IN18 - FactoryTalk ProductionCentre: What's New in R10 and Industry Suites

Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. RA-TechED 2015 @RA-TechED #RA-TechED

PUBLIC INFORMATION

IN18 - FactoryTalk® ProductionCentre® MES Overview Presentation


Agenda

FactoryTalk® ProductionCentre®

MES Strategy & Portfolio Overview

Industry Suites

Fit for Purpose Applications

Success Stories

Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. RA-TechED 2015 @RA-TechED #RA-TechED 3

Leading Global Provider of Industrial Power, Control and Information

Solutions

Automation

Solutions for a

Broad Range

of Industries Serving Customers for 110

Years

Strong Culture of Integrity and

Corporate Responsibility

22,000 Employees in

80+ Countries

Fiscal 2014 in excess of $6 billion

US

Canada

EMEA

Asia Pacific

Latin America

Control Product &

Solutions

Architecture &

Software

Rockwell Automation® at a Glance


Industry Suites that provide Specific Functionality for Vertical Industries

Fit for Purpose Applications that Perform Specialized Functions and Interoperate

Information Software Portfolio that unifies all Software Layers for an Enterprise

Architecture that is Proven, Scalability & Flexible

Leading Standards Based Java Technology for Scalability, Performance and Cost Effectiveness

HTML5 Client User Interfaces

Mobile & Tablet Solutions

Innovative, Cost Effective Solutions that Deploy Easily & Scale with the Organization

Configurable Business Workflows, Rules & User Experience

Multi-site Customer Deployments Globally, Centrally, Distributed & Cloud

Market Leading Manufacturing Solution


Deliver Customer Value

Standardize Business Practices & Global Visibility

Improve Collaboration & Efficiency across Multiple Facilities

Manage Global Plants & Facilities including Suppliers, Customers and Partners

Effectively Control As-ordered, As-built and As-shipped

Brand Integrity

Reduce IT Lifecycle Costs: Installation, Configuration, Management & Maintenance

Reduce HW and SW Costs

Deliver Best in Class MES Suites and Fit for Purpose Applications

Comprehensive Suites Solutions Tailored and Configured for Specific Industries.

Fit for Purpose Applications are Interoperable and Installed Together to provide a Comprehensive

Solution for Discrete and Process Industries

Rockwell Automation MES Strategy


Deliver Application and Data Integration Solutions

Data Integration Platform to Organize and Visualize all Factory Data

Aggregate Factory Data Globally across the Enterprise providing KPIs and Data Analysis

Message Bus Application Integration Platform for ERP and PLM

Deliver on Promise of the Connected Enterprise and Internet of Things

HTML5 Client User Interfaces

Mobile & Tablet Interfaces

Cloud Enabled Suites & Applications

Products that Address Level 0 to Level 4

Rockwell Automation MES Strategy


Machine Line Enterprise Plant

Line Performance OEE

Enterprise Performance, OEE, Track&Trace, Quality, etc.

Machine Performance OEE

Pro

gre

ssiv

e F

un

ctio

nal

ity

Low

High

Plant Performance, OEE

Scalable Progressive Solutions Machine - Line - Plant - Enterprise

Deployment Options

Stratix/Edge

Panel

View/PC

IDC/Server

Cloud

Appliance

Mobile


Integrated Control & Information Software

8

Level 2

Info

Platfo

rm (Eq

uip

men

t, Mate

rial, Oth

er Mo

dels)

Clo

ud

, Mo

bile (M

FT Too

lkit)

Partn

ers (OSI, M

uleSo

ft, IBM

, Red

Hat)

