Mfgsummit 201003 Improve Flexibility and Efficiency 2

Solution for
Manufacturing
Flexibility and
Efficiency
Business Intelligence
Chatchai Wajakiet / Chee Hoe Lee
Copyright 2009 Rockwell Automation, Inc. All rights reserved.
Agenda
1. Basic Manufacturing Problem

2. The FactoryTalk VantagePoint Solution
3. Built-In Functionality for Plant Floor
4. FactoryTalk VantagePoint Advantages
5. Ordering, Training and More Information
Manufacturing: An Information Problem
Material
Time
Product
People
Waste
Energy
Data:
Control systems
HMI systems
Alarm and event systems
Historians
3
3
Universal Problem
Manufacturing
Production
Testing
Rework
Inventory
Shipping
Control
Systems
Information Workers
Co-workers
Management
Production Supervisor
Quality Department
Sales
Marketing
HMI /
SCADA
69
1
5
0
8
05699 8918
16 8091996 9
44
7 7
77 7
44
4
44
44
44
7 7
77 7
4
Alarms &
Event History
186891
5
0
6
0599 98
168091996 7
7 7
77 7
69
1
5
9
0
8
0569 8918
16 8091996 8
69
1
5
0
8
05699 8918
16 8091996 3
7 7
77 7
7 7
77 7
186891
5
0
6
0599 98
168091996 5
Production
HMI /
Historians
SCADA
?
?
BAD INFORMATION
POOR DECISIONS
Agenda

Two Products for Two Solutions
FactoryTalk VantagePoint
L IN
K
Visualization
& Reporting
Multiple Sources of
Manufacturing Data
RS Logix
FactoryTalk FactoryTalk FactoryTalk OPC DA

OPC HDA
View
Historian Alarms/Events
SoCal
Suppliers
Area 1
Area 2
InTouch
Area 3
Proficy
OSI PI
InSQL
Customers
All Data in a Unified Production

Model (UPM)
RS Logix

OPC HDA
View
SoCal
Suppliers
Area 1
Area 2
InTouch
Area 3
9
Copyright 2009 Rockwell Automation,
Inc. All rights reserved.
Proficy
OSI PI
InSQL
Customers
A Realistic, Flexible Model
ISA
ISA88/95
88/95
Open
OpenO&M
O&M
B2MML
B2MML
Model
ModelReflects
Reflects
The
TheBusiness
Business
ProdML
ProdML
RS Logix

OPC HDA
View
SoCal
Suppliers
Area 1
Area 2
InTouch
Area 3
10
Proficy
OSI PI
InSQL
Customers
10
Built in Analytics, Extensibility
Schedule
Schedule
React
React
Calculate
Calculate
Aggregate
Aggregate
Unified Production Model

RS Logix

OPC HDA
View
SoCal
Suppliers
Area 1
Area 2
InTouch
Area 3
11
Proficy
OSI PI
InSQL
Customers
11
Rich Content, Easy to Use and

View
Trend
Trend
Excel
Excel
Portal
Portal
KPIs
KPIs
Reports
Reports
Dashboards
Dashboards
Analysis
Unified Production Model
RS Logix

OPC HDA
View
SoCal
Suppliers
Area 1
Area 2
InTouch
Area 3
12
Proficy
OSI PI
InSQL
Customers
12
The VantagePoint Difference

Increased IT Agility
and
Leverage Existing Information Assets

Accommodate Change
Extend Infrastructure
Deeper Manufacturing Insight

Unified Information
Business Context
Knowledge Building and Sharing
SoCal
Suppliers
Area 1
Area 2
Area 3
Customers
13
Agenda

14
Rich, Interactive Browser Experience
Universal access via a browser
Start
Startwith
withKey
Key
Performance
Performance
Indicators
Indicators
No client install necessary

Role based reports and custom
links for your users
Links to reports, client tools and
help:
VantagePoint Manager
Trend
XY Plot
Documentation
Links to Help and Support
Drill
Drill Down
Downtoto
Underlying
Underlying
Calculations
Calculations
15
Excel Reports Available to Everyone
Create powerful Excel reports

Retrieve data from any
supported data source
Calculate, analyze and format
reports using Excel
functionality
Publish reports via portal for
viewing by anyone with
access to a browserno
client install
Dynamically refresh data
Calculate,
Calculate,
Analyze
Analyze
and
andFormat
Format
Retrieve
Retrieve
Data
DataFrom
FromAny
Any
Source
Source
Publish
Publishtotothe
the
VantagePoint
VantagePoint
Portal
Portal
Pre-configured Excel reports

in Sample Reports
16
Trending Made Easy
Easy model navigation

Diagnose and analyze data from
any supported data source
Access to real-time and
historical data
Powerful trend functionalityPan, zoom, stack & synchronize
Publish & share trends to the
portal
Pre-configured trends available
in Sample Reports
17
Powerful Easy to Read Dashboards
Create powerful dashboards that

monitor real-time data and key
manufacturing KPIs
Dashboards can update
dynamically and on demand
Easy access to all dashboards
via a browser
Pre-configured dashboards
available in Sample Reports
18
FactoryTalk Vantage Point XY Plot
Create XY Plots using the XY

