MOBILE HUMAN MACHINE INTERFACE (HMI): INNOVATION THAT EMPOWERS THE MOBILE OPERATOR
Mobile operators are critical to ensuring the overall efficiency and uptime of the production line and play a critical role in the success of any manufacturing business. The operator performs daily rounds assessing performance of machinery, performing line-side quality tests and even completing basic maintenance tasks such as machine calibration. When efficiency or equipment goes down, it costs money. Proper monitoring, maintenance and management of systems and equipment are at the core of a successful operation. Whether a manufacturing business is trying to improve line and plant performance, boost profitability, or achieve real-time visibility and automation control, mobile human machine interfaces (HMIs) can help meet operational and financial objectives. By empowering workers with immediate access to critical information when they need it, plants can optimize allocation of scarce human resources, significantly elevate their efficiency levels, and more nimbly and accurately respond to customer demand. WHAT IS HMI? HMI is the bridge between humans operators and supervisors and the machinery and computers on the plant floor. It is what ties people into the programmable logic controllers (PLCs) that run the machinery. Typically, operators and supervisors are on the move in process areas or on the manufacturing floor. They move back and forth from machinery to desktop computer stations located at or near their workstations or in control rooms. This is where they enter and access data, anything from inspection information and alarm codes to key performance indicators (KPIs) and maintenance schedules. Personnel also use their workstations for e-mail, to adjust shop orders such as changing components or routing instructions, and to access enterprise resource planning (ERP) systems. Unfortunately, plant designs like these are limiting. Fixed workstations take operators away from the floor, their eyes off machinery, and can introduce opportunities for error in the management and maintenance of critical shop equipment. Case Study: Huntsman Corporation Who: Challenges: Solution: Result: Huntsman is a global manufacturer and marketer of differentiated chemicals Design and implement a system that extends business value and process improvement Reduce the high costs associated with equipment downtime and lifecycle run time Capture and document knowledge from experienced personnel. Approximately 30% of workforce eligible for retirement Software that enables field operators to execute rounds and enter work requests in real time, monitor and control operating conditions for equipment, and access up-to-date standard operating procedures Utilize industrial-grade Motorola MC9090, ruggedized mobile handheld computers Provide wireless network infrastructure 75% reduction in safety incidents Significant process improvements with mobile computers Reduced maintenance costs Increased equipment uptime and productivity PAGE 2
MOBILE HMI DEFINED Mobile HMI takes the fixed workstation and places it in the hands of operators and supervisors. With mobile computers, information can be delivered to the point of work. Operators no longer need to leave the production line or step away from their machinery. Everything they need to do their jobs and do them better is literally in the palms of their hands. Mobile computers are the logical evolution within the plant management system. They can supplement desktop PCs and put plant operators and supervisors closer to the production line where they can make real-time decisions in the management of the plant. PLCs, SCADA and Mobile HMI PLCs create the foundation of the manufacturing automation system; on top of the PLCs is the supervisory control and data acquisition system (SCADA); and what ties it all together is the HMI. Together, these systems provide the necessary data and controls to manage the manufacturing process, throughput, quality control, and profitability. Mobilizing the HMI enables personnel to determine in real time, at the point of work, whether or not machines are running according to KPIs or to take immediate action in the case of alarm or production exceptions. This on-thespot decision making helps to ensure safe operations, keep equipment operating properly and guard against unplanned downtime. KPI Checklist for Managers Line speed Quality Downtime/uptime OEE, alarms/events Set-point changes Recipe execution Operator actions Key Items to Consider Before Implementing HMI Key Considerations Time required for system development Installation Integration with the factory system Operator training (and retraining) costs Project management Maintenance Software upgrades and modifications Key Questions What tasks need to be performed? What are the key visual/ performance requirements? What environmental factors need to be considered? Who will program the system? What equipment will the system interface with? What are the requirements of operators? Key Implementation Process Steps Identify users and understand their needs Involve users early and design processes to meet their working environment Test with real use cases Deploy with beta users Make enhancements Deploy to larger organization Continuously train and improve based on key performance indicators PAGE 3