Sen

sin

g

man

ipu

lati

ng

pro

du

ctio

n

pro

cess

Bat

ch, D

iscr

ete

&

Co

nti

nu

ou

s

Co

ntr

ol

Man

ufa

ctu

rin

g O

per

atio

ns

Man

age

men

t

Bu

sin

ess

Pla

nn

ing

&

Logi

stic

s

Business Intelligence ERP/PLM

Portal parts

and content Manufacturing

derived KPIs

Production &

Process data

Level 3

Levels 0 and 1

MES Suites and Fit for Purpose Applications

InfoPlatform Services

FTBatch

eProcedure®

MaterialTrack

PhaseManager™ Sequence

Manager

Ladder Logic

Structured Text

Function Blocks

SFC Programs

InfoPlatform Services

IA / Resource / InfoPlatform Services

Operator Visualization

RAPID PlantPAx®

EnergyMetrix

AssetCentre

Historian


MES Portfolio

9

Solutions


Enterprise Integration Gateway

DataMart

Fit for Purpose Application for Process & Discrete Manufacturers

Order Management & Execution

Scheduling & Sequencing

Quality Management & Performance Management

Recipe Management & Execution

Material & Inventory Management

BOM Management

Equipment Management

Specialized Industry Suites for Vertical Markets

Automotive

Consumer Packaged Goods

Pharmaceutical


Agenda



Industry Suites


Success Stories



Platform provides environment for application

development and base capabilities

Capabilities

Foundation

Platform Capabilities extended as a library

Common clients and other foundation artifact

ensure reusability

Activities

Move

Consume Test

Scan

Reusable components that represent the

business logic for any step in a workflow

Workflows model operator actions,

automated processes and the business

processes

Applications

Application executes workflow, provides UI

based on current steps and allowed tasks

Workflow-based Applications

11

Workflow

Platform


Java EE7 Technology

Industry-standard Technology

Widely adopted by well-known Applications like SAP R/3, ORACLE Applications, and

other Enterprise-class Applications

Proven Scalability for Single Plant and Multi-Plant Installations Designed to Support

Characteristics of Enterprise Applications

High Data Volumes, High Throughput

Many Users Accessing Data Concurrently

Complex Business Logic

Integration with other Enterprise Applications

Scalability

Fault-tolerance (High Availability)

(Confidential – For Internal Use Only) Copyright © 2011 Rockwell Automation®, Inc. All rights reserved.

Proven Technology for Mission-critical Enterprise Applications


Key Business Values

Security and Stability

Platform Choice

Ease of Integration

Configuration versus Customization

Easy to Extend

Deployment by Rockwell Automation®, IT

Organizations & Partners

Service Oriented Architecture (SOA)

Feature-Rich Business Layer

Supports Rich and HTML5 Clients

Java EE7 – Proven Technology for Mission-critical

Enterprise Applications

Security and Stability

Scalability without Limits

Variety of Supported Platforms

IBM WebSphere & JBoss

Windows & Linux

SQL Server & ORACLE

Built-in Application Development Framework

Comprehensive, Flexible & Extensible

Multi-tier Data Model

Service Oriented Architecture (SOA)

13

FactoryTalk® SOA – Reliable and Scalable Enterprise Architecture


Differentiators:

HTML5 Clients, Mobile & Tablets

Manufacturing Models for Discrete, Process &

Hybrid Manufacturers

Multiple Device Support (Internet of Things)

Mobile, Tablet, Workstation & HMI

Flexible Installation Architectures

Centralized, Distributed & Hybrid

Reduced IT Infrastructure Cost

HTML5 Clients

Cloud Support

Sample Customers: GE Healthcare, St. Jude

Medical, Pfizer, Mahindra, Betaseed, Hexcel,

Mondelez & Kraft

Market Leading MES Product

Built on the latest JAVA EE7

Only MES with pre-built Functionality Required by

Discrete, Process & Hybrid Manufacturers

Powerful Workflow and Process Configuration

Built-in Configuration & Extension Tools

Workflow Editor & Form Builder

Configuration Management

Flexible Client Options

Rich Thick Client Supports Advanced Features

Mobile & Tablet Client

Open Platforms

IBM WebSphere, JBoss

Windows, Redhat Linux

SQL Server & ORACLE

R10 – Next Generation MES Product built on the latest JAVA EE 7 Standard


Supported Platforms

Application Servers

IBM WebSphere 8.5.5.3

RedHat Jboss EAP 6.2

Operating Systems

Microsoft Windows 2008 (Enterprise & Standard Editions, 64-bit) R2 SP1

Microsoft Windows 2012 (Standard Edition, 64-bit) R2

Red Hat Enterprise Linux AS5 Update 10

Virtual Hardware Version 8 with VMWare ESX/ESX1 5.0

Operating Systems (Client)

