I2 - An Overview of Wonder Ware MES Products - Jan Rasmussen Version 0.92 NXPowerLite

An Overview Of Wonderware MES Products

Jan RasmussenSales Director EMEA - MES

Microsoft Technology & Industry Standards

System Platform

Clients

EnterpriseIntegration

Industry Applications

&IndustryPacks

Wonderware MES & EMISoftware Solutions

Operations PerformanceQualityBatch

Asset Monitoring Food &

Beverage

Local Scheduling

WonderwareOPERATIONS 3.5 - STANDARD

WonderwarePERFORMANCE 3.5

WonderwareOPERATIONS 3.5 - PREMIUM

Wonderware Manufacturing OperationsSoftware Solution Offerings

WonderwareQI Analyst

WonderwareInBatch

‘Mtelligence forWonderware’PartnerSolution

WonderwareEMI Offerings


System Platform

Clients



&IndustryPacks




Beverage

LocalScheduling

Wonderware System Platform Native integration of plant model with MES

production model for low TCO

Superior reusability via object templates and deployment with sharing of best practices

Intuitive user interfaces for appropriate operator involvement

Unparalleled data connectivity incl. leading historian for process data, and advanced security model

Common Industrial IT Services for Increased Sustainability

Platform


System Platform

Clients



&IndustryPacks




Beverage

LocalScheduling

Batch

Wonderware Operations Software Simple batch management with recipe

definitions using site specific processes

Accurate equipment setup with automatic download of set points

Wonderware InBatch Powerful batch execution engine with

dynamic allocation of shared equipment for even the most complex batch processes

Graphical recipe definitions according to S88 with unit procedures, operations and phases for equipment independent master recipes

Accurate Management of Batch Processes


System Platform

Clients



&IndustryPacks




Beverage

LocalScheduling

Operations

Wonderware Operations Software Dispatching and management of electronic

work orders, with multilevel BOM

Improved process and production consistency and repeatability

Accurate inventory mgt and operational enforcement through procedural steps

Equipment Operations Modules Non-model based approach for recording

of production events and ‘as-built’ records as simple extension of supervisory system

Improved Execution of Operational Activities

Wonderware Operations Software…

Provides a scalable & configurable Manufacturing Execution System

solution for a wide range of industries

Provides a scalable & configurable Manufacturing Execution System

solution for a wide range of industries

Background:Core MES software capability (formerly Factelligence) obtained from 2007 acquisition of leading MES software provider, CIMNET

Product History

2002

July 2007

October 2007

February 2008

November 2008

Wonderware Operations Software…

► Comprehensive MES Functionality▪ Bill of Material, Work Orders, Events, Data Collection,

Specifications, Set Point Download, Inventory, Certifications, Steps/Procedures, Labor Management, User Management, Genealogy, Traceability, Web Reporting

► Fully Scalable▪ Functionality – Standard & Premium Edition, Enterprise

Integration, MES Clients plus .net controls to embed in InTouch▪ Physical Scalability – equipment, lines, plants▪ Taking advantage of ArchestrA services

► Highly Configurable Application

Highly Configurable User Interface

Wonderware MES Features

Deliver planned vs. actual production•Electronic Work Order Management•Recording of Production Events•Electronic Work Order Management•Recording of Production Eventsusingusing

Improve process and production consistency

•Centralized Manufacturing Model•Production Rules•Certifications

•Centralized Manufacturing Model•Production Rules•Certifications

usingusing

Improve inventory velocity

•Real time inventory management•Detailed definition of materials, substitutes and byproducts•Bill of Materials

•Real time inventory management•Detailed definition of materials, substitutes and byproducts•Bill of Materials

usingusing

Reduce order lead time•Dynamic prioritization and sequencing•Labor management •Connection to HMI/SCADA

•Dynamic prioritization and sequencing•Labor management •Connection to HMI/SCADA

usingusing

Monitor and analyze production performance

•Downtime•Utilization•OEE

•Downtime•Utilization•OEE

usingusing

Solutions “Powered By” MES Modules…

► Track & Trace► Error Proofing► Electronic Batch

Records (EBR)► Electronic Work

Instructions► Procedural Execution► Performance Mgt. (OEE)► Asset Utilization► Labor Mgt.

► Receiving► Order Management► WIP Management► Inventory Management► Quality Data Collection► Weigh & Dispense► Batch Processing► Recipe/Spec. Mgt.► Master Data Mgt.

