Manufacturing Operations Management...

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Manufacturing Operations Management (MOM)

ANZ Ops Manage 2013

Tim Sowell - VP , Invensys Fellow , Global

Grant Kelly - MES Solution Consultant, APAC

1 Invensys Offerings for MOM

MES, Batch and Quality • Manufacturing operations (MES) • Performance and efficiency (OEE) • Batch planning, execution and tracking

Intelligence • Aggregate, contextualize, visualize • Dashboards, Key Performance Indicators

Production &

Performance

Production and Performance Offerings

Mobility • Mobile workflow and decision support

• Maintenance, production and compliance

Software Solutions that

Help Ensure Your

Success in Real-Time

Environment and Safety Excellence

Asset Excellence

Productivity Excellence

Control Excellence

Collaboration / Workflow • Business Process Management

• Standard Operating Processes

Enterprise Integration • Between plant applications • Between plant and business apps.

Additional

Initiatives… Additional

Initiatives… Additional

Initiatives… Lean

Manufacturing

Quality

Regulatory

Compliance

Product

Lifecycle

Real Time

Enterprise

Total

Productive

Maintenance

Additional

Initiatives…

Financial & Performance

Focused

ERP

Product Focused

CAD, CAM,

PLM

Compliance Focused

Docs, ISO,

EH&S

Supply Focused

Procurement

SCM

Asset Reliability Focused

EAM

Resource

Tracking

& Status

Performance

Analysis

Process

Management

Data

Collection

Acquisition

Quality

Management

Product

Tracking &

Genealogy

Customer

Focused

CRM

Labor

Management

Dispatching

Production

Units

Logistics

Focused

WMS, TMS

Control

PLC, DCS

Enterprise

Control

Systems

(ECS)

Events

Bar Code

&

RFID

Manual

Data

Collection Control

Systems

Databases

& Cubes

Events Events

Historians

Control

PLC, DCS

Supply Chain Connector / Wonderware Enterprise Integrator

Performance

Performance

Analysis

Quality

Quality

Management

Operations

Resource

Tracking

& Status

Process

Management

Data

Collection

Acquisition

Product

Tracking &

Genealogy

Labor

Management

Dispatching

Production

Units

Logistics

Focused

WMS, TMS

2 Invensys Approach to MOM

MOM Logical Architecture in Mining

Application Object Servers (AOS)

Plant / Production Model

Operational Embedded Procedures (Workflows)

Hist

MES

Supply Chain Infrastructure

AOS


Operational Workflows

Tier 1

Hist

Operational Infrastructure

AOS




Tier 1

Hist

Standards

• Plant Equipment

• Production Activities

System Platform Configuration/ Deployment

• One Names Space

• Logically One

• Physically Distributed

• Version Mgmt

Enterprise Service Bus

Messaging Infrastructure

Message Transformation

LIMS Delay Acctng Time Usage

Logistics Scheduling

Rail Status Board

Inventory Management

Mines Planning

Supply Chain Apps

Mine Port

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Single Namespace

Managed as Logically ONE

Supply Chain

Plant Equipment Model Context

Platform

AppEngine

Plant Equipment

Model

Historian Time Series Tier 1 (local) Tier 2 (SC)

Equipment Context

Time Series Process data

Time Series Calculations Data

Time Series Events/ Alarms

Existing Systems Tags

End User Standards

• From Equipment Standards

• From Calculation Standards

• Tags are assigned to

Equipment

• Equipment Time Series is

captured

Product comes with Standard

Objects

• Standard Objects

• Domain Objects

• Toolkits to Build Further

Flexibility in Standardization

• “Infrastructure” for Real-time Management of

Operational Data

• Unified Plant Model

• Common Name Space

• Software, Systems and Devices Connectivity,

Independent of Hardware

• Management & Extensibility

• Templates Driven with Extensiation and Derivation

capabilities (Objects, Scripts and Graphics)