BENEFITS OF MOBILE HMI Time is money, and when a business moves from a wired to a wireless world the benefits are numerous. Operators work in real time, are closer to their machines, and closer to the products being manufactured, which increases control over the manufacturing process and overall profitability. Mobile Online/VPN remote monitoring with proactive notification Mobile-based HMI can access machine output data such as production variables, sensor output signals, and alarm notifications. This enhanced flexibility can be extended throughout the plant as well as over virtual private networks (VPNs) for management from geographical dispersed locations. Remote engineering, troubleshooting Mobile HMI solutions enable businesses to capture root causes of incidents and correlate them with compliance and maintenance data. Operators can send machine data, photographs, and written or verbally recorded remarks to engineering personnel for help in order to diagnose and troubleshoot a problem. In addition to troubleshooting, mobile HMI enables operators to proactively schedule maintenance as soon as they detect a problem during their rounds. Extend functionality and performance Equipped with a single mobile device, operators are able to control a myriad of applications to monitor and manage PLCs and SCADAs, as well as collect and analyze valuable performance and operational data. Functionality can be extended further through the use of bar code and radio frequency identification (RFID) technologies. Mobile computers can track and record information associated with factory assets such as last maintenance, operator IDs, part upgrades and work time. Improved reaction time to real-time events Businesses will eliminate the need for technicians to spend valuable time on end-of-shift data entry, which translates into more time for work on the plant floor. They also will gain insight through the more timely correlation of, and access to, data that can help them transform their manufacturing environment and respond to events to better protect assets and product quality. Businesses can make informed production, inventory, stock and delivery decisions with real-time knowledge of the customer order status and the location of parts, tools and assets at any given time. Going green Mobile HMI provides greater access for regulatory compliance monitoring, collecting data in remote areas for environmental safety compliance, and accessing energy consumption reports and management. Space and cost saving The flexibility of mobile HMIs enables businesses to reconfigure the floor more easily in order to accommodate evolving product lines or new regulatory requirements. Businesses also save by removing the costs associated with fixed wiring and freeing additional physical space that was once required to accommodate desktop PC stations on the manufacturing floor. Industrial-grade networks and mobile equipment Today s industrial mobile computers are designed for rugged environments more so than standard PCs. Mobile computers, with RFID readers and bar code scanners, can be utilized in locations with high temperature, vibration, chemical exposure and other environmental constraints. PAGE 4
Connection Methods: Connecting Handheld Mobile Computers to Automation Systems There are four methods of connecting a handheld mobile computer to your automation system the option that is right for your manufacturing enterprise is dependant upon your existing infrastructure and budget: Industrial Ethernet the Direct PLC Connection Designed for newer PLCs with industrial Ethernet A direct connection to PLCs with industrial Ethernet is the most robust and preferred option available. Since all nodes, PCs, PLCs and mobile computers are connected to the main industrial Ethernet network the mobile computer can easily access all PLC data via standard XML, APIs and client applications. All devices that need to access the PLC data must be equipped with an Ethernetbased driver, preferably OLE for process control (OPC)-compliant. This option is most compatible with large companies that have an existing IT infrastructure and strategy as well as PLCs with industrial Ethernet capabilities otherwise the cost to upgrade to industrial Ethernet-based PLCs may be cost prohibitive. HMI as a Mobile Bridge Designed for companies with a fairly sophisticated HMI server In this scenario, an HMI client on the mobile computer connects directly to an HMI server that is in turn either: connected directly to a PLC; connected to the PLC via a client bridge; or connected to the same network as the PLC. Dedicated Card in the PLC Rack Designed for companies with a compatible PLC rack This option enables companies to more fully leverage an existing PLC rack. A special card is placed in the PLC rack that enables the bridging of data from the PLC to the network. The mobile computer can then access the PLC data via XML. This solution usually requires more advanced and more expensive PLCs. Wireless Client Bridge Designed for older PLCs For companies with older PLC models or PLCs with only serial communications, an access point or access port can act as a client bridge that can be utilized to enable real-time PLC access from the mobile device. The access point/port must have either an RS232 or USB serial connector, which is connected to the PLC s serial port. The client bridge then broadcasts the information in 802.11 (WiFi) standard formats that are easily received by the mobile devices. In order to interpret and utilize the data, the handheld device must be equipped either with a standard driver or client, or a small custom application. This option is the least sophisticated, and does have several pitfalls. The primary disadvantage is that the client bridge adds another point of failure to the network, increasing rather than reducing IT vulnerability. In addition, this connection tends to be less secure than an organic Ethernet connection. For More Information For more information how you can use Motorola s innovative HMI solutions to empower your organization s mobile operators, visit www.motorolasolutions.com/manufacturing or call 1-866-416-8593. MOTOROLA, MOTO, MOTOROLA SOLUTIONS and the Stylized M Logo are trademarks or registered trademarks of Motorola Trademark Holdings, LLC and are used under license. All other trademarks are the property of their respective owners. 2011 Motorola, Inc. All rights reserved.