►

Summary of Planned vs Actual Production

Reduce Production Errors & Increase Yield

Consistent interpretation of operating guidelines and procedures

 Accurate paperless execution of work orders & jobs  Show work instructions, SOPs, drawings, NC programs

Central, detailed definition of user privileges and security roles

 Assign user rights per entity or process  Job based login  Common security definition using ArchestrA security, including Operating System integration

Central definition of process and product parameters

  Electronic Bills of Material Define processes, specifications, Classes

Execution of Work Orders

►

Create a Process

►

Create a Work Order from the Process

►

Start and Monitor the Status of a Work Order

Central Definition of Process & Product Parameters

►

Electronic Bills of Material

►

Specifications

►

Processes

Operations Premium Edition Functional Overview

Operations Standard Operations Premium

Improve Inventory Turns & Reduce Inventory Costs

via Accurate Records and Increased Visibility

Accurate records of actual material consumptions and production levels

  Automatic data collection Broad inventory mgt functionality; receiving, shipping, scrap, hold, transfers, splitting/combining, re-classifying lots

Detailed definitions of materials

   Bills of Materials Material substitutes Status information on raw materials, Work in Progress (WIP) & finished goods

Immediate access to real-time inventory status

Reduce Production Lead Time

through Dynamic Allocation of Production Assets

Electronic production order management

  Ability to perform prioritization & sequencing Enforcement of production rules

Flexible operational planning based on accurate, detailed information

 Actual production resource information

Dynamic allocation of production assets

 Based on actual availability of material, equipment or personnel

Reduced Time to Volume for New Products

via Enforcement of Production Rules

Rapid binding of process capabilities and product definitions

 Integration of ArchestrA plant model with Operations’ production model  Detailed definition of sequencing of operating activities  Manual/auto tasks  Steps (procedures)  Accurate records for cycle times, yields, consumptions during initial production runs

Common system environment for model definition, execution and operations

 Ability to define Process “State” as experimental or production  Ability to Certify resources according to defined process “State”

Improved Compliance & Governance

via Complete Production Records

Complete electronic system records for production, quality and processes

 Rapidly respond to unforeseen events, such as product recall or audits (internal, external)

Internal process harmonization

 Share best practices and scale across multiple installations

Help ensure safe operations with enforcement of SOPs

 Comply with environmental, health and safety standards

Genealogy & Traceability Reporting

► Operations Software’s complete data record & easy retrieval make responding to governmental information requests straightforward & easy

Summary

► 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, Supply Chain Connector, MES Clients ▪ Physical Scalability – equipment, lines, plants ► Highly Integrated ▪ Wonderware Connectivity • Historian, System Platform MX, OPC, Suite Link ▪ Wonderware’s System Platform • Single Industrial Application Development Environment ▪ Wonderware InTouch • World’s leading HMI