Microsoft Windows 2008 (Enterprise & Standard Editions, 64-bit) R2 SP1

Microsoft Windows 7 (Professional Edition, 32- & 64-bit & Enterprise Edition, 64-bit) SP1

Database Servers

Microsoft SQL Server 2008 (Enterprise & Standard Edition, 64-bit): R2 SP1

Microsoft SQL Server 2012 (Enterprise Edition, 64-bit) SP1

Oracle (Enterprise Edition, 64-bit) 11g Server & 11g RAC

Oracle 12c 15


Message Bus Data Integration Leverages MuleSoft MSB Certified by SAP Proven Scalability, Flexibility & High Availability Message Bus Guaranteed Event Driven Messaging

Over 120 Standard Out-of-the-box Connectors

Supports B2MML & iDoc File Types Orders, BOMs, Parts, Work Instructions Batches & Sublots, Production & Consumption ECO, Inventory, Genealogy

Drag & Drop Graphical Design

Graphical Data Mapping Configurable Workflows

Integration Productivity

Rapid Graphical Configuration for Applications Applications, Technologies & Protocols: SAP, PTC, MS SQL,

Oracle, DB2, Files, Active MQ, JDBC, etc.

16

Differentiators Message Bus Integration Standard Out-of-the-box Touch Points

Discrete & Process Industries Pharmaceutical Automotive Consumer Packaged Goods

Sample Customers: Roche, Mondelez, GE Healthcare, CJLR & Fonterra



DataMart

17

Big Data

Graphical easy to use Application Data Integration Platform

Transform, Clean & Distribute Data from & into Applications, Files,

Databases & Warehouses

Application Specific Reporting Schemas


Industry Suites

Configurable & Extensible

External Databases

VantagePoint Dashboards & Reporting

Key KPIs for Machines, Lines, Sites & Regions (Yield, Scrap, OEE,

Advance Genealogy)

Pre-defined, Extensible ETL Transformations

Powered by Talend ETL

Differentiators Enables Manufacturing Big Data

Strategy Pre-defined Specialized Reporting

Schemas Application Data Integration Platform Premier Integration to Rockwell

Software® & Devices


FTPC Architecture

18

Production

Database

Operational

Data Store

Internet Browser

EJB

Business Objects

Object Relational

Mapping

JDBC

RMI Web Services

DataMart

Terminals Tablets

Multi-Tier Database Benefits High Performance Transactions

Unattended Reporting

In-Depth Analysis

Java Application

Server Benefits Industry Standard / Open System

Scalable solution with High Availability

Simplified, low impact upgrades

Near Zero $ IT support

HTML5 Client Benefits Fast, low effort deployments

Global Reach

Zero $ IT Support

Service L

ayer

HT

ML

5

Servlet

3rd Party

Applications

Java Applications

Service Layer

Mobile

Smartphones


Distributed Architecture

19

N. AMERICA

Enterprise Reporting

Benefits

Plants and Facilities have Local Systems to

ensure uptime and effectiveness

Each Sites Maintains own Server & Data

Reporting at Local Site or Enterprise Level

Load Balancing & Clustering Support via the

Application Server at each Site


Centralized Architecture

20

Benefits

Hosted in a Single Data Center

Private & Public Cloud

Reduced IT Costs

Global Real-time Visibility


Agenda



Industry Suites


Success Stories


Business Value Lean & Continuous Improvement Progressive & Autonomous Maintenance Operational Excellence

