WW OPS-05 Improve Production Execution Visibility, Agility & Performance with Wonderware MES

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2 WW OPS-05 Improve Production Execution Visibility, Agility & Performance with Wonderware MES / #SoftwareRevolution Jeff Nuse /InvensysVideos Senior Product Manager MES /Wonderware /company/invensys Operations Management Jeff Barkehanai Product Manager MES Quality 2013 Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are proprietary marks of Invensys or its subsidiaries. All third party trademarks and service marks are the proprietary marks of their respective owners.

3 World-Class Manufacturing & Production What s the Journey?? Organization Design Align their organization to satisfy the needs and wants of its customers in an effective, timely manner Eliminate organizational barriers to communication Performance Measurement Recognize the importance of measurement in defining the goals and performance expectations of their organization Relentless commitment to continuous improvement, which cannot be achieved without measurement Slide 3

4 World-Class Manufacturing & Production What s the Journey?? Information Systems Leverage world-class information systems for collecting, processing and disseminating data Operations Capabilities Capable of producing the right quantity, the right quality, at the right time, and at the right price Highly available production assets Quality All quality costs (prevention costs, cost of defects, etc.) are evaluated and held to the lowest reasonable sum Zero defects is the goal Slide 4

5 The Supply Chain Let s Explore How Wonderware Production and Performance Offerings Enable Organizations to Achieve and Maintain World-Class Manufacturing / Production Status! Slide 5

6 Wonderware s Operational Management Approach Enabling the Journey to Operational Excellence Series of Functional Programs Asset, Safety, Env, Productivity, People Enable Horizontal Value Scenarios Across our Industrial Capability Acceleration to Result Foundation of Capability for Solutions Enabling Sustainability Enabling Evolution on Journey Slide 6

7 Invensys s Operational Management In Context with the Supply Chain & Automation PLM Level 4 Business Planning & Logistics ERP EAM SCM Level 3 Manufacturing Execution System Wonderware Enterprise Integrator (WEI) Level 0, 1 & 2 Control Application & Reporting Clients Production & Performance Applications Batch Slide 7 Continuous Discrete 3rd Party

8 Wonderware MES Software Full MES Functionality according to MES/MOM standards Operations (incl. Inventory) and Quality operations & Performance Management Enables step by step functional implementations Sustainable Standard Software Highly configurable Wonderware MES Software Operations Flexible, consistent enhancements in scope and size Integration with Customer processes Performance Superior shop floor integration and execution Standardization support and reusability Enterprise Integration Slide 8 Quality

9 Wonderware Operations Improves Production Execution Consistency, Visibility, and Agility Slide 9

10 Wonderware MES Operations Overview Business Value Foundation for Agile Production Processes Improve Production Consistency Empower Supply Chain Applications Enforce Compliance & Governance Key Capabilities Open, Modular, Scalable, Extensible Full-Featured MES Capability Dock-to-Dock Real-Time Visibility to Production Activities Comprehensive Manufacturing Genealogy Slide 10

11 Wonderware MES Operations Features Product Definition Order Management WIP & Inventory Management Step Execution Product Definition Instructions Work Create Work OrdersofManually from an External Setpoint Management. or Import Define a Hierarchy Storage/Stock Locations to Track Order Management Configure Steps (or Tasks) for each Operation within a Route Import Electronic Product from External Applications Application (e.g.definitions ERP) Define Folders with Associated Documents and Materials Fixed or Moveable Define Values (e.g. Min., Max., Nominal), Instructions, Configure and Enforce Step Execution Order Multiple BOMs (e.g. versioned) for each Finished or Work Instructions (Multiple Versions) Attach Routing Instructions, BOMs, BORs, Setpoints, SOPs, WIP & Inventory Management Track Comments Materials and Work as BulkInstructions and/or Lotfor Based each Setpoint SemiData Finished Material and Attached Work Collection Instructions Requirements to a Types Step to a(e.g. Work Order View Many Different Document PDF, Microsoft Assign Associate Configurable Setpoints with Grades a Particular and States Work to Center/Machine, all Materials a Documents, Web Pages, etc.) Define Multi-Level BOMs Capture Assign Work Items Order to Events a Step (e.g. Status Change, Production, StepBOM Execution Material or a Procedural Step Calculate and Enforce Expiry Dates Consumption) at each Operation on to afor Process RouteItem Link Work Instructions and Documents toeach Products, Work Define Machine Multiple Substitute Materials BOM Assign and BOM Setpoints a Step Download Setpoints to Automation Devices Capture Complete Genealogy Trail of all WIP and Inventory Orders, Operations, Work Centers or Procedural Steps Setpoint Management Sequence Work Orders Manually or through a Finite Capacity Attach Work Instructions to Materials Configure Step Activity (e.g. Collect Data, Consume Material) Activities Scheduling (FCS) Application Work Instructions Slide 11

12 Wonderware MES Operations Seamless Integration to Automation Operations Capability Object (OCO) Supports the following automated transactions: Create & execute jobs/orders Record production & consumption Create & transfer inventory Load specifications Record production events Invensys 23 October 2013 Slide 12

13 Wonderware Performance Improves Asset Utilization, Increases Capacity and Empowers Operators Slide 13

14 Wonderware MES Performance Overview Business Value Improve Asset Utilization (OEE) Reduces Capital Expenditures Increases the Capacity of Existing Assets Empowers Operators Key Capabilities Detect, Capture & View Utilization Events Manual & Automated Data Collection Real-Time Visibility to Production Performance Bottleneck and Root-Cause Analysis Slide 14

15 Wonderware MES Performance Features Equipment Utilization Equipment Utilization Performance Production Progress Equipment Performance Calculate Detect Capture for Equipment Utilization / Line Events Provideand a OEE Clear Indication of Work Order Progress to the Production Progress Operator in Real-Time View Trigger Equipment Events and Events Display Calculate OEERecord and Other Custom KPIs MonitorEvent Analyze and Frequency Equipment and Duration State Estimate Expected Completion Date and Time Automatically Assign What States or Manually Affect OEE Assign Calculation Reason Codes Slide 15

16 Wonderware MES Performance Seamless Integration to Automation Utilization Capability Object (UCO) Provides the following capability: Configure utilization events to collect for each asset Automatically captures event data (start/stop time, etc.) Automatically collects production performance data Invensys 23 October 2013 Slide 16

17 Wonderware Quality Improves Product Quality and Consistency Through Real-Time SPC and Analysis Slide 17

18 Wonderware Quality Overview Business Value Improve Quality and Consistency, Reduce Process Variation Identify, Correct Deviations in Real-Time Meet Regulatory, Customer Compliance Key Capabilities SPC Alarms, Alerting and Charts Integrated Specification Management Sample Plan Definition and Execution Slide 18 6σ

19 Wonderware Quality Features Specification Management Sample Plan Definition Management Statistical Process Control (SPC) Specification Management Sample PlanPlan Execution Management Sample Definition Mgt. Import the Sample Plan from External Source (ERP/PLM) Standard Run Rule Selection Specifications from anan External Source (ERP/PLM) Sample Collection Notification Configure What Characteristics tomgt. Collect SPC Charts Plan XBar andspecifications Sigma, Moving X of Define Product andrange Process in Average, the Context Sample Execution View Sample Details & Recorded Data Individual, p/np/c/u/dpmo Materials, When Equipment, OperationsShould be Collected Configure the and Characteristics Additional Sample Request Generation Statistical Process Control Feedback Control Rule Violations Define andofattach Characteristics (Variable & Qty, Attribute) Select from Multiple Frequency Types: Time, Event, etc. Manual or Automatic Sample Collection (SPC) Additional Operator Data Collection Comments) Define Multiple Specification Overrides Attach Frequency Types to a(e.g. Sample Plan Slide 19

20 Wonderware MES Product Roadmap Performance Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are proprietary marks of Invensys or its subsidiaries. All third party trademarks and service marks are the proprietary marks of their respective owners.

21 Wonderware Performance 2014 New Line Management functionality Bottlenecks Parallel Entities New Web Client Configuration Line Management Entity Standards / Configuration Runtime Production Operations Historical Utilization and Production Information Slide 21

22 Line Functionality The Line Has a Utilization Reason Set manually / automatically at the Line level or set based on Reason from child entities in the Line Has Current Job(s) Multiple Work Orders, Item, Operation for the Line, Quantities Production Counters (Good / Reject) for ERP reporting Performance Counters for performance KPI s of the same type as the individual Entities in the Line Slide 22

23 Line Functionality Parallel Entities as Bottleneck The Bottleneck in a Line is the Entity with the slowest Production Rate. The rate of the Bottleneck Entity or Segment in a Line determines the production rate of the Line. If Parallel Entities are the Bottleneck, then the production rate of the Line is the sum of the rates of the Entities making up the Bottleneck. Slide 23

24 MES Performance 2014 Utilization Capability Object (UCO) Performance / Utilization / OEE / Utilization Object (UCO) OEE Calculations exposed in the UCO Imports / Export of Configuration into UCO Simplification of Performance for easy deployment High Speed Status changes Slide 24

25 MES Operations 2014 Operations Objects Operations Object (OCO) High Speed transactions Split off Specifications from the OCO new Specifications Object SCO Counter Capability Object CCO Slide 25

26 Wonderware MES Roadmap Q1/Q MES 2014 Performance Q MES 2014 Operations CY2013 CY2014! Dates are for guidance only and will change Slide 26 CY2015

27 Wonderware MES Product Roadmap Quality Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are proprietary marks of Invensys or its subsidiaries. All third party trademarks and service marks are the proprietary marks of their respective owners.

28 Cause and Cause Group Definition Slide 28

29 MES Client Configuration - Categories Add ability for Categories to contain cause groups and characteristics Used to limit list of assignable causes shown in an SPC Chart Slide 29

30 SPC Chart to Add Cause Slide 30

31 SPC Chart Control Enhancements Enable/Disable Display statistics on the chart Individual values, mean, and range Cp / Cpk / Pp / Ppk Populate Header Fields and options of what to show (none, minimal, most, all) Characteristic / Chart type / Item (Minimal) Item Description / Operation / Entity (Most) Operator / Test Equipment (Most) Specification Limits / Unit of Measures (All) Right Click Option Assign / Unassign Cause to a Point Mark a Sample as Ignored Mark a Sample as Control Move Comments / Notes Management Chart color options and Y-axis control Slide 31

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33 Sample Frequency Definition Added New Frequency Type - Production Unit Count Generate new sample after X units of production have been reported Will predict into the future based on job/entity standard production rate Production count reset options on job change, main item change, shift change, or never Slide 33

34 Additional MES Quality Items Automatic Calculation of Control Rules to include Number of samples to use How many samples must exist before calculating limits Archive / Restore Quality data from the Sample table and dependent tables Sample Plan can be marked as requiring verification of the user User must reenter password when saving manual data System Parameters for setting maximum number of samples or time period when calculating process statistics Sample Recording Object trigger command for creating a new sample Evaluation of Control Rule Violations for Attribute Characteristics Includes p, np, c, u, and DPMO chart evaluation of rule violations Sample Viewer Control Improvements Configurable Refresh Rate Added Priority and Severity to grids Next / Previous button in Results Editor Slide 34

35 Wonderware MES Quality Management Roadmap Nov 2013 QI Analyst V 8.0 SP3 September 2012 MES Quality Management Release (MES 2012 v4.5) March WW MES QM MES 2012 P1 QIA to MES QM Migration Q WW MES 2014 CY2012 CY2013! Dates are for guidance only and will change Slide 35 CY2014 CY2015

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