Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.

PUBLIC INFORMATION

American Colloid Company: Boost Accuracy and Use of Reliability Data from HMI to C-suite

Wendy Armel, Stone Technologies

Principal MES Analyst

Agenda

Introductions/Technologies Used

Customer Information

Situation/Goals

Project specifics

Wrap Up/ Q&A

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Introduction

Wendy Armel – Principal MES Analyst

Audience – How Many…

End Users

Systems Integrators

Rockwell Automation

Distributor

Other

Experience with

FactoryTalk® Metrics

Business Objects

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What is FactoryTalk Metrics?

OEE and Downtime Tracking

Overall equipment effectiveness (OEE) can provide you with critical insight into how well you are managing your production operations.

Downtime - identify specific causes of inefficiency, including sophisticated methods of analysis that allow you to measure or compare the performance of plants, lines, machines or even individual production teams.

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What Business Intelligence Tools Were Used and Why?

SAP Business Objects Provides for ad hoc analysis at a strategic level

Why use SAP Business Objects? American Colloid Company already uses SAP and owned the BI stack.

Using this product made the data available to a wide audience

The IT Department at American Colloid Company was able to support this solution internally by using a technology they already owned

American Colloid Company needed a way to do strategic level analytics on the data being captured from the FactoryTalk Metrics product

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Customer Information

Plant is located in Lovell, WY. American Colloid Company (ACC) is one of the world’s leading producers of bentonite clay.

Make products for the following: oil drilling

consumer products good (cat litter)

Pharmaceutical

taconite steel

Agriculture

industrial applications

Process: bring in crude bentonite, dry and process and load into rail cars and trucks

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Goals

Reduce Downtime

Increase production rates

Gain visibility into plant operations

Needed more accurate information for strategic and tactical decisions for allocating resources toward continuous improvement.

The goal was to improve efficiency and reduce costs.

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Challenges

Focusing everyone on the right (biggest) issues

There are four crews running 12 hour shifts. Communications between the crews were difficult to keep updated. Each crew had a different perspective on what the issues were.

Needed to change the culture from using tribal knowledge to using data from an automated collection system - FactoryTalk Metrics

A previously installed automated data collection system was ineffective. The end users were skeptical of another solution.

Integrating manually recorded data from both domestic and international locations.

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Project Approach

Implemented small pilot

Refined pilot to provide for base configuration

Expanded base configuration

Implemented data warehouse to allow for high level analytics

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Pilot

Stone Technologies and FactoryTalk Metrics were put on trial to deliver a solution that could improve our reliability.

Implemented on one Mill process line (work cell)

Began receiving automated emails of key reports to become aware of the data.

Root Cause Analysis report – reviewed end of each shift. Reviewed to see if there are indication of unexpected issues.

Production Summary– reviewed daily. Provided information on productivity

Downtime Summary – reviewed daily. Provided insight into downtime.

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Pilot – Root Cause Analysis AG

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Pilot – Production Summary AG

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Pilot – 24 Hour Downtime Summary AG

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Pilot Refinement

Refined machine states and down time reasons

Linked data into MSAccess to allow ad hoc analysis by reliability team

Refined automatic notifications Added email notification to key personnel when a downtime reason changed

Determined the only automatically delivered report needed was the Root Cause Analysis report

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Expansion

Expanded data collection to the following:

3 Mills

2 Dryers

3 Screening Systems

Geosynthetic clay liner

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Data Warehousing/Ad Hoc Analysis

After analyzing data in MSAccess, it was determined what data was needed at the strategic level

Categorized the machine states and events into buckets that impacted the asset availability

Total hours of downtime

Number of occurrences

Production rate

Corporate IT implemented a data warehouse Identify the data and define the summarization criteria

Set the automated routine to extract the data to keep data fresh

SAP Business Objects applied for ad hoc analysis

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Asset Availability AG

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Availability by Work Cell

Shows Final compiled data warehouse data

Packaging data is manual data that was merged into the data warehouse

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Detailed Events For Selected Bar AG

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Downtime Hours

This chart allows allocation of resources

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Downtime Occurrences

Selected the “shock switch” bar and the following details are displayed.

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Production Rate

Actual vs MAC (Maximum Achievable Capacity)

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Results

American Colloid Company realized results Focused resources on the correct areas

78% - 94% Asset Availability

Increased MAC across the plant by 30%

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Benefits

While the project was successfully implemented by Stone, it is critical to the customer that they not be reliant on Stone for future support

Stone personnel (even ones new to the system) can support the standard configuration

Should the customer ever need it – there are MANY other integrators who can support the standard FactoryTalk Metrics implementation

Not stuck with a single provider as they were with the prior solution

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Benefits of FactoryTalk Metrics - Customer

Support is easier if new people are introduced to the project

TIME – standard objects shorten implementation time frames significantly

MONEY

Out of box cost

Ongoing support

Integration

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Lessons Learned

People cannot accurately estimate what is taking place in a production environment.

Prior to implementation – ~60% accuracy

Automated solution - ~95% accuracy (time is 100% accurate)

Having data to support the issues, allows operations, maintenance and quality to focus on the same issue instead of working against one another, solving what they think the problem is.

Interdepartmental communications are more efficient and having the correct data takes the emotion out of decisions. When the teams start to succeed, people are more eager to work together. Success is contagious

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Take Away

When you are on an effort to improve, if you solve the wrong problem, you wind up with two problems. The original, plus the one you created.

FactoryTalk Metrics provides the data to focus on the right problem

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Summary

Goals

Get new data acquisition solution up and running quickly and efficiently

Keep the solution cost effective

Approach

Stick to standard configuration as much as possible

Results

Streamlined, repeatable solution that provides valuable data to multiple levels of the organization

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CO

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Stone Technologies

$15M 2013 revenue

54 full time employees

Average 20% year over year growth for past 10 years

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Stone Technologies, founded in 1996, is a national system integrator providing automation/control, information (MES) and operational consulting solutions. Based in St. Louis, MO with resources in 15 states/ 1 province.

Employee Business

Satisfied people deliver successful projects and provide long term continuity

Stone Technologies long term relationships built on performance, trust, & keeping promises.

Average 95% employee retention rate for the last 10 years The technical staff has an average of 22 years of experience

Of our top 20 clients (by services revenue) since the inception of the company 15 years ago: Doing business with ALL of them today

Average relationship is over 9 years Average of 50 projects per client Average adding 2 – 3 new clients a year

We have paid employee bonuses every year since inception

Our best revenue generating tool is the successful delivery of projects

CO

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S Contact Information

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Wendy Armel - Principal MES Analyst

warmel@stonetek.com

Office: (972) 395-1627 Cell: (727) 244-5588

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.

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