Plotter Tool
Analyze one value with respect
to another over time
Publish and share XY Plots to
the Portal
Pre-configured XY plot available
in Sample Reports
19
Composite Reports for Greater Visibility

Reusable
Components
Dashboard
Builder
Trend
Excel
Plot
20
Agenda

21
A Rockwell Solution for

Rockwell Products
User Defined Data Types

Save engineering time creating data structures
Make it easier to design and maintain programs
22
Create Tank Reports, Trends,

Dashboards
VantagePoint Types
Save engineering time mapping to data sources
Make it easier to create, manage, view reports
23
Map Logix UDTs to VantagePoint

Types
VantagePoint
The Logix tank UDT is mapped to the VantagePoint tank type.

Tank UDT members are mapped to tank type properties.
Logix
24
Import Logix Configuration into VantagePoint
VantagePoint
Instances of the tank UDT are imported as items of type tank

into the VantagePoint Unified Production Model
Logix
Users can now easily find tanks and associated tags, and
can see the real time value of these tags (via LiveData)
25
Correlate Logix Tags with FT Historian Tags
VantagePoint
FT Live Data tags are associated with FT Historian tags in

the VantagePoint Unified Production Model.
VantagePoint can now retrieve the history of a tank
from FT Historian, and the real time values of tank tags from
Live Data. Users dont need to know where the data is
coming from.
FT Historian
Logix
26
View Tank Reports, Trends and

Dashboards
Tank reports, trends and dashboards work

automatically against tank items imported
from Logix.
Authorized users can access tank
information by browsing to the
VantagePoint portal.
27
One Set of Tools For All Data Sources
Any 3rd Party Data Source

28
28
Real World Model For

Information the Way You Need It
Process Control Engineer
Pressure
Flow
Speed
Live Data: Control System/HMI
Production Manager
Volume pumped
Product throughput
Operation history
Power consumed
Historian
Maintenance Manager
Running hours
Performance spec
Manufacturer data
Spares on hand
Maintenance date
Maintenance
Management
System
ERP, LMS, SQL

Database
Process Engineer
Related equipment
Rating
Vibration data
Asset
Database
Quality Assurance
Batch record
Leak test data
Lab sample
Asset Manager
Purchase date
Cost
Warranty
Manufacturer
Engineering Specs
29
Single Point of Access, One Version of the Truth

Access to ALL plant floor, production and business systems
Integrate and organize time series and transactional data
Users at all levels of enterprise can view role-based KPIs, reports
and dashboards
30
All You Need is a Browser
No client install is needed to

view trends, reports and
dashboards
Simply publish reports in the
portal to allow access
31
Non-programmers Can Create and Publish

Reports, Trends and Dashboards
Build ad-hoc reports and publish

to the model
Reports can be saved and
modified easily as needed
Reduces the marginal cost
of curiosity
32
Agenda

33
How would you answer these

questions?
What types of control systems do you have?
What types of Historians do you have?
What types of HMI systems do you have ?
Who has access to the information from these systems?
Would your engineering / maintenance / quality /
supervisory staff benefit from access to this information?
Would it help to have a common set of tools to report
against all of these data sources ?
Would a web based reporting solution help ?
How much time do you spend creating production / quality
/ maintenance reports ?
What happens if the owner of the reports is not available?
Would you benefit from reports being generated from
the structure data types in ControlLogix (UDT)?
34
Additional Connectivity via

FactoryTalk VantagePoint EMI
For connectivity to
FactoryTalk Metrics,
Transaction Manager, Batch
or other manufacturing data
sources utilizing a SQL
database, a connector is
available with FactoryTalk
VantagePoint EMI
Contact your local
Information Solutions
Regional Manager (ISRM)
to receive additional
information on ordering and
configuring
35
Building Your FactoryTalk

VantagePoint Solution

36
36
Where to Find Additional Information
Discover Rockwell Automation Portal

http://discover.rockwellautomation.com/mi
Includes Product Demo / Videos
Discover Webcast Recordings
Product Profiles
Ordering Information
System Requirements
Case Studies
37
Training
Training is available for FT VantagePoint and FT VantagePoint EMI through Rockwell
Automations training site at:
http://www.rockwellautomation.com/services/training/schedules.html
Copyright
Copyright 2009
2009 Rockwell
Rockwell Automation,
Automation, Inc.
Inc. All
All rights
rights reserved.
reserved.
38
Customer Value Food &

