Siemens Corporate Design PowerPoint-Templates Measuring Overall Equipment Effectiveness Machine...

© Siemens AG 2015 All rights reserved.

Company characteristics

SIDAT is one of the significant Czech companies

• (= System Integration & Deliveries of Automation Technology)

• Ltd. company (100% shared by Czech nationals)

• Automation of production processes and technologies

• Production information systems

mainly in the following branches

• Food & Beverages

• Production of building materials

• Oil & Gas industry

• Others (e.g. automotive, waste treatment, etc.)

Established: 1990

Number of employees: 80


SIDAT solutions and platforms

Industrial automation Industrial informatics

Real-time data archiving and processing

Energy monitoring and management

Labelling systems

OEE and maintenance monitoring and management

Control systems for mixing and dosing (solid and liquid)

Control systems for transport (solid and liquid)

Control systems for production and manipulation

machines

Control systems for compressors and cooling

Safety control systems

Integration of control systems and MIS/MES

LIMS

Design Production SW Installation Commissioning Training Support


25 years on the world market

1990 1995 2000 2005 2010

Oil & gas industry

Waste-treatment facilities

Production of food and beverage

Production of building materials

PLC + HMI/SCADA

NET

DCS

MIS

RTDB

Automotive industry

Activity fields

Branches

Chemical and pharmaceutical industry

Handling of nuclear fuel

Automation

Informatics

MES

Today


Training centre

Standard trainings, specific trainings, workshops

• Automation: PLC, HMI, communication...

• Standard Siemens courses (Siemens authorized training centre) concluded by issuing the

respective certificate – see www.sidat.cz

• Specific courses for customer specific needs.

• The training centre is entitled to provide also

education sponsored by EU funds.

• Courses may also be conducted outside of SIDAT

premises.

• Various languages (CZE, ENG, GER, RUS, ESP...).

• More than 3000 participants trained.

http://www.sidat.cz/

http://www.google.cz/url?sa=i&rct=j&q=&esrc=s&frm=1&source=images&cd=&cad=rja&docid=1jh3RrcRfKJrzM&tbnid=si_sfDBTDJFjkM:&ved=0CAUQjRw&url=http://www.karmoxie.com/technology-and-business-training/&ei=wZElUqbsEsKUtQay3ICIBQ&bvm=bv.51495398,d.Yms&psig=AFQjCNEbvH53h3zN1Wm-hJky3wnzMq5anQ&ust=1378280238550810


SIDAT solutions and platforms

Industrial automation Industrial informatics

Real-time data archiving and processing

Energy monitoring and management

Labelling systems

OEE and maintenance monitoring and management

Control systems for mixing and dosing (solid and liquid)

Control systems for transport (solid and liquid)

Control systems for production and manipulation

machines

Control systems for compressors and cooling

Safety control systems

Integration of control systems and MIS/MES

LIMS

Design Production SW Installation Commissioning Training Support

siemens.com/answers Restricted © Siemens AG 2013 All rights reserved.

Siemens AG, Digital Factory – Industry Software

SIMATIC IT Unilab

Your Next Generation LIMS


Digital Enterprise Realization

• R&D and Manufacturing

Operations Management brings

Realization to the Innovation

Platform

• Reducing Time-to-Market is the

combination of an efficient product

design and optimized

manufacturing

• Industry Software allows customers

to put their best laid plans to

practice :

• Execute product development

• Execute production

• Enforce quality

• Reduce waste

• Provide transparency

PLM

Core

Product

Formulation

Manufacturing

Engineering

Manufacturing

Execution

SCADA

Quality Mgt

Manufa

ctu

ring

Inte

lligence

The Customer’s Digital Enterprise


Siemens Industry Software Portfolio for Hybrid Industries

Quality offering with SIMATIC IT Unilab

ERP

Automation

Teamcenter

Electronic Lab

Notebook

Recipe

Transformation

Specification Mgt

Lab Exp.

LIMS

Formula Workbench General Recipe Mgt Dashboards

Scorecards

Analytics

Bench-marking

Reports Process Mgt &

Execution

Inventory Mgt &

Traceability

Quality Mgt

Asset Mgt &

Maintenance

Orders Mgt &

Scheduling Site Recipe Mgt

Primary Process Storage & Transfers Filling & Packaging

Ideation Planning Feasbility

Purchasing

Accounting

Planning

Finance

SIM

AT

IC I

T

Pro

du

cti

on

Su

ite

SIM

AT

IC I

T

R&

D S

uit

e

SIMATIC IT

Intelligence Suite Requirements Portfolio


Page 10

ISA 95 In-line, at-line and off-line testing definitions

SIMATIC IT Unilab takes care of At-line and Off-line inspections

In-line At-line Off-line

Sampling No sample taking Sample taking Sample taking

Frequency

of quality control

Continuous measurement From every 15 minutes

to a few times per shift

From a few times per shift

to once a year

Level of implementation Plant level Plant level Plant level and/or enterprise level

Where Measurement point

at production line

Workstation at the production line Laboratory

Performed by Automatic Production operator or lab

technician

Lab technician

Exception handling by Shift leader

Production manager

Shift leader

Lab and/or production manager

Lab and/or production manager

Corrective action

taken when

During production During or after production After production


Page 12

The Answer ...

SIMATIC IT Unilab 7

Single Page

Application

Responsive Web

Design


Page 13

SIMATIC IT Unilab

User Interface & User Experience

New, state of the art

look & feel

Integrating applications in a

single Web environment

Designed for web, multiple

devices, browsers &

platforms

Support of multi touch and

gestures

Created by designers

Future proof to SCADA &

MES UI integration


Page 15

SIMATIC IT Unilab

Powerful functionality at your fingertips

Trending & Analysis Sample Management

Request Handling Work Lists


Page 16

Use Case – Lab Management

Reports and Graphs

Sample

overview

Management

reports


Page 17

SIMATIC IT Unilab

Business Benefits

SIMATIC IT Unilab provides competitive advantages and cost savings within quality

management and production

Worklists and easy configuration – improve lab efficiency

Integration between lab and production – shorter lead-time for samples and analyses

Lab automation and instrument connection – reduce administrative tasks and errors

Immediate feedback on quality exceptions – reduce scrap and rework

Workflow management – enforce QA/QC procedures throughout the entire organization

Communication of quality data – unified overview of all quality measures

Enterprise architecture for centralized LIMS – accommodates both QC & R&D labs

Standard and modular software product – easy roll-outs to other plants, reduced TCO

Audit trail and flexible reporting – reduced cost of regulatory compliance

What is the cost of “Non-Quality”?


Page 18

SIMATIC IT Unilab

Proven solution

Industry branches

• Food & Beverage

• CPG

• Chemicals

• Pharma & Biotech

• Metals & Mining

• ...

Laboratory types

• Production (QC)

• Environmental

• Development

• Service

• Regulated

• Water treatment

• …

Thousands of users

• From single-site version with a

few users

• To multi-site multi-language

licenses for Fortune 500

companies with thousands of

users across 50+ sites


Page 19

SIMATIC IT Unilab

Customers in Food & Beverage and CPG

siemens.com/answers © Siemens AG 2015 All rights reserved.

SIMATIC IT

Line Monitoring System

siemens.com/simatic-it


Page 21

Overall Equipment Effectiveness (OEE) is a Key First Step to Continuous

Improvement

• The KPIs generated by an OEE package

deliver a wealth of actionable information

with minimal effort

Machine Performance Quality Rate Machine Availability

Good indication of resource

scheduling & logistics in the

plant

Good indication of how well

maintenance & operational

procedures are coordinated

Good indicator of how well

operational & quality

procedures are coordinated


Page 22

By Measuring Overall Equipment Effectiveness


Total Production Target Production Scrap Produced Total Production Operating Time Planned

Production Time

Good Counter Bad Counter Status Time Model Reason Codes Production

Context


Page 23

By Measuring Overall Equipment Effectiveness

Meantim

e

Betw

een

Failu

res

Meantim

e to

Repair

Meantim

e

Betw

een

Changeo

vers

Changeo

ver

Dura

tion

Meantim

e

Betw

een

Mate

rial S

top

s

Tim

e lost D

ue to

Mate

rial

Sto

ppages

Spee

d lost due

to U

nd

er

Utiliz

ation

Guilt

y M

achin

e

Fre

quencie

s

Good Counter Bad Counter Status Time Model Reason Codes Production

Context


Total Production Target Production Scrap Produced Total Production Operating Time Planned

Production Time


Page 24

Scalability over Functional Scope

LMS

Equipment scalability

Multiple users

Station 1 Station 2 Station ... n

Equipment 10 Equipment 20 Equipment n Equipment 50 Equipment 100 ....

Equipment scalability SIMATIC IT LMS 2.2 licensing starts from 5 Equipment items up to 3.000

Equipment 1 .... Equipment 2 Equipment 5

SIMATIC IT

Reporting Framework

SIMATIC

WinCC SIMATIC IT LMS

PLC Interface


Page 25

Scalability on Visibility Levels and

Data Management

Scalability:

from Line-Level LMS Reporting ... Scalability:

... up to Plant-Level Integrated MES Reporting ...

Scalability:

... up to Enterprise-Level Manufacturing Intelligence

LMS on OEE/Downtime

and Energy

Real Time Line

Reporting

Manufacturing

Intelligence

Global

Dashboards

and

Scorecards

Equipment 1 .... Equipment 2 Equipment n

SIMATIC IT

Reporting Framework

SIMATIC

WinCC SIMATIC IT LMS

PLC Interface

MES

Integrated Reporting

Reporting

on Multiple

ISA 95

Functionality

ERP Interface

SIMATIC IT Platform

Load-In Warehouse

Mgt

Primary

Production Mgt

Tank Farm

Mgt

Secondary

Production Mgt

SIT Reporting

Framework

Integrated

Quality Mgt


Page 26

Manufacturing Information System:

Main Functions

Visual representation of manufacturing plant status in real time

(WinCC 7.3SE and WinCC Web Navigator)

Fat and web clients are supported for SCADA/MIS information

OEE KPIs for individual machines or larger lines

Shift Calendar integration

Reporting functionalities done using Microsoft standard products

Key Benefits:

Increase production plant availability

View the status of the entire production plant

Identify weak spots in the production system

Availability of detailed pre configured graphical pages, KPI’s and reports about the production plant

Dramatically reduce effort and risks in MIS projects


Page 27

Line monitoring and controlling – with CAB Portal screens

Main Functionalities:

Calculation of standard and custom KPIs

Downtime Management and analysis support

Integration with LMS Message management

Key Benefits:

Decision support system based on real time information

Operational cost improvement thanks to high plant reliability,

equipment utilization optimization

Improved ROI


Page 28

Easy and flexible engineering phases

Overall Equipment Effectiveness:

Configuration

Equipment Model Definition

Time Model Declaration

Machine State List

States & Levels

Reason Tree

Counters / Design Speed

Standard and Custom KPIs algorithms

Equipment Attributes Management:

Counters Acquisition


Page 29

Production monitoring with dedicated graphical components


Monitoring and Management

Out of the box web operator screens

Touch Screen interface

Short term performance check

State declaration

Unknown stoppage justification

Production control compared with targets and actual state

visualization

Plant / Line / Equipment navigation

Equipment runtime status


Page 30

A contextualized analysis against manufacturing events


Analysis

Downtime Management

detailed information about equipment states can be

displayed and updated

Downtime Analysis

exploring the causes that have generated a production

breakdown

Production Counter Analysis

current production can be compared with theoretical

production

On-the-fly OEE calculation

line or equipment OEE calculation for hour, shift, or daily

analysis


Page 31

Reporting Framework:

Data Model views

Scalability:

from Line-Level LMS Reporting ...

Scalability:

... up to Plant-Level Integrated MES Reporting ... Personalized Reports for all users in the Plant

The Report Parts, already organized

and structured in specific entities

(Downtime info, algorithm, shifts, etc.), can

be used to create custom reports with a

standard Drag & Drop action and quickly

parameterized

Different levels( Production Manager,

Maintenance manager, Plant Managers, etc.)

can easily generate different reports

based on different analysis

requirements


Page 32

Manufacturing Intelligence

Scorecards & Dashboards

Functionality:

Collects data from the plant in real-time and integrates it with

business and financials

KPI calculation, rollup and drilldown

Covers all portfolio elements (Production, Quality, Assets, Inventory,

Utilities, etc)

Provides several levels of reporting:

Analytics

Excel Export

Operators, team leaders,

production managers

Business Benefits

Scalability from the Single Site to the Enterprise

Access to corporate data, reports and KPIs via various devices

Enables Continuous Improvement in the plant

Provides rollup and benchmarking capabilities

SIMATIC IT Intelligence Suite provides to End Users simple

but powerful views on their domain of responsibility


Page 33

Alarms & Production Messages:

Management and Monitoring

Key Benefits:

Empowered root cause analysis extended to equipment subcomponents

Centralized Alarms Reporting

Easily configuration of machine state calculation logics

Association of Alarms & Production Messages with

machines status

Support for root cause analysis

Down Time justification extended to root cause alarm

Graphical user interface for Alarm statistical analysis

Centralized monitoring of active Alarms

Siemens Corporate Design PowerPoint-Templates Measuring Overall Equipment Effectiveness Machine...

Documents

Transcript of Siemens Corporate Design PowerPoint-Templates Measuring Overall Equipment Effectiveness Machine...