Differentiators Capabilities

Performance Management

HTML5 Thin Clients, Mobile & Tablets

Machine Event Tracking

Downtime Data Collection

Overall Equipment Effectiveness (OEE)

Mean Time Between Failure (MTBF)

Mean Time to Repair (MTTR)

Simple Data Collection Configuration – tag browsing requires no changes to automation

Operator Console – OEE Analytics & Event Management in one simple user interface

Drives Operations Excellence – Advanced Dashboard offers 50+ Performance Reports & 20+ Performance Dashboards

HTML5 Clients

Pre-built Functionality Required by Discrete, Process & Hybrid Manufacturers

Simple User Experience & Reduced IT Infrastructure Cost

Standalone or Integrated into Production Centre MES

User Configurable Reports

Premier Integration leverages existing Rockwell Automation Investment

Operational Performance Dashboard


Business Value Brand Protection Positive Release Eliminate Plant Floor Quality Paper Work Reduced Cost of Compliance Right 1st Time Manufacturing


Quality Management


Quality Recipe Configuration

Innovative Sample Plan UI Configuration & Workflow

Flexible Sample Plan Triggering

Quality Business Process Workflow Enforcement

In-process Quality Sampling

Flexible Notification Engine – never miss a scheduled quality check

Out-of-spec Escalation – dynamically change quality testing regiment based on test results

Quality Dashboard

HTML5 Clients


Multiple Collection Sources


Configurable Out-of-spec Escalation

Configurable UI Workflow


Standalone or Integrated into Production Centre MES



Best in Class Recipe Management – advanced user interface or ERP Integration

Bill of Material Configuration

Process Parameter Management & Integration to Automation ensures that equipment is configured correctly for every order

Order Planning & Execution

Innovative UI Configuration & Workflow

Process Sequence & Route Enforcement

Complete Electronic Batch Record

Complete Electronic Production Record

HTML5 Clients



Integrated Genealogy Reporting


Out-of-the-box ERP Integration

Sample Customers: Beta Seed, Hexcel, Align Technologies & Beechnut

Business Value Right 1st Time Production Golden Batch Operational Excellence

Differentiators

Production Management

Capabilities


Business Value Supply Chain Efficiency & Build to Order Inventory Stock Reduction Lean Manufacturing


Material Management

HTML5 Thin Clients, Mobile & Tablets Bulk Material Receiving Bulk Material Inventory Management WIP & RM Inventory Management Innovative Material Path Modeling –

never start an order before validation required materials are available

Wet & Dry Inventory Consumption Rule Configuration ensures that the correct material lot is consumed & recorded

Innovative UI Configuration & Workflow Carrier Management Pre-configured Inventory Transaction

HTML5 Clients



Integrated Genealogy Reporting



Sample Customers: Mullins Foods, Kraft & Ford


Agenda



Industry Suites


Success Stories


Business Value Operational Excellence Reduced Cost of Compliance (Trading Partner &

Regulatory) Supply Chain Effectiveness


Best in Class Recipe Management

Recipe & BoM Management

Order Planning & Execution

Complete Electronic Batch Record Recording

Bulk Material Receiving

WIP & RM Inventory Management

Backwards & Forwards Genealogy

Quality Business Rule Enforcement

In-process Quality Execution

Real-time Performance Reporting via our OEE & Performance Dashboard

Industry Specific Workflows & UIs on Production Centre MES

Modular Solution – Invest in the capability needed to support today’s key business problem



Sample Customers: Kraft, Fonterra, Beechnut & MARS


Business Value Right First Time Production On-hand Inventory & Inventory Holding Cost Reduction Supports Lean & Continuous Improvement


Work Order Management

Route & Processing Sequence Enforcement

eKanban Management

Line Side Inventory Reduction leveraging eKanban & Kitting capability

Backward & Forward Genealogy

Track & Trace

“Mistake Proof Unit Assembly” – supported by integrated error proofing

In-process Quality Management & SPC

Operational Intelligence

HTML5 Clients

Industry-Specific Workflows & UIs on Production Centre MES

Modular Solution – Invest in the capability needed to support today’s key business problem




Sample Customers: Ford, CJLR, Tata, Mahindra & Volvo Powertrain


Business Value Lowered Cost of Compliance Increased Production Efficiency Reduce Inventory


Holistic Electronic Batch Recording

GMP Aligned Material, Equipment & Personnel Tracking

Weigh & Dispense

Master Recipe & Workflow Design supported by best in class Recipe Designer

Electronic Batch Record Execution with uniquie usability paradigm on the shop floor

Review by Exception in Real-time with innovative Quality Dashboard

Integration to the ERP and Automation Layer

Role-based Optimization for Each Stage of the Recipe Life Cycle – “time to results for every user”

“Open Content“ Architecture to allow content building by 3rd parties & customer IT

Broad Capabilities to Adapt, Configure & Extend



Technology to Lower Deployment & Maintenance Cost

Scalable, Reliable & Upgradable

Sample Customers: Pfizer, Avon, Dr. Reddy’s, Roche Diagnostics & Sanofi-Aventis


Agenda



Industry Suites


Success Stories


20 YEARS AVG PRODUCT LIFE

PRODUCT TYPES • Stock + Configure to Order

• Engineered to Order

387, 000 SKUS

200 PARTS AVG ORDER

20 PLANTS

The Connected Enterprise at Rockwell Automation® Our Journey: Discovery to Implementation

The Rockwell Automation Experience


Challenges

32

ISSUES DISCOVERED Independent

ERP systems

Custom

applications

Model replication

cost prohibitive

Autonomous

P&L centers

No single

system to

run plants

Numerous

functional

experts

People + Process + Technology


The Connected Enterprise Implementation at Rockwell Automation®

PL

AN

T

FL

OO

R

MA

NU

FA

CT

UR

ING

O

PE

RA

TIO

NS

M

AN

AG

EM

EN

T

EN

TE

RP

RIS

E

Data Collection

Secure Network

Infrastructure

Multi-discipline

Control & Information

Smart Assets

Scalable computing

Mobility

Integrated Control and Information - Logix Manufacturing Execution System -

Standard Ethernet with Common Industrial Protocol (CIP)

Rockwell Automation® Cloud platform

MACHINES & TESTERS

INDUSTRIAL “THINGS”

MATERIAL &

TRANSPORT

SHOP FLOOR PERSONNEL

PRINTERS & LABEL SERVICES

PLCS & SCANNERS

FINANCIALS HR LOGISTICS QUALITY WAREHOUSE ERP

Modular Information System –


LOWER TOTAL COST OF

OWNERSHIP

Inventory

120 days to 82 days

CapEx

30% per year in

capital avoidance

Productivity ►4% to 5% per year

FASTER TIME TO MARKET

Delivery

Mid-80s to 96%

Lead Times

Reduced 50%

ENTERPRISE RISK

MANAGEMENT

Time to Want

82% to 98%

Quality

50% reduction in PPM

The Connected Enterprise Rockwell Automation® Transformation


Results

Reduced Back Orders (80% lower for 1 plant)

Reduced Inventory, Increased Inventory Accuracy


Customer Success – Building Materials

Large manufacturer of high quality residential and commercial building materials and related products improves quality and reduces

costs …

Lack of Inventory Accuracy, Supplier Visibility

High Shop Floor Inventory (stock) to Ensure Availability to Deliver is Costly

Unplanned Stock-outs Decrease Productivity and Impact Delivery Times

Build-to-stock & Build-to-order Required Flexibility in Manufacturing Execution

Paper Based Systems Introduced Variability, Cost and Complexities

Scrap & Re-work is Costly (esp. in Build-to-Order)


Work Order Execution

KANBAN

Quality: SPC & Reporting

Supplier Integration for Material Requests &

Quality Reports

ERP Integration (BAAN)

Reduction of Scrap by Identifying Short Term Trends & Take Action

Increased Reliability in Supplier Management (integration reduces problems with wrong parts)



Accelerate NPI

High Overhead Costs

Lack of Visibility into Production

Lack of Predictable Quality

Efficiently Satisfy FDA & ISO

Manage Migration to Outsourcing

Supplier of small medical devices looking to improve overall quality & reduce NPI time through improved CAPA, electronic (paperless)

support for regulated industries…


eDHR

Quality – CAPA

Supplier Management – IQA

RMA

Knowledge & Dashboard

Root Cause Analysis Reporting

Customer Success – Medical Device

Results 25% CAPA Cycle Time Reduced

20% Reduced Admin Time

20% Decreased Process Defects



Remove Legacy Solutions & Reduce IT Spend

Support GMP Requirements

Increase Manufacturing Yield

Enhance Product Quality

Genealogy

Single System Deployment across Manufacturing Sites

Closely Aligned with SAP Deployment

Results Deployed at Over 40 Sites

Closes the Loop between Shop Floor & ERP

Complete Production Genealogy Record

Reduced Order runtime

A large dairy manufacturer with multiple sites tasked with time-to-delivery, quality (freshness) and planning challenges …

Customer Success – Dairy Manufacturer


Recipe Management

Order Execution

ERP Integration Gateway

Integrates MES & SAP – recipe download, order download, production declaration upload



Supplier Quality

Problem Cycle Time Resolution

Paper Based Factory (errors)

Quality/Failure Analysis

High Field Returns

High Warranty Costs

Results

25% Quality Improvement

40% Problem Resolution Cycle Time Reduction

Replaced 7 Legacy Systems – Saved $1.2 M

Global Implementation includes Direct Access to 50 Suppliers

Customer Success – Semiconductor


WIP Management

Quality

SPC & Yield Management

Defect & Issue Resolution

Knowledge & Dashboard

Root Cause Analysis

Proactive Alerts & Notifications

Large supplier of yield management and process control solutions for semiconductor and related microelectronics industries looking to improve overall quality through deep unit tracking, non-conformance…



Enabling Regulatory Compliance

Improving Quality Effectiveness

Reducing Labor & Operating Costs

Reducing Material Consumption

Improving Equipment Performance

Results High Reduction in Manual Effort to Comply with Quality & Regulatory

Requirements

Reduction in Operator Omissions & Errors

Reduction in Manual Effort in Dispensing

Reduction Operating Costs

Reduction in Wastes & Variability

Improved Availability of Accurate & Timely Information for Data Analysis

Customer Success – Life Sciences

Rockwell Software® PharmaSuiteTM

Recipe Management

Weigh & Dispense

$ 1.9 Million Savings ROI 832 %



Multiple Assembly, Body In White, Engine & Paint Shops Covering Distances over 5 kms

Complex Product Mix and Variants

Enterprise Real-time Visibility

Obtain Product Consistency & Quality Targets

Guide a Diversely Knowledgeable Workforce to Perform Correct Tasks & Achieve Desired Quality

Results

Leveraged Centralized Data Center & High Availability Local Plant Architectures to:

Eliminate Down Time & Production Losses Due to System Unavailability

Reduce System Support Staff for 3 Plants

Continuous Improvement in Product Quality by Error-proofing, In Line Quality

Inspection & Coordinated Prevention Measures

Inventory Cost Reduction with MES Enabling JIT / JIS Lean Manufacturing Principles

Industry Recognition: CSI 2014 Award for “Excellence in IT”

Customer Success – Automotive

Roll out of a common MES solution to leverage investment of centralized software and support


Order Execution

Sequencing

Error proofing

Quality Management


FactoryTalk® View & FactoryTalk Vantage Point for Real-time Displays, Reporting & Dashboards


Agenda



Industry Suites


Success Stories

IN18 - FactoryTalk ProductionCentre: What's New in R10 and Industry Suites

Technology

Transcript of IN18 - FactoryTalk ProductionCentre: What's New in R10 and Industry Suites