Factory talk

Industrial Control Systems has been in business since 1998 and specializes in automated control systems and data collection for the manufacturing industry.

We provide complete project management covering Field Wiring, PLC Programming, Motion control, Panel Design and Assembly, Startup and Training of the maintenance partners involved with the project.

We also provide Data Collection and Reporting utilizing Rockwell FactoryTalk software systems including PlantMetrics, Historian and RSSql to report downtime, efficiency (OEE) and historical information.

For more information please visit our web site at www.indconsys.com

The following slides contain charts that we have developed for real-world applications.

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Rockwell Software

PlantMetrics

Customizable and scalableMake it unique to your plantContinuum from simple to complex; small to

largeMeasure what is important to you

Reliable, 24/7 data collection from any OPC-compliant devicesfrom any manufacturer

Data storage in an efficient, open database

Access to all reports with a Web BrowserBuilt-in HTML report writerBuilt-in Web ServerAutomatic website creation and

maintenance

A complete system for:Event collection and analysisEfficiency monitoring

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PlantMetrics

Records data to calculate OEE:Availability: are machines running when they are supposed to?Performance: are machines (or people) working as fast as they

should?Quality: how much waste is being produced?

Production counts, downtime, cycle times, schedules etc.

Reliable Production Data Collection (no more clipboards)

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PlantMetricsWhat is Overall Equipment Effectiveness (OEE)?OEE stands for Overall Equipment Effectiveness (also referred to as Overall Equipment Efficiency) and is a standard measure of performance which brings together the three most significant production metrics, Availability, Performance and Quality.

Why is Overall Equipment Effectiveness (OEE) important to me?While many companies monitor and act upon downturns in availability, performance and quality, few look at the three together or fully consider the impact that changes made to improve one area may have on the others. OEE bridges that gap by unifying all three aspects of the production process into one single measurement.

How can I justify investment in an OEE tool without first identifying the ROI?This is a bit of a ‘chicken and egg’ question – only a very coarse assessment of the potential for improvement and, from that, return on investment (ROI) can be made prior to the implementation of a system of this kind. However, from experience we know that you will start to feel the benefit almost immediately and, dependent on the solution that you select, will recover the initial investment costs within the first few months of operation. It’s a point to note that while many companies believe that they can’t significantly improve without major capital investment, those companies, when measured, are only typically achieving 40% throughput with what they’ve got (world-class companies achieve greater than 80%!).

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PlantMetricsPlantMetrics uses an OEE (Overall Equipment Effectiveness) model to measure the performance of manufacturing equipment. The OEE model yields a single performance rating for every activity area (workcell, line, area, or plant) being monitored, thereby providing a simple way to determine quickly if an activity area is performing adequately. The OEE value can be used to assess a single machine’s performance over time or to compare the performance of machines to each other. Three components contribute to an OEE value: availability, throughput, and quality. Each is a percentage, and the OEE value is the product of these three percentages, and therefore is also a percentage. Availability is a ratio of running time to available time. Available time may be defined by a schedule or modified by planned downtime events such as preventive maintenance.

Throughput is the performance of a machine when it is running compared to its ideal cycle time. Quality is the percentage of good parts that are produced. The OEE calculation that is used by PlantMetrics is the product of these three components:

OEE = Availability * Throughput * Quality

OEE is a valuable method of analyzing performance because it is widely recognized and can be applied to any type of industry,factory, or machine. OEE is the default efficiency calculation performed by PlantMetrics; additional or alternate calculations can be implemented. Further, PlantMetrics supports the collection of detailed event data, which can be used to analyze the specific causes of inefficiencies.

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PlantMetricsOEE Trend

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PlantMetricsOEE Trend – View and Save Data

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PlantMetricsOEE Trend – Data.csv in Excel

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PlantMetricsOEE Trend with Statistics

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PlantMetrics

You NEED Data:Production countsScrap ratesMachine cycle timesDowntime times and causesUnproductive time (in all its forms)Quality problems

But you also needA way to identify the real problemsA way to figure out what else you need to measure

You can’t do it (well) with a clipboard and a spreadsheet!