General OverviewWonderware Operations & Performance

System Platform benefits on MES

Lower Cost of IT in Industrial Applications for data collection and automated transactions

Connect and Collect : out of the box connectivity to any information source

Reduce effort and cost on designing, building and maintaining system

Complete scalability, upscaling in size and functionality without impact to existing system

Lower Cost of IT in Industrial Applications for data collection and automated transactions

Connect and Collect : out of the box connectivity to any information source

Reduce effort and cost on designing, building and maintaining system

Complete scalability, upscaling in size and functionality without impact to existing system

Building the Production Model

Highly configurable & customizable to ensure a complete & accurate model of your production processes


System Platform

Clients



&IndustryPacks




Beverage

LocalScheduling

Quality

Wonderware Qi Analyst Realtime and historical SPC with

comprehensive charts and custom run rules with alarm generation upon violations

Minimize costly scrap and rework through detection of process variations better understanding of actual process capabilities

Wonderware Operations Software Central administration of process and

product specifications with versions and min/max limits per BOM entity

Reduce Variances with Specification and SPC

Using Standard Deviation

► Cream Cheese▪ Online Controlling Water percentage▪ Operators only allowed to adjust paramaters

based on rule violations from QIAnalyst▪ Water is cheaper than milk

► Mozarella▪ Planning production based on the orders solid

material requirements in the cheese► Cream Cheese

▪ On line Weight control in filling line► Butter

▪ On line controlling fat and water

Using standard deviation


System Platform

Clients



&IndustryPacks




Beverage

LocalScheduling

Performance

Wonderware Performance Software Improve asset utilization by automated

data collection and selective involvement of operators

Consistently monitor and compare equipment performance and OEE.

Wonderware System Platform Powerful reporting infrastructure through

Information Server

Rapid and Accurate Decision Making via Realtime Visibility

Improve Asset Utilization and OEE

Operations / Mgt Engineering IT & Infrastructure

Productivity gains drop straight to bottom line Productivity gains drop straight to bottom line

Engineering Efficiency

Operations / Mngt Engineering IT & Infrastructure

IT Environment Consistency

Operations / Mngt Engineering IT & Infrastructure

Increase Capacity

► Reduce unplanned equipment downtime▪ By tracking and analyzing equipment downtime

► Improve the output of existing equipment▪ Track and analyze equipment output (performance)

► Reduce quality related losses (scrap)▪ Track and analyze first pass yield

All require detailed equipment performance information

Empower Operators

► Leverage existing automation system▪ Provide more accurate, reliable and granular downtime data than

manual systems

► Flexible capture of downtime events with unlimited downtime reasons per equipment

► Enhanced operator involvement with highly configurable.NET based Operator interface

Real-time Graphics

► OEE KPI Control ▪ Displays OEE value and/or the

OEE components (Availability, Performance, Quality)

► Count/Duration KPI Control▪ Displays the number and

duration of events for the current entity

► Production Progress Control▪ Displays the current progress

of production for the current shift compared to a provided target

Drill Down to Root Cause

Enterprise Integration

Enterprise Integration Out-of-the-box integration using pre-

defined mappings.

Simple, yet powerful integration capabilities in a standardized formats

Tight Alignment withBusiness Processes


System Platform

Clients



&IndustryPacks




Beverage

LocalScheduling

• Attributes• BOM Item / Oper. Links• BOM Item / Oper. Step Links• BOM Item Substitutes• BOM Items• Data Log 16 and 48• Folders & Files• Operation Routes• Operation Step Entity Excl.• Operation Steps• Operations

• Operations Step Groups• Operation / BOM Spec Links• Operation / Entity Links• Operation / Entity Spec Links• Operation Attributes• Process / Item Links• Process Attributes• Processes• Rework Process Usage• Specifications

• Item Attributes• Item Classes• Item Folders• Item Reasons• Item Substitutes• Items• Standard Operations• Standard Operations Entity Links• Standard Operations Attributes• Utilization Reasons

Master/Static Data (30+ templates):

Dynamic Data (20+ templates):• Customer• Inventory Items• Job Attributes• Job BOM• Job Step Links• Job BOM Substitutes

• Sales Order• Sales Order Items• Work Order Attributes• Work Order Folders• Work Orders (with Process)• Work Orders (without Process)

• Job Routes• Job Specifications• Job Step Groups• Job Steps• Jobs• Lot Attributes

► Provides standard mechanism to import and export data from WW Ops & Perf Database

► Provides a set of data import and export templates► Integrate with ERP, SCM, LIMS and other business level

or plant level systems ► Used to synchronize BOM, orders, WIP, items, specs,

certifications, attributes, etc.► Configurable data formats including XML, flat file, and

