Date post: | 16-Aug-2015 |
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Technology |
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Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
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FactoryTalk® MetricsConfigured Performance Management in 50 minutes or less.
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Agenda
What is FactoryTalk® Metrics?
Scope / Session Overview
First Pass – required steps – 10 minutes
What is ReportExpert?
Second Pass – optional steps – 10 minutes
Summary
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
What is FactoryTalk® Metrics?
A performance management solution that out of the box enables you to track and trace manufacturing operations now.
FactoryTalk® Metrics is machine centric – you do not pay for a tag count you pay for a work cell and configure as many tags as you need.
KPIs – OEE, Availability, Performance, Quality, MTBR, MTTR +
Supports Machine States Running, Faulted, Blocked, Starved, Changeovers etc.
Context-based support using an S95 plant model and user-defined context fields.
Event Tracking including energy, batch and mass balance.
Report Engine that supports weighted average roll up across the plant model, user-defined context and time dimensions like shift or hour.
Vantagepoint Enabled / Connector Link.
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Scope
Show the work step by step.
First Pass Configuration Basic steps to meet requirements for FactoryTalk® Metrics
Cycle Time (in seconds), good part counter and a running bit.
Define two states Running and Down.
Report Overview
Second Pass Configuration Recommended steps that increases detail and delivers information to improve operations
now.
PartId – not just 10,000 parts but by type
12oz / Bottle / x13 / SAP Id / Complex Id – link to MES / MOM.
Detect Scrap – add a scrap part counter
Add Starved, Fault and Operator reason codes.
Report Overview
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Session Overview
We have about 40 minutes
Simple worksheet of basic performance data / tags
Transform these data points into actionable information Part Counts by type – Good / Scrap / Total Parts
Define Machine states that measure your assets your way.
Comprehensive reporting that enables you to make changes right now. Decrease Down time and complete production in 5 days not 7.
A two pass scenario
First Pass Configuration – delivering key KPIs quickly.
Second Pass Configuration – delivering additional detail that will enable you to focus on key operation targets providing the root cause reasons for downtime.
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
First Pass – Required Steps
S95 Plant Model
This is quick, simple and industry standard.
Provides structure to the data and adds roll-up. Example: My Company (Enterprise) | My Site(Site / Location) | Production (Area) |
Line 1 (Line) | L11 Filler (Workcell). You can use this model to summarize your data (KPIs, downtime and others) at any S95 Level.
Key to organizing plant operations and provides a saleable link to enterprise software.
Software Schedule
Assign a basic schedule to store you data by shift to support time date reporting.
Metrics supports variable length shifts but we are not covering that feature in this lab.
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
First Pass Configuration
You need three tags.
Running Indication This should be a Boolean bit that is high (= 1) when running. Running means you are producing
parts.
Down State when the run bit is low (= 0) – configure on First Pass then delete on Second Pass.
Good Part Counter This should be an accumulated value that does not reverse or go negative but can reset
automatically.
Cycle Time In seconds how long does it take to make one part / pound / case – you pick the unit of measure.
Cycle time can be a tag, derived from a lookup or typed in.
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Using the Configuration Console ….
Add the tags to support this configuration.
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
First Pass Configuration complete…
After less than 9 minutes and 3 tags.
Production Reporting
Good part counts
Detect downtime
Down time versus Fault Time?
OEE, Availability, Performance and Quality.
Dashboards including a white board with dynamic time
Lets take a look!
ReportExpert
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
What is ReportExpert?
ReportExpert is a Rockwell Automation® (RA) application that simplifies SQL Server Reporting Services (SSRS) to configured steps using templates and parameter sets.
Anyone can learn how to configure reports.
No SQL training required.
Not required to be a Database administrator
Configure report templates using easy to define parameter sets.
Configuration versus Programming
Create custom reports in seconds.
Demo
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Do it …….
Load ReportExpert and view the following reports.
Water Fall
Production Overview
Whiteboard
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Second Pass Tag List - **Optional**
Track parts by type
Track performance by operator or any other criteria
Add scrap part counter to measure waste / calculate Quality.
Detect Starved conditions / protect OEE while Starved.
Add Boolean faults – most common
Integrated event driven by an Operators input – Trigger / String
Tag List -
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Using the Configuration Console …
Complete the Second Pass Configuration.
Add PartId
Add Operator
Add a scrap part counter
Add a fault event Drive Stop
Add Starved as a machine state.
Add an event that captures operator added comments.
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
After 10 minutes and 10 tags
Every thing we just showed is based on a configured application
S95 Model
Plant Schedule Assignment (variable schedule support not covered
here)
Configuration shown with only the most basic tags – anyone with a run
bit, part counter and cycle time can deliver OEE now.
Configuration shown with additional tags that drive advanced topics.
Default Report Options using ReportExpert
VantagePoint Linked with connector that ships with the product.
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Using ReportExpert …
Load ReportExpert
Waterfall
Production Overview
By Part
By shift, hour and rolled record
Rolled record is user-defined by workcell selection summarizing performance
data from every 5 minutes to once an hour.
White Board enhanced
Top Ten (user defined) Event Chart.
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Summary Results -
Scalable performance management that grows with you
Self Service Reporting
Dashboards, whiteboards totaling 69 standard reports
Report packs available via samplecode.rockwellautomation.com
Operator Ranking
Production reporting with part counting by type including good/scrap/total parts.
Blocked and starved detection – machine states.
Root cause support.
Simultaneous events limited only by server resources.
All KPIs including OEE, Availability, Performance, Quality, MTBF and MTTR to name a few.
www.rockwellautomationteched.com
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.
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Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Questions?