• Common Configuration

• Engineering Reusability

• Change Propagation

Maintainable

Integration

Application

Standardization

Future

Changeability

Easier Deployment

Easier Installation

Easier Configuration

Easier Maintenance

Easier Management

Templatized Approach

Reduced TCO

Lower Risk

System Platform is the foundation for adapting standardization to your business

Alarms & Events

Inputs/Outputs

Logic/Scripting

Historical Information Security

Equipment Centric Objects

Text & Email Alerts

Asset Performance • Downtime • Productivity •Instrument Asset

Graphic Symbols/Faceplates

Predictive Maintenance

Operational Discipline • WorkFlow •Escalation •Signoffs

How Companies Develop Standards

Leading companies are building Toolsets:

• Exxarro

• Kumba Mining

• Nestle

• General Mills

• Arcellor Mittal

• China High Speed Rail

• EDF Power

S95 Standards can be modelled

Providing the Plant Model Context

Enterprise Site

Area

Sub-Area

Process Cell

ASSMANG Khumani

Iron Ore Mine (South Africa)





Hist

MES


AOS



Tier 1

Hist


AOS




Tier 1

Hist

Standards

• Plant Equipment



• One Names Space

• Logically One


• Version Mgmt






Rail Status Board


Mines Planning

Supply Chain Apps

Mine Port

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Single Namespace


Supply Chain

Add Equipment Performance Context

Platform

AppEngine

Plant Equipment

Model

MESDB

Database Asset Utilization Capability Object

Raw Reason

Delay Context

Delay Time

I/O for Work Order

I/O for Production Counts

I/O for Machine State

Current Values

© Invensys 13 May 2013

Reduce Capital Expenditures by identifying the most productive assets for continued operation

Improve Asset Utilization by identifying production bottlenecks more quickly and increasing supplier accountability

Increase the Capacity of your existing assets by pinpointing the causes of unplanned downtime and improving operational efficiency

Leverage Best Practices by comparing line-to-line and plant-to-plant performance, including real-time OEE measures

Empower Operators by providing visibility to real-time asset performance KPIs that enable them to “take action”

Wonderware MES – Performance Value Proposition

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Equipment Utilization

Ability to Detect and Capture Utilization Events Ability View Equipment Events Ability to Monitor and Record Equipment State Ability Automatically or Manually Assign Reason Codes

Equipment Performance

Ability to Calculate OEE for Equipment / Line Ability to Trigger Events and Display Ability to Analyze Event Frequency and Duration Ability to Assign What States Affect OEE Calculation

Production Progress

Provide a Clear Indication of Job or Production Order Progress to the Operator in Real Time

Ability to Calculate OEE Other Key Parameters Ability to Estimate Expected Completion Date and Time

Wonderware MES – Performance Features


Wonderware MES - Performance GUI Examples

Add Production Context

Platform

AppEngine

Plant Equipment

Model

I/O for Work Order I/O for Production

Counts

I/O for Consumption

Counts

Production Operations Capability Object

MESDB

Database

Inventory / Movement

Current Values

Asset Utilization Capability Object

Create WO

Raw Reason

Production / Consumption

Delay Context

Delay Time

I/O for Work Order

I/O for Production Counts

I/O for Machine State

Improves Manufacturing Agility by providing real-time production execution information and alerts to the right people, at the right time

Drives Consistent Production Execution through strict enforcement of electronic manufacturing procedures (process, operator, equipment & materials)

Captures Comprehensive Manufacturing Genealogy by collecting a complete production routing history (including assets), labor history and material usage history – improves compliance and governance

Improves Decision Support & Planning within the Supply Chain by providing real-time order, material (raw material & WIP), equipment and labor status

Wonderware MES - Operations Value Proposition

Product Definition

Ability to Define Raw, Semi-Finished or Finished Goods Attach Multiple BOM Definitions (versions) to a Product Attach Multiple Specifications (versions) to a Product Synchronize Products Definitions with External Systems

Bill of Material Definition

Multi-level BOM (n-tier) Define Multiple Substitutes per BOM Item Define Co-Products / By-Products Configure Specific Material Processing and Tracking

Business Rules per BOM Item (e.g. backflush, maintain inventory, must consume from previous step, etc.)

