MI16 - FactoryTalk Metrics Introduction Lab RSTechED2014

8/19/2019 MI16 - FactoryTalk Metrics Introduction Lab RSTechED2014

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

PUBLIC INFORMATION

FactoryTalk® Metrics Introduction Lab


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

Objectives

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This is an Introductory Lab, so noprior exposure to FactoryTalk Metrics is

assumed.

If you have prior exposure to FactoryTalk Metrics, you may have seen thismaterial before.

There is an Advanced Pick & Choose Lab offered

Understand how a user can use the data that FactoryTalk Metrics collectsto help improve operations.

Become familiar with the Report Expert reporting environment.


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Do You Ever Hear This?

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Plant Management

Maintenance

Control Engineering

Quality

Machine Builder

Scheduling

Information Technology

Planning and Logistics

Operator

Knowledge Worker

Do we

have enoughcapacity?

Where arebottlenecks?

How can wereduce costs?

What is myequipmentutilization?

What is my firstpass quality?

What aredowntimecauses?


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What Are Your Challenges?

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You may want to:

Track downtime

Reduce cycle time variation Increase production without buying new

equipment

Reduce unit costs

Reduce overtime

You may call it: Performance Management

Machine Monitoring Downtime Tracking

Process Improvement

Overall Equipment Efficiency

(OEE ) LEAN

All of the above…or none of the

above… Bigger question: who doesn’t need to:

Make better use of existing assets

Be more productive in manufacturing

Increase profitability


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Let’s Make This Simpler.

Would You Like to be More Profitable?

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Goal: Increase Revenue and Profitability

You suspect this can be done by Increasing the Productionof

manufacturing assets and Reducingproduction Costs.

You are almost certainly right.

This area is often called Performance Management, and OEE is the most

common methodology

Performance Management is the most strategically important IT

investment (23%) (AMR survey)


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Overall Equipment Efficiency (OEE)

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Quality% =

Total – Scrap

Total

Performance% =Total * Ideal Cycle

Running Time

Uptime% =Running Time

Available Time

Overall EquipmentEffectiveness (OEE) =

Uptime x Performance x Quality

One Shift

Avai lable Time S c h e d

U n a v a i l

Running Time D o w n

t i m e

Production @ Rated Speed S p e e d

L o s s

Good Production S c r a p

Scheduled Unavailable Time

Breaks, meetings, maintenance, etc.

Downtime

Breakdowns, setups, changeovers

Speed/Cycle Time Loss

Reduced speed, cycle time variation

Quality Loss

Rejects, scrap

Time Loss Causes

Avai lable Time = Shift time – Unavailable Time

LostCapacity%OEE %

Key Performance Indicator (KPI)


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Does an OEE System Make Sense?

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There are three general ways to reduce costs in an automated process:

1. Reduce unproductive machine time

2. Reduce cycle times3. Reduce waste/scrap

OEE measures the three things that reduce costs:

1. Productive time = “Uptime”. Are the machines running when expected?

2. Cycle times = “Performance”. Are they running as fast as expected?

3. Good vs. scrap = “Quality”. Are they wasting cycles and material producing scrap?

OEE % = Availability % x Performance % x Quality %

Higher OEE = Lower costs


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Why is OEE so prevalent?

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It is a simple performance indicator that everyone can relate to –it is

the ratio of actual good parts produced vs. what could have been

produced under ideal conditions: no downtime, no cycle timeerosion, and no scrap.

OEE = Actual / Ideal

It can be applied to any machine, in any industry, anywhere in the

world.

Because it shows a machine’s actual performance compared to its

theoretical maximum, OEE can be used to accurately compare the

performance of any machine, line, etc. to any other.

Increasing OEE leads to decreasing costs.


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Is OEE Enough?

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OEE is effective at measuring:

Overall Efficiency

Efficiency in 3 broad categories

Progress over time

Comparative performance of machines/lines

OEE data alone is not sufficient to impact performance Your objective is not just to measure, but to improve

You need to know the WHYs behind the numbers

Need detailed, machine-specific data that uncovers the causes of inefficiency

Without this, you have a stick and no carrot continuing profits for years.

You need OEE … and More!


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IncreaseOEE…

Which meansIncreasing• Availability,•Performance,•Quality

From OEE to

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Reduce:•Downtime

•Unproductivetime•Cycle times•Scrap

Reduced:•Unit costs•Material costs•Labor costs•Capital costsfor morecapacity

If you want to: You must: And that will result in:

Increased:

•Production•Revenue•Profitability

This is where theimprovement

happens.

And the $$ willfollow!


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What’s the Strategy for Reaching Your

Goal?

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Goal: Increase Revenue and Profitability by Increasing Production andReducing Costs

Strategy: Reduce Downtime, Unproductive Time, Cycle Times, and Scrap

This is where you must take action –Directly

Changes here impact Production, Costs, Revenue and Profitability – Indirectly

Everyone can participate in this strategy


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So How Do You Improve Efficiency?

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You need to “measure”…

Production counts, Scrap rates Machine cycle times Downtime durations and causes Unproductive time (all forms)

You need to “analyze”… To uncover the real problems that are impacting production To quantify and prioritize the problems

You need to “take corrective action”… To make changes that will result in the greatest improvement

To make decisions based on accurate data Then “repeat” …

Strategy: Reduce Downtime, Unproductive Time, Cycle Times, Scrap

You need a system to Measure and Analyze


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You “Measure” and “Analyze” Now…

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Typically, information is gathered manually or from various plant

systems. Reports are generated in Excel spreadsheets and

distributed in paper form.

Some issues: Gathering data is tedious and time

consuming (and expensive)

Manual data collection is inaccurate

Data is “stale” at time of reporting

Data and reports are not available

for analysis

Data is not detailed enough to beactionable

No time - you still have to attain

today’s production goals!

Is that working for you?


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What Will You Do to Get to Your Goal?

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Goal: Increase Revenue and Profitability by Increasing Production andReducing Costs

Strategy: Reduce Downtime, Unproductive Time, Cycle Times, and Scrap

Methodology:

Measure –need a (better) system

Analyze –need a (better) system

Take Corrective Action –with confidence

Repeat


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Something Like This Would be Better

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Reliable, accurate,

timely, automatic

data collection

One place for all

data

Flexible reporting

that gives each user

what they need


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FactoryTalk Metrics

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A complete system for collection and analysis of:

OEE data

Detailed event data required for process improvement (You need both…)

To Measure

Automatic, 24/7 data collection from the control system

Configurable to use existing PLC/HMI programs Timely and accurate data

To Analyze

Real-time data for plant floor personnel

KPI’s and summarized data for management

Detailed downtime and root cause data for driving

corrective action

Context data for multi-dimensional analysis


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How Does FactoryTalk Metrics Measure?

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Collects and stores machine performance data

Not on a clipboard; not in an Excel spreadsheet From the control system, using existing PLC/HMI programs

24/7 in real time – timely and accurate

In an open SQL Server database

What kinds of data?

Production counts, Scrap counts

Downtime events and reasons

Events that represent unproductive time (in all its forms)

Context data – Part Id, Operator, Work Order, etc.

Minimum needed from control system –1 data point (Good Part Count) No maximum number of tags –the more tags, the more detailed the potential analysis

Takes raw control system data and:

Computes timers and counters, calculates KPIs, cycle times

Computes States using a built-in state engine Adds context data for analysis


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How does FactoryTalk Metrics Analyze?

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Provides 69 out-of the box reports

Dashboards – real-time machine information for operators

Performance and production information Including KPIs, Scrap/Quality, Actual Cycle Times

Event data Including Downtime and causes, Unproductive Time

Reporting interface that supports/encourages ad-hoc analysis

Dynamic filtering/grouping on all reports

Drill-down and drill-through functionality

Connector to FactoryTalk VantagePoint for Enterprise Manufacturing

Intelligence analysis


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FactoryTalk Metrics Architecture

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System Configuration Define work cell properties and data

collection with Configuration Console

Data Collection Collects all data automatically via

FactoryTalk Live Data Server andFactoryTalk Transaction Manager

Aggregates and stores performance

and event data via Metrics ServerManager

Data editing through Report Expert

Report Client Report Expert –web client using SQL

Server Reporting Services FactoryTalk® VantagePoint® Portal –

web client Report Expert reports

FactoryTalk VantagePoint reports

FactoryTalk VantagePoint dashboards

Report Client

Live ata Server

Automat ion Devices

SystemConfiguration

Report Expert

ConfigurationConsole

SQL Server ReportingServicesetrics Server

Manager

Server

FactoryTalk

Transaction Manager

Data Collection

VantagePoint

VantagePointPortal

Excel/Trend

Dashboards


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What’s New in FactoryTalk Metrics

11.50?

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Support for Windows Server 2012

Support for SQL Server 2012 SP1

SQL Server 2012 SP1 Standard Edition Included Existing SQL licenses must be upgraded

Support for Windows 2003 and SQL 2005 dropped

Performance improvements

Reports

Editing

Some new reporting capabilities

New Gantt chart report Reporting on Event Comments

Includes FactoryTalk VantagePoint 6.0

July 2014

&

Metrics


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FactoryTalk Metrics Lab Architecture

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One VMWare image

Contents:

FactoryTalk Metrics Report Expert

FactoryTalk VantagePoint

SQL Server 2008 R2

Control System/simulation

SoftLogix™

FactoryTalk View SE

Report Client

Live ata Server

SoftLogix

SystemConfiguration

Report Expert

ConfigurationConsole

SQL Server ReportingServicesetrics Server

Manager

Server

FactoryTalk

Transaction Manager

Data Collection

VantagePoint

VantagePointPortal

Excel/Trend

Dashboards


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Introductory Lab Overview

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You will use FactoryTalk Metrics 11.0 and Report Expert 3.1

FactoryTalk®View Site Edition HMI and SoftLogix provides simulated data.

You will use Report Expert to answer some common questions: How is my operation performing?

History / Now

By various measures

By Line/Machine/Shift/Part/Operator How can we start reducing downtime?

Where is the most downtime occurring?

What is causing the most downtime?

Can we increase machine speeds?

Can quality be improved?

How can we get the right information to the right users?

You will use FactoryTalk VantagePoint to view FactoryTalk Metrics data.

Does not cover product configuration. (That’s an Advanced Lab)


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Other FactoryTalk Metrics Sessions

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MI17 - FactoryTalk Metrics: Pick and Choose Lab Lab 1 - Report Expert Overview

Lab 2 –Configuring FactoryTalk Metrics Lab 3 –FactoryTalk Metrics Connector for FatoryTalk VantagePoint

Lab 4 –Manual Workcells and Manual Data Entry

MI15 - FactoryTalk Metrics: Showing Value in 50 Minutes

Customer Case Studies:

AP01 - American Colloid Company: Using FactoryTalk Metrics to Provide Reliable Data toImprove Plant Operations

AP06 - Barry Callebaut: Reducing Raw Materials Losses With FactoryTalk Metrics


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PUBLIC INFORMATION

Questions?


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We care what you think!

On the mobile app:

1. Locate session using

Schedule or Agenda Builder

2. Click on the thumbs up icon onthe lower right corner of the

session detail

3. Complete survey

4. Click the Submit Form button

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Please take a couple minutes to complete a quicksession survey to tell us how we’re doing.

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3

4

1

Thank you!!


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PUBLIC INFORMATION

Thank you for participating!

Please remember to t idy up your work area for the next session.

We want your feedback! Please complete the session survey!

• Minimize the VMWare image• Click on the Survey link on the Desktop of the Host computer

• Session Id =

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MI16 - FactoryTalk Metrics Introduction Lab RSTechED2014

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