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PlantMetricsCaptures machine events

What are your machines doing?Downtime, setups, blocked/starved, etc.Completely customizable

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PlantMetricsCaptures upstream and downstream events (Inclusive)

What causes a machine to have a non-operating status?

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PlantMetricsUpstream and downstream event summary (Non-Inclusive)

What causes a machine to have a non-operating status?

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PlantMetricsCreate Custom Reports

Parts per Minute trend AND Machine Status over Time

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PlantMetricsPlantMetrics reports can include:

• KPIs

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PlantMetricsKPIs

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PlantMetricsPlantMetrics reports can include:

• KPIs

• Total/good/scrap production counts

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PlantMetricsTotal/good/scrap production counts

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PlantMetricsPlantMetrics reports can include:

• Ideal production counts

• KPIs

• Total/good/scrap production counts

• Time in custom events such as downtime, setup, changeovers, waiting, blocked, starved, idle, etc.

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PlantMetricsTime in custom events such as downtime, setup, changeovers, waiting, blocked, starved, idle, etc.

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PlantMetricsPlantMetrics reports can include:

• Ideal production counts

• KPIs

• Total/good/scrap production counts

• Time in custom events such as downtime, setup, changeovers, waiting, blocked, starved, idle, etc.

• Event counts

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PlantMetricsEvent counts

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PlantMetricsPlantMetrics reports can include:

• Ideal production counts

• Faults

• Ideal and actual cycle times

• KPIs

• Total/good/scrap production counts

• Time in custom events such as downtime, setup, changeovers, waiting, blocked, starved, idle, etc.

• Event counts

• MTBF, MTTR

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PlantMetricsMTBF, MTTR

by Day

by Shift

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PlantMetricsThe data can be reported by:

• Machine

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PlantMetricsThe data can be reported by: Machine

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PlantMetricsThe data can be reported by:

• Machine• Shift

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PlantMetricsThe data can be reported by: Shift

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PlantMetricsThe data can be reported by:

• Machine• Shift• Part number

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PlantMetricsThe data can be reported by: Product

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PlantMetricsThe data can be reported by:

• User-defined fields

• Machine• Shift• Part number

• Hour, day, week, month, year

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PlantMetricsThe data can be reported by: Hours etc.

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PlantMetrics

Users can drill into the data they want to see and modify report content at runtime usingbuilt-in filters and toolbars

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Historian

FactoryTalk Historian is a complete, Windows-based solution for the analysis of time-series process and production data. With Historian, you can monitor and understand process variability that is critical to maintaining world-class product quality. Rich reporting, graphing, and querying functionality makes Historian a flexible, comprehensive solution for time-series analysis.

Historian provides an easy way to scale data so that all values of interest fall within a common range. This makes it easy to spot relationships in data sets. And Historian’s sophisticated data-filtering tools provide multiple ways to drill into a data set and find the valuable information.

With the Time Series template selected, you can select the data point of interest and drag it onto the template.

Historian provides a set of analysis tools that makes it very easy to analyze any selected time-series data set. Simply select a statistical function and drop it on the target data set in your chart.

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HistorianTime Series Trend

Initial

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HistorianTime Series Trend

Add data point

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HistorianTime Series Trend

Select data point

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HistorianTime Series Trend

Data point displayed

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HistorianTime Series Trend

Add statistic

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HistorianTime Series Trend

Select color

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HistorianTime Series Trend

Configure trend finish

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HistorianCreate Custom Reports

Spec and Control chart

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HistorianCreate Custom Reports

Process Control Points

Industrial Control Systems Can Provide:

• Networking skills to gather data from various devices

• The PLC logic to support the report framework

• SQL Database knowledge to create any customized data source• FactoryTalk expertise in order to provide the reports you need• Local availability for quick and efficient modification, maintenance or troubleshooting of installed systems

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FactoryTalk

Thank You

Quit