Product Definition

Wonderware MES – Operations Features

Production Management & WIP Execution

Full Production/Process Order Management Define and Execute Product Specific Production Routings Record and Track Production, Consumption and Labor WIP Status and Characteristics


Configure Business Rules for Tracking Inventory (e.g. maintain composite lots, etc.)

Can track bulk, lot or serialized inventory items Ability to Transfer, Split, Combine, Receive, Ship and

Reclassify Inventory Items

Production Execution

Storage Management

Ability to Define Fixed or Mobile Inventory Locations Ability to Monitor the State of Inventory Locations Track the Movements and Location of Mobile Storage

Devices

Wonderware MES – Operations Features (cont.)

Equipment / Machine Setup

Common Equipment Setup Templates Enable Consistency in Equipment setup Ability to Capture a “Golden” Setup Ability to Enforce Steps and/or Procedures

Procedure Step Manager

Guide an Operator Through a Manual or Semi-Automatic Procedure at a Particular Manufacturing Operation

Configure Required “Step Actions” (e.g. consume material, acknowledge message, view document, etc.)

Equipment Operations

Production Event Tracking

Ability to Capture Production Events Including Counts, Weights, Scrap and Reason codes

Ability to Report and Drill Through History, Enabling Genealogy, Traceability

Wonderware MES - Operations Features (cont.)

Enable Plant Document & Work Instruction Definition

Define Electronic Folders with Associated Documents and Work Instructions (multiple versions)

Configure Document Viewers to Use for Specific Document Types

Manage Links to Other Documents

x x Work Instructions & Document Management

View Many Different Document Types (e.g. PDF, MS Documents, Web Page, etc.)

Link Work Instructions and Documents to Products, Production Orders, Operations, Work Centers or Procedural Steps

Work Instructions

Wonderware MES - Operations Features (cont.)

Process/Route

Item(s) Operation(s)

Attributes Attributes

Machines

Documents

Specifications

Machine Specs

BOM Consume

Certifications

Data Collection

Steps

BOM Consume

Certifications

Documents

Data Collection

Attribute(s)

Specifications

Machine Specs

BOM Specs

BOM Specs

All Master Data Elements are Bound to a

Process/Route

Wonderware MES - Operations Process Routing


Wonderware MES - Operations GUI Examples


Improved Product Quality and Consistency

• By improving quality and consistency, you increase your ability to get it right the first time; enabling you to improve scheduling accuracy and meet the delivery needs of your customer

• Enhanced product quality builds brand equity and reinforces the overall value and standing of your business to customers

Decrease Costs Through Reduction of Waste

• Monitor processes in real-time to identify quality problems or excursions, allowing you to take corrective action sooner

• Employing statistical process control techniques, you can prevent defective products from leaving the facility, reducing the impact of repair and warranty issues

Wonderware Quality Value Proposition


Item and Item Class Definition Entity and Entity Class Definition Variable/Attribute Definition Specification Definition Import Specifications from External Source (ERP/PLM)

Wonderware Quality Features


Specification Management


Sample Plan Definition Sample Naming Scheme Sample Plan Frequency Definition Import Sample Plan from External Source (ERP/PLM)

Sample Plan Definition Mgt.


Wonderware Quality Features (cont.)

View/Record Sample Details Sample Collection Notification Additional Sample Request Generation Automatic Sample Collection

Sample Plan Execution Mgt.


Standard Run Rule Selection SPC Charts – Xbar Range and Sigma, Moving Average, X

Individual, p/np/c/u/DPMO Run Rule Violation Trigger Additional Operator Data Collection (e.g. Comments)

Statistical Process Control

Wonderware Quality GUI Examples

Case Study: Esperance Port MES

Existing System: • InTouch SCADA and a

custom built Access Data

Base to capture production

data

• Considerable manual

entries were needed with

room for errors

• Hard to maintain and

unreliable

Requirements for New System: • Remove customization adding a robust and

reliable commercial solution

• Address limitations by having a fully

scalable solution able to expand

• Compliment its existing SCADA investment

and enhance operator access

• Optimize production throughput and reduce

Down Time

• Product tracking and access to product

stages when loading or in storage

• Generate plant wide production reports

accessible to all users

“Management was pressed to increase efficiency, visibility of data, expand operator effectiveness and monitor accurately load throughput through the port and in to ships.”

Case Study: Esperance Port MES

Solution • InTouch Upgraded and Extended with ArchestrA System

Platform and Wonderware MES

• Sustainable Solution based on Products that can upgrade

• Central access to information via Information Server

accessible real time reports

Operational Benefits • Product base – removing performance and maintainability

risk

• Using a centralised and scalable repository, one Operator

interface

• Distributed and compliments existing WW and IIS

infrastructure

• Up to the minute Reports. From Wagon to Ship

• Report downtime and performance KPI’s, OEE

• Rapid expansion to add in existing equipment

• Potential to expand with workflow / ERP integration etc

• After 3 months in use the ROI indicates 3-6 months.





Hist

MES


AOS



Tier 1

Hist


AOS




Tier 1

Hist

Standards

• Plant Equipment



• One Names Space

• Logically One


• Version Mgmt






Rail Status Board


Mines Planning

Supply Chain Apps

Mine Port

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Single Namespace


Supply Chain

Production & Performance

Context

Add Operational Procedure Workflows

Platform

AppEngine

Plant Equipment Model

Escalation - of events and conditions to required people

Enforce - SOP’s, enable collaboration, lean/six sigma, dynamic change mgt

Real time - end-to-end institutionalization of Operational Processes Management

Knowledge management - through standard responses to normal & unscheduled events

Historian Time Series

MES DBase Transactional

ArchestrA Workflow Extending System Platform with transactional Capability

Business Value

• Enable Operational Improvements

• Improve Procedural Quality, Consistency

• Adhere to and enforce Regulatory Compliance

Key Capabilities

• Native extension to ArchestrA

• Ability to handle human interaction

• Digitally capture, institutionalize Best Practices

• Preconfigured Workflows

• Business to Mfg. Connectivity (human

centered)

• Sustainable Interoperability

Empower Expert Operators & Workers to perform the right tasks at the right time using

procedural enforcement, documents, best practices

Model-Driven Operations Management Key Elements

Business Rule/Process Management

Composite solution business rules managed in an intuitive, visual workflow-modeling environment

Out-of-the-box configurable workflow activities for common MES, Quality, Labor, Maintenance, etc. transactions and tasks

Ability to add and manage custom workflow activities for our legacy applications

Ability to build libraries of templates of workflow activities and tasks adapted to your respective business segments

Single Framework to Manage “Solution Business Rules” that Cross-Over Production Application and Organizational Boundaries

Model-Driven Operations Mgt. Key Elements (cont.)





Hist

MES


AOS



Tier 1

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AOS




Tier 1

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• Plant Equipment



• One Names Space

• Logically One


• Version Mgmt






Rail Status Board


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Model-Driven Operations Management User Interface Elements

UI Management

Model simple or complex forms to collect or visualize data in support of composite business rules/processes

Out-of-the-box forms for standard MES, Quality, Labor, Maintenance, etc. functions

Support composite application development (e.g. forms can host data from multiple data sources, etc.)

Forms accessible via many channels (e.g. web client, mobile client – multi platform, ArchestrA graphics, etc.)

Single Framework to Manage “Solution User Interfaces” that Cross Over Production Application Boundaries

Model-Driven Operations Mgt. User Interface Elements (cont.)