Beverage
SCOPE
69 plants
140+ data sources SCADA, control, MES, LIMs,
Asset Management, SAP, ORACLE & SQL
databases, InSQL historian
Many legacy systems and in-house designed MES
2.5 MM 10 MM objects in the database
(FactoryTalk VantagePoint model)
TV (One plant)
Corporate portal system
TV monitor above every production line
available to 28,000 employees
Dashboard tracking the following for each line
Production target
Results so far
Current projection against target
Targets
Cost
MTBF/MTTR
Downtime cause
RESULTS
Improved throughput by 8%
Reduced waste by 3%
39
Customer Value Chemical

SCOPE/OBJECTIVE
A global fortune 500 manufacturing company
Objectives
Increase production due to higher demand
Without adding new capital or resources
Replace antiquated batch reporting
No rip-replace of other legacy systems
Rational for EMI

Integrated easily with existing production control
systems
Provided deep insight into our batch processes
Reports available to production and management to
monitor production in context of individuals role
Future expansion capabilities for integration with
our ERP
One of the main benefits of using FactoryTalk VantagePoint was greater

performance. We have better insight into how we perform, how long
processes take and how fast we can make our products. Weve reduced
our production cycle times by 90% already.
Manager
RESULTS
Changeover time reduction
Control Loops optimized
Schedule improvements
More product produced in 2
shifts than previously done in 9
40
Customer Value Energy

Management
SCOPE
Small university 70 buildings
Central plant to manage: electricity, heat and cooling
Cogeneration of electricity and heat from fuel oil
Buildings metered / data stored in historian and control
OBJECTIVE
Manage/reduce energy consumption
Make vs. Buy
SOLUTION
Track and accurately predict electricity and oil
consumption
Reduce impact of high cost peak-demand energy
Calculate / predict individual building demands
Integrate islands of information from water treatment,
HVAC, co-generation and weather reports
RESULTS
Reduced overall energy
consumption by 23%
Lowered total energy bill by
$3M / year
41
Customer Value Water

Management
SCOPE/ENVIRONMENT
Mid-size city municipality
Multi-vendors SCADA and Control
Many disparate data sources
Facing severe environmental issues with
storm run-off
OBJECTIVES
Consistent reporting
Yield
Quicker leak detection
Reduce contamination
Improve water quality
RESULTS
Reduce energy
Remediated detection, quality and
consumption
energy issues
Reduced operating cost (dbl digits)
Were taking business intelligence to the next level because our

departmental staff recognize opportunities earlier, react more swiftly
to them, more easily communicate the issues involved, and make
better decisions.
Manager
42
Backup Slides
How do you manage your

challenges?
Reduced Mfg Cost

Improve Mfg Agility
Improve Quality
Reduce Mfg Lead Time
Reduce FG Inventory
Improve Schedule Compliance
BEST IN CLASS
TOP THREE
OTHERS
Improve Throughput
Reduce Raw Material Inventory
Reduce WIP Inventory
Source: Aberdeen Group, Mfg Perf Mgt2, 2006
SYSTEMATIC DATA COLLECTION A MUST

4444
Applications for Manufacturing

Historians
Historians are utilized across many industries and applications:
Consumer Products, Food and Beverage, Automotive, Life Sciences
Continuous Process, Packaging, Material Routing, etc.
Key benefit of a Historian:

Capture and process high-speed, time-series data
Store in a central (Site or Enterprise) data repository for future analysis
Historical data is used for:

Analysis through calculations, statistical processes, quality controls, etc.
Supports business and operational analysis:
Trends and graphs of data
Turns
Turns Data
Data into
into Information
Information !!
4545
Value of a Data Historian

Helps improve overall operations through analysis of manufacturing, process
and production data.
Accelerate Six Sigma and Lean initiatives
Identify under-performing production areas
Increase quality
Identify the root causes of process

variability
Improve processes
Analyze complex process data easily

Capture non-relational data very efficiently
Extreme capture speed and

compressed storage
Reduce variability
Verify production parameters versus
targets/norms
Capture critical performance and quality

data in real-time
Decrease overhead costs
Save time in collecting data and preparing
reports
Centralized storage repository

Enables a platform for standardization of
data collection and reporting of key
performance indicators (KPIs)
4646
A New Twist Distributed