Database table transfers► Configurable triggers including period, weekly, data

changes, table data exists, file exists► Delivers standard production reports, exception reports

and email alerts

Enterprise IntegrationBasic Features


System Platform

Clients



&IndustryPacks




Beverage

LocalScheduling

Industry App for Packaging

Vertically oriented Packaging Solution Leverage System Platform, InTouch,

Performance Module and Information Server

Provides a window for Planners (job sequencing and dispatching), Operators and Supervisors (line and machine state, status, yield, Performance, Events and alarms)

Generates and distributes reports via Wonderware Information Server

State Model Compliant with OMAC and PackML

Food& Beverage, Tobacco, Consumer Packaged Goods (CPG)

Easy setup via Excel Utility

Alternative to traditional MES/Performance project

Wonderware InBatch Powerful batch execution engine with

dynamic allocation of shared equipment for even the most complex batch processes

Graphical recipe definitions according to S88 with unit procedures, operations and phases for equipment independent master recipes

Comprehensive Application for Packaging Lines


System Platform

Clients



&IndustryPacks




Beverage

LocalScheduling

Condition Based Monitoring - Mtelligence Endorsed Partner Solution

Equipment run-time hours fed to maintenance system with automatic generation of work orders

Detect health degradation and prevent equipment failures

Open Standards eliminate Upgrade and Migration Risk (MIMOSA, ISA-95)

Improved Maintenance Strategy with Condition Based Monitoring

Asset Monitoring


System Platform

Clients



&IndustryPacks




Beverage

LocalScheduling

Preactor Finite Scheduling Wonderware offers you a world class MES

solution

Preactor offers the best available finite scheduling tool available on the market today

The two have been integrated to offer both scheduling and manufacturing shop floor control

Improved Maintenance Strategy with Condition Based Monitoring

Local Scheduling

Certified !!

With a record that shows a ROI which is unsurpassed

Largest installed base of any independent planning & scheduling software company for the manufacturing sector

>2,300 companies in almost every manufacturing sector

Discrete/process/hybrid

>10,000 licenses Users in 64 countries

Translated into 30 languages

Adopting a Flexible Approach to Improve Your Manufacturing Operations

Enable an incremental, low-risk deployment of increased application functionality, one step at a time.

Enable an incremental, low-risk deployment of increased application functionality, one step at a time.

Milkshake Manufacturer – Scenario #1

► Three Lines Produce Milkshakes► Two Manufacturing Sites► Currently, no MES

► Goal: Monitor/Improve equipment performance ▪ Answer the question, “How are we doing?”

• Overall Equipment Effectiveness (OEE)

• Downtime

• Asset Utilization

Manufacturing ‘Pains’

► Fillers not running at designated capacity▪ Output & profits lower than forecast

► Not meeting daily schedule► Pasteurization process blocked

▪ Production storage is full► No information about filler stops► Operators often wait around

▪ Don’t knowing how to resolve issues

Scenario #1: Performance

Line 1 Clients Line 2 Clients Line 3 Clients

System Platform

Production Server

MES database

Historian

Info Server

Install System Platform

Install InTouch, ‘WW Op’s & Perf’

Install Historian, ‘WW Op’s & Perf’, Info Server



Install System Platform license

Install InTouch license



Install Historian, ‘WW Op’s & Perf’, WIS licenses

Initial Deployment of Performance

Manufacturing Scenario #1

Machine Utilization

Reports

MES Configuration

Scenario 1: Machine Utilization

Solution Diagram

Reports

► Scenario #1 – Asset Utilization▪ Downtime▪ OEE▪ Utilization

Milkshake Mfgr – Scenario #2

► Mfgr now has visibility to performance▪ OEE & Downtime ▪ Asset Utilization

► Goals (one or more): ▪ Increase consistency using electronic work

orders for line management▪ ‘Track & Trace’▪ Consistent data model


► Possible pains▪ Can’t correlate process conditions with WOs or batches when issue detected▪ Small issues become big problems because impacts can’t be easily assessed.▪ Mistakes are made repeatedly▪ Major concerns about recalls▪ Operators waste time figuring out what to produce next▪ Differences in time to complete jobs between lines, shifts, operators▪ Different definitions of product formulas / recipes ▪ Introducing new product variants causes issues▪ Too much time spent compiling manual reports

► Potential Self-Diagnosis▪ Increased requests for additional / special reports▪ ‘Firefighting’ since information not shared across

shifts and departments▪ Reduction in customer service due to delays in

response time▪ Rework has increased ▪ Production costs have increased▪ Changeovers take too long

Scenario #2: Op’s Standard


System PlatformProduction Server

MES database

Historian

Info Server

Install Op’s Standard license

Deployment of Operations (Standard)


