1. Process Automation Integration Utilizing ABB’s 800xA and OPC.

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Process Automation Integration

Utilizing ABB’s 800xA and OPC

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ERP / EAM

Automation equipment / Production

Customer - Supplier

Internet

AIP

The Integrated Plant System

Scheduling Plantstatus

Inventory

Customerorder

Rescheduling

Maintenance

B2B / B2E Delivery

Purchaseorder

Confirmation

Materialrefill

Productiondata

Analysis andOptimization

Alarm orIncident

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Asset OptimizationProcess Portal

Object Info

OEE

Aspect Integrator Platform / 800xA

Fault Report

Active WO

AIP/800xA as an Integration Platform

Aspect System

Aspect System

IFS Maintenance Aspect System

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Asset Cost Reduction

Electrical diagram

Equipment data sheet

P&I Diagram

Active work orders Business performance

Work order history

Equipment cost analysis

OEE

Information Availability

Seamless navigation between different information systems

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Object Synchronization

To achieve Asset Cost Reduction, it is vital that the various systems that contains assets can be synchronized – both in batch and online.

V-101

AIP/800xA

Database

IFS

Biz

AP

Is

LU

LU

LU

Object with a functional object aspect is created

Object is created and inserted in Equipment functional structure

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Condition-based Maintenance

Calendar-based PM could be compared to a man that visits his doctor once a month and asks him to open up his stomach to see if everything looks good. With the risk of forgetting his scalpel or infecting the wound before stitching the stomach together again, the doctor usually says it looks alright. The goal should be to let the factory – as well as men – ask for maintenance when it is needed.

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Condition-based Maintenance

Monitoring

Detection

Alarms / EventsIFS WO/ PM module

Direct input

Fault Report Wizard

PM Event

PM / WO Event

Operator input

Predictive maintenance

Parameters

Operational hours, etc.

PDAevent

Collecting

data from

field devices

Asset

Monitors

Seamless access to the maintenance system from the operators environment

Automation equipment triggers maintenance actions based on real time information

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Overall Equipment Efficiency

It’s all about how to increase profit through cost reduction activities as well as real performance enhancements!

Maximum performanceLost profit

Real performance (OEE)

Maintenance, Engineering and Procurement costs

Time

$

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Available operating time

Planned production time

Total available time

A

P

QNet operating time

Planned stop time

Unplanned stop time

Reduced speed

Quality losses

Planned stop time

How is production capacity used?

Value adding

operating time

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Overall Equipment Efficiency– Without automation integration

OEE index = Availability x Performance x Yield

OEEDatabase

Availability

Performance

Yield (Quality rate)

Manual registration- If remembered!

An event occurs:- Start/Stop - Speed change - Quality loss

Manual OEE Data acquisition leads to poor quality of the OEE index!

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Overall Equipment Efficiency– With automation integration

Real-time data acquisition of OEE events by utilizing OPC

Monitoring

Start / Stop - events

Operator adds data and submits registration

Speed change - events

Quality losses

OEEWeb

portlet

OEEDatabase

Availability

Performance

Yield (Quality rate)

Collecting OEE data

from processequipment

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DemoIntegrated Plant System

Level 1: Connectivity

Asset Information –Demands, Spare parts, Inventory

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Work Order Planning

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Document Management

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Fault Reporting

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