Strategy
Pervasive
PervasiveInformation
InformationAcross
AcrossEnterprise,
Enterprise,Site,
Site,Machine/Device
Machine/Device
Copyright 2009
2010 Rockwell Automation, Inc. All rights reserved.
47
Distributed Historian Strategy
MANAGEMENT
SUPERVISOR
OPERATOR
The
y
TheRight
RightInformation,
Information,at
atthe
theRight
RightTime,
Time,with
withthe
theRight
RightFidelit
Fidelity
Copyright 2009
48
Automation Fair 2006

Announcement
4949
Strategic Partnership
Leadership in Automation and

Information Solutions
Solution Provider
Automation and Controls
Expertise
Solution Platform
Real-time Performance Management

Software Products
Technology Provider
Data Historian and Context Experts
Product Platform
Market
Market leaders
leaders joining
joining together
together to
to provide
provide winning
winning solutions
solutions
5050
FactoryTalk Historian Machine

Edition
FactoryTalk Historian Machine Edition
Based on FactoryTalk Historian SE

Module-based historian
Data Collection over backplane
More granular data
Solid-state data storage
Part of the Distributed Historian

Strategy
Three-tiered historian
Aggregating data upward
Auto-discover sources downward
Auto configure tags
Performance and scalability
3rd-party connectivity
Copyright 2009
51
Platform Architecture
Trend
Trend
Portal
Portal
Reports
Reports
KPIs
KPIs
Dashboard
Dashboard
Excel
Excel
EAI, SOA
Data Rollup
Production Data
FactoryTalk Platform
Process Data
Single Operator Interface
Mobile
HMI
OPC
Alarm & Events
3rd Party Controllers
UDT Definitions*
Structured Data*
Alarm & Events
Self Discovery
Control Logix
Copyright 2009
Self Discovery*
Historian ME*
52
Thank You

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Solution for

Copyright 2009 Rockwell Automation, Inc. All rights reserved.

1. Basic Manufacturing Problem

Copyright 2009 Rockwell Automation, Inc. All rights reserved.

Manufacturing: An Information Problem

Copyright 2009 Rockwell Automation, Inc. All rights reserved.

Copyright 2009 Rockwell Automation, Inc. All rights reserved.

1. Basic Manufacturing Problem

Copyright 2009 Rockwell Automation, Inc. All rights reserved.

Two Products for Two Solutions

Copyright 2009 Rockwell Automation, Inc. All rights reserved.

FactoryTalk FactoryTalk FactoryTalk OPC DA

Copyright 2009 Rockwell Automation, Inc. All rights reserved.

All Data in a Unified Production

FactoryTalk FactoryTalk FactoryTalk OPC DA

A Realistic, Flexible Model

FactoryTalk FactoryTalk FactoryTalk OPC DA

Built in Analytics, Extensibility

Unified Production Model

FactoryTalk FactoryTalk FactoryTalk OPC DA

Rich Content, Easy to Use and

FactoryTalk FactoryTalk FactoryTalk OPC DA

The VantagePoint Difference

Leverage Existing Information Assets

Deeper Manufacturing Insight

Copyright 2009 Rockwell Automation, Inc. All rights reserved.

1. Basic Manufacturing Problem

Copyright 2009 Rockwell Automation, Inc. All rights reserved.

Rich, Interactive Browser Experience

Universal access via a browser

No client install necessary

Copyright 2009 Rockwell Automation, Inc. All rights reserved.

Excel Reports Available to Everyone

Create powerful Excel reports

Pre-configured Excel reports

Copyright 2009 Rockwell Automation, Inc. All rights reserved.

Trending Made Easy

Easy model navigation

Copyright 2009 Rockwell Automation, Inc. All rights reserved.

Powerful Easy to Read Dashboards

Create powerful dashboards that

Copyright 2009 Rockwell Automation, Inc. All rights reserved.

FactoryTalk Vantage Point XY Plot

Create XY Plots using the XY

Copyright 2009 Rockwell Automation, Inc. All rights reserved.

Composite Reports for Greater Visibility

1. Basic Manufacturing Problem

Copyright 2009 Rockwell Automation, Inc. All rights reserved.

A Rockwell Solution for

User Defined Data Types

Create Tank Reports, Trends,

Map Logix UDTs to VantagePoint

The Logix tank UDT is mapped to the VantagePoint tank type.

Copyright 2009 Rockwell Automation, Inc. All rights reserved.

Import Logix Configuration into VantagePoint

Instances of the tank UDT are imported as items of type tank

Correlate Logix Tags with FT Historian Tags

FT Live Data tags are associated with FT Historian tags in

Copyright 2009 Rockwell Automation, Inc. All rights reserved.

View Tank Reports, Trends and

Tank reports, trends and dashboards work

Copyright 2009 Rockwell Automation, Inc. All rights reserved.

One Set of Tools For All Data Sources

Any 3rd Party Data Source