Standard form provided

with MES for configuring

Line Classes

Form supports

displaying data from

multiple data sources

(e.g. MES and Galaxy)

Form is extensible

within Forms

Designer

Form button is

linked to workflow

Model Driven Configuration and UI 2013 Release

Visibility/ Reporting / Analysis Presentation

Operations

SQL Server Databases

OLE DB Sources

Other Historians

& OPC-HDA

WW Historian

Real-Time Galaxy

Galaxy Plant Model

Oracle Databases

Reports, Dashboards,

etc.

Analytics

Dashboards Reports Process

Displays

Analytics OverView Mobile

Information Model

Presentation Model

Content

Meta-data

Intelligence

Dimensional

Data Store

Pass Thru Model

Runtime Metrics

Data Source Mappings

Types

Relationships

Rules

• Enables Performance Improvements

– Visibility of Operational metrics provide visibility of improvement potentials in efficiency and cost across responsibilities

– Near real-time monitoring enable corrective actions to running production to minimize losses and cost impact

• Optimize Profit

– Take decisions which provide the best use of capacity and/or lowest cost of delivery

• Improve Collaboration and Leverage Employee Expertise

– Self service access to drill down dashboards and analyses tools enable process improvements

Real-time Operations Metrics Drive Higher Performance

Intelligent Analytics Dashboard Examples





Hist

MES


AOS



Tier 1

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AOS




Tier 1

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Standards

• Plant Equipment



• One Names Space

• Logically One


• Version Mgmt






Rail Status Board


Mines Planning

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Mine Port

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Single Namespace


Supply Chain


Reduces Integration Cost

• Reduces the cost of ownership for integrating Wonderware software to enterprise systems, supporting industry standards such as ISA-95 and B2MML

Increases Inter-Operability

• Enables existing business and manufacturing systems to work in a complementary fashion that is loosely coupled, yet extremely reliable

Enables Business Continuity

• Enables WW MES application to run disconnected from ERP, with the ability to re-synchronize transactions after ERP has come back online

Wonderware Enterprise Integrator Value Proposition


Wonderware Enterprise Integrator

Key Capabilities

Facilitates exchange of information between systems

Maintains message history for fast recovery

Provides store & forward capability to support disconnected operations

Receives & delivers messages to multiple shop floor applications

Provides advanced message management & administration capability

3 In Summary

Wonderware MES/MOM Software

• Operations, Performance, Quality management

– Reduces project scopes, risks, shorter time to value

– Enables step by step functional implementations

• Model Driven Operations

– Embedded Operational Practices

– Enable Consistency of action/ procedure

• Highly sustainable standard software

– Fast adoption of individual customer requirements

– Flexible, consistent enhancements in scope and size

• ArchestrA System Platform Integration

– Leverages investments in System Platform and HMI

– Superior shop floor integration and connectivity

– Standardization and reusability

– Wonderware Applications real-time integration layer

Wonderware

MES Software

Performance

Operations

Quality

Mod

el

Driv

en

(W

orkfl

ow

)

Com

po

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e

Presen

tati

on

Thank You

Model-Driven Operations Management

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

Transforming Software into “Process-Oriented” Applications

SCADA/HMI

Scalable / Adaptive Object Architecture

Asset

Condition

Mgmt

Operation/Log

Book

Task Mgmt

Simulation Alarming

History

Equipment

Object

(Service)

Hist

Mill

Loc

Template Library

ArchestrA Service Bus (iSOA)

Physically Distributed can grow as you need

Application Abstracted from Physical

Mill 1 Mill 2 Mill 3 Mill 4 Mill 5 Diesel Power MES

DBases

Mining Library

• Lonmin

• Exxaro

Model-Driven Operations Management User Interface Example

Process Orders

Start Stop

Pause

Model-Driven Operations Management User Interface – Composite UI (MES & EAM)

Manufacturing Operations Management...

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