Machine Utilization

Reports Reports

MES Configuration MES Configuration

Machine Utilization


Scenario 2: Work Order Execution

Solution Diagram Solution Diagram

Reports

► Scenario #2 – Track and Trace, Execution▪ Consumption and

Waste▪ Production and

Rejects▪ Genealogy▪ Traceability ▪ Yield

► Scenario #1 – Asset Utilization▪ Additional domains▪ By item, work order

Milkshake Mfgr Scenario #3

► Mfgr now has… ▪ Visibility to equipment performance▪ Increased consistency w/electronic work orders▪ ‘Track & Trace’

► Goal #3: Add more MES capabilities…▪ Inventory tracking capability▪ Reduce WIP inventory▪ Manage expiration of WIP▪ Improve inventory turns▪ Reduce inventory costs ▪ Reduce order lead time ▪ Reduce Time-to-volume

► Excessive Scrap► Too Much Inventory► Inventory Costs Too High► No Traceability To Quality Check► Accurate Labor Costs Unknown► No enforcement of business rules for

intermediate WIP► Starved processes


Scenario #3: Full MES



MES database

Historian

Info Server

Install Op’s Premium license

Deployment of Operations (Premium)


Machine Utilization

Reports Reports Reports

MES Configuration MES Configuration MES Configuration

Machine Utilization

Machine Utilization

WIP Inventory Tracking


Scenario 2: Work Order Execution

Scenario 3: WIP Inventory

Tracking

Solution Diagram Solution Diagram Solution Diagram

Reports

► Scenario #3 – Inventory Tracking▪ Additional reports available

► Scenario #2 – Track and Trace, Execution▪ Additional information provided to previously

available reports

More Manufacturing Scenarios

► Example 1: Scalability ▪ … from a Small System to Large System

• Scale from a pilot to a larger system with ease

▪ Procedure to scale:• Start with a pilot system

• Add clients and servers without re-engineering the applications

• Reuse library of templates for multisite rollouts


MES database

Historian

Info Server

Line 1 Clients Line 2 Clients Line 3 Clients Line 4 Clients Line 5 Clients

Scalability

More Manufacturing Scenarios

► Example 2: Incremental Growth▪ … from One Application to Multiple

Applications ▪ Scale to address additional functional

requirements▪ Procedure to grow ’incrementally’

• Start with Performance

• Add Operations Standard

• Add Operations Premium

… all by simply changing the license file!!!


MES database

Historian

Info Server


Incremental Growth

Differentiators

► Standard application content out of the box► Single comprehensive database for all

MES capabilities – not disparate solutions► Modular operator interface concept► Support for mixed manufacturing modes► Data master flexibility► True integrated SCADA through MES

capability► Modern Microsoft-based architecture

Additional Benefits of Wonderware MES

► Integrated use of System Platform + MES

► Templates for MES User Interfaces

► The Value of a consistent data model▪ Templates ▪ Deployment

In Conclusion…

► Wonderware Operations and Performance Software offers:▪ Rich MES functionality that can be deployed

incrementally▪ Maximizing effectiveness▪ While reducing risk and time to value

Wonderware WorkshopsOperations Management - Monday

Time Topic Zunkles Room

10.00-10.50 An Overview of Wonderware MES Products

Jan Rasmussen

11.00-11.50 NEW! - Wonderware Performance Software - Real-time equipment downtime and performance tracking

Dawid Sadie

14.00-14.50 Manage and maintain your assets utilising Wonderware's condition based monitoring (CBM)

Tim Sowell

15.20-16.10 NEW! - Wonderware Industry Application for Packaging

Andrea Sartori

Wonderware WorkshopsOperations Management - Tuesday

Time Topic Zunkles Room

10.00-10.50 Manage and maintain your assets utilising Wonderware's condition based monitoring (CBM)

Tim Sowell

11.00-11.50 NEW! - Wonderware Operations Software - improve production consistency, visibility and agility

Andrea Sartori

14.00-14.50 NEW! - InBatch 9.0 - Flexible management for batch processes

Jos Peters

15.20-16.10 Advanced Scheduler for Wonderware MES

Chris Mollison - Preactor

Time Topic Injasuti Room

11.00-11.50 NEW! - Wonderware Performance Software - Real-time equipment downtime and performance tracking

Dawid Sadie

14.00-14.50 NEW! - Wonderware Industry Application for Packaging

Andrea Sartori

Questions

Thank [email protected]

I2 - An Overview of Wonder Ware MES Products - Jan Rasmussen Version 0.92 NXPowerLite

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