Building a Reporting and Analytics System Connected Enterprise Seminar PUBLIC INFORMATION Rev 5058-CO900E
Enterprise PRODUCTIVITY SUSTAINABILITY Smart Grid AGILITY Customers Supply Chain Distribution Center
Agenda Part 1 1. Information Portal - From Vision to Deployment 2. Historian - Big Data handling in Production Part 2 1. Mobility KPI Dashboard and Reports for your tablet or smart phone 2. Business Integration ERP and SharePoint
4 Manufacturing Landscape Common Issues Manual Data Collection Data consistency / Standardization Energy Usage / Optimization Productivity Unplanned Downtime Equipment Efficiency / OEE Virtualization & Thin Clients Reduction in Physical Servers Shop Floor Thin Clients Network Convergence & Security Infrastructure Modernization Security & Anti-Virus / Anti-Tampering Protection Top Floor to Shop Floor Asset Management Preventative / Predictive Maintenance Reduced MTTR Quality & Operations Compliance Tracking Improved First Pass Quality / Process Consistency
5 The Vision Trending Reporting Portal Analyze by Order Emailing Targets Excel Mobile, secure Plant Model Connectivity
Manufacturing Information System Role based specific information Web access and mobile clients Business integration Performance One common production model Production Energy Maintenance Available production data Trusted data storage One common network
Integration more than just connectivity! Role based specific information Web access and mobile clients Business integration Performance Production Energy Maintenance Available production data Trusted data storage One common network
FactoryTalk VantagePoint EMI Building a Reporting and Analytics System Connect to Data Build Logical Model Visualize Data Connect to Data Sources Seamlessly integrate to Rockwell Automation devices Connect to 3 rd Party Sources via OPC / OPC-HAD External Database Connectivity (SQL / Oracle) Build a Logical Model Organize information so anyone can understand Combines multiple data sources into a logical unit References data directly from its source Visualize & Analyze Data Creating reporting content to meet customer needs Leverage a variety of reporting options including Excel, Advanced Trending tools and SSRS View information in your favorite web browser including mobile device support
Let s start with Data Connection Options Connect to Data Build Logical Model Visualize Data Define a Physical model Identify what data is available Some data may need to be aggregated in a controller or historized for post analysis Connect to the Data Sources Seamlessly integrate to Rockwell Automation devices through FactoryTalk Services Connect to 3 rd Party Historians Connect to 3 rd Party Data Sources via OPC-DA / OPC-HDA Connect to databases Data stays with the source Only accessed when data is needed PUBLIC INFORMATION
Building the Logical Model I ve connected to the data, now what? Common Equipment Connect to Data Build Logical Model My Plant Visualize Data Common Properties Same at other facilities
Building the Logical Model I ve connected to the data, now what? Connect to Data Build Logical Model Visualize Data Define organizational model to present to users Combines multiple data sources into a logical unit Typically includes organizational hierarchy References data directly from its source Present information in context that anyone can understand
Building a Logical Model What does it look like?
Why is a Model Important? Giving Data Context Example: Process information is stored by a historian Typically you can get the data out of a historian and into Excel The model allows you to combining process data with event data or alarm data or order data and increase the value of the data, by giving it context MES Energy Control Systems Historian OEE/Downtime PUBLIC INFORMATION 14
Why is a Model Important? Location Transparency Should you need to know that the temperature of Tank 1 comes from a BrandX Historian, located in Server Room 3 of plant Y? Should you care when you migrate a BrandX Historian to a FactoryTalk Historian? When you build your analysis on the model, you only need to correct the connection layer, NOT the Trends/Dashboards/Excel Reports, etc. PUBLIC INFORMATION FactoryTalk Historian Historian BrandX
Why is a Model Important? Elevating the Level of ALL data / Unified View Using BrandX Historian in Plant 1 makes it challenging to review it against the process in Plant 2 that has a BrandY Historian You cannot see information of one Historian vs. the other Ends up Apples-to-Oranges Unifying Historians into the Model allows you to do the analysis off of any data coming from either Historian Allowing you to see apples-to-apples comparison Historian BrandY Historian BrandX
Why is a Model Important? An Easy to Understand Model Individual Plant Areas May not use the same terms or same systems Using a model can be a way everyone is using the terms that make sense to them What was the tank temperature when I made product XYZ? Historian Tag Value BrandXHistorian.Server1.PLCA.area51. tank3453.t_z12.pv Product 1291992 was made from 22:12:10.012 UTC to 23:45:51.292
Why is a Model Important? Make the Model fit Your Needs Production Managers may want to see the logical layout of the plant that matches an S95 Model But Maintenance may want to see this in a way that groups ALL like machines together, they see the SAME data, but can navigate to the information differently One Version of the Truth
Why is a Model Important? Reusable Content Equipment definitions, calculations, asset properties, KPI s, tag/object names, etc. Re-use Engineering across the 1000 s of assets in a manufacturing business Makes standardization and copy/paste (inter/intra-plant) feasible Can set reusable content that works for an item in in the model Note how Summary Status and KPI Details show for the Capper and Labeler
Visualizing the data Create meaningful content, role specific Connect to Data Build Logical Model Visualize Data Determine what information you want to present to the users Add computation or analytics when data is required in a different form Build report content Leverage built in capability to configure reporting content Use pre-defined or Ad Hoc Trending or XY Plots Create Excel Reports leveraging built in capability Create dashboard or advanced reports leveraging reporting integration built into the model
21 Many Reporting Tools Available From Excel Through Enterprise Reports VantagePoint Portal VantagePoint Reporting Create a wide range of reports from dashboards to tabular reports using SQL access to the model VantagePoint Client Tools Excel, Trend / XY Plotter, and HTML Dashboard Builder SharePoint Portal Model-Based Report Elements Charts & Grids Status Indicators SharePoint Excel Services and Web Parts
22 VantagePoint Reporting (VPR) More Reporting Options to Convey your Information Power to create a wide range of enterprise reports from dashboards to tabular reports Reporting Services Query the model (UPM) using MS Reporting Services (SSRS) reports or other Business Intelligence tools Access a growing library of sample VPR reports for VantagePoint EMI Author and publish VPR reports to the VantagePoint EMI Portal
Excel - The Most Common Reporting Tool Shared Reports Save Valuable Time Create powerful Excel reports leveraging the VantagePoint EMI Excel Add-In Retrieve data from any connected data source (Live or Historical values) Calculate, analyze and format reports using Excel functionality Publish reports to the Portal for Excel or SharePoint Excel Services for viewing by anyone with access to a browser Retrieve Data From Any Source Calculate, Analyze and Format Publish to the VantagePoint Portal
24 Powerful Trend Tool Delivers Actionable Information Diagnose and analyze data from any connected data source Access to real-time and historical data Powerful trend functionality - Pan, zoom, stack and synchronize Publish and share trends with others through the portal
Dashboard Builder Powerful Easy to Read Dashboards Create powerful dashboards that provide real-time data and key manufacturing KPIs Dashboards provide dynamic information (periodic or on demand) Drill down capability to provide more detailed information Easy access to all dashboards via a browser Pre-configured dashboards available in Sample Reports
Agenda Part 1 1. Information Portal - From Vision to Deployment 2. Historian - Big Data handling in Production Part 2 1. Mobility KPI Dashboard and Reports for your tablet or smart phone 2. Business Integration ERP and SharePoint
Why Historian? You can t improve what you can t measure! Government Regulations in many industries REQUIRE data! Manufacturers are often asked for a birth certificate on their product Your process often is where you have big Energy spends Again, if you can t measure, you can t improve that spend! You want to RECORD your process data and review it back at any time! You may need to review historical process information WAY after product was made, so it can t be temporary! The answer is you need a Historian! You need to get slow and HIGH speed data Reliable, uninterruptable Getting data OUT must be easy You need to store it for LONG periods of time
Shortcomings of Traditional Historians Tedious configuration and setup Multiple definitions of Tags (Controller, OPC, HMI, Historian) Inconsistent data management techniques in a heterogeneous controller environment Historians are typically primarily used as a trending tool Data primarily used in trends and simple reports Only limited data interfaces are offered and often proprietary Missing context in the information model Missing manufacturing / business model Difficult to transform the data for financial gains Hybrid and discrete application support Blending of event and process data difficult Historians are typically not fully utilized Typical pricing models restrict how many tags are collected in a Historian Only limited analysis are used in most Historians Historians have either proprietary formats or slower open formats Some historians store data in inefficient open relational databases Others store data in proprietary formats Performance and fidelity Bandwidth management of existing network technologies Inadequate enterprise model for roll-ups, store and forward and segregation of data Data collection speeds limited to network performance event-based data typically requires backplane performance PUBLIC INFORMATION
Distributed Historian Strategy MANAGEMENT SUPERVISOR OPERATOR The Right Information, at the Right Time, with the Right Fidelity
Strategic Partnership Leadership in Automation and Information Solutions Solution Provider Automation and Controls Expertise Solution Platform Real-time Performance Management Software Products Technology Provider Data Historian and Context Experts Product Platform Market leaders joining together to provide winning solutions
31 Time Series vs. Relational Data Storage Time Series Database HISTORIAN Use to store process data over a period of time Pressure, temperature, etc. Stores events with value and timestamp Optimized data storage and archive capability to store only what s required Retrieve large some of data efficiently that may span weeks/months/years Plant wide Data Storage Solution SQL Relational Database Use to store process and production data as records and relationships: Products, recipes, units, machines, orders, order lines, batches, etc. Add Context To Time Series Data (UPM) Moving away from a flat data structure to an organizational structure Link time series data to assets Event Framing Store events like: Batches (full S88 model), shifts, material flow, alarm and events
The FactoryTalk Historian Vision Multi tiered Architecture With integration into Universal Production Model You don t need to know where the data physically resides system finds data on request Factory Talk Historian Enterprise Edition with multi site aggregation Plant Historian capability with and enterprise Analysis, High visibility Speed Calculation at and machine Consolidation level with local trending Data and data aggregation can be easily moved between the tiers and derived values can easily be configured where needed
33 Historian Key Components Data Collection Interfaces, FactoryTalk Historian Machine Edition Adv. Calculations Visualization Excel, Trend, Dashboards Data Access 3 rd Party Integration (ERP, MES, BI Tools, etc.)
Key Differentiators of FactoryTalk Historian Market Leading Historian Technology Optimized time series data storage and retrieval Advance Calculations & Data Access capabilities Quick to Deploy and Easy to Own Integrated with Logix and FactoryTalk Technology Auto Discovery & Configuration Low Total Cost of Ownership Rich Set of Clients FactoryTalk View Site Edition HMI trending integration with FactoryTalk Historian FactorytTalk VantagePoint EMI bundled with FactoryTalk Historian Site Edition Package Multi-tiered Architecture Based on same platform allowing seamless integration and common client access throughout the portfolio
Integration more than just connectivity! Role based specific information Performance Energy Historian Server Web access and mobile clients Situation Awareness Optimize and increase production with performance drift, base lines, KPI calculations Reporting Performance Solve quality problems / reduce waste Business integration Production Provide data for performance or energy management Root Cause Determination Detailed analyses to identify bottlenecks Increase plant costs - identify cost intensive processes or assets Maintenance Available production data Trusted data storage One common network
Integration more than just connectivity! Role based specific information Web access and mobile clients Business integration Performance Production Energy Maintenance Available production data Trusted data storage One common network
Agenda Part 1 1. Information Portal - From Vision to Deployment 2. Historian - Big Data handling in Production Part 2 1. Mobility KPI Dashboard and Reports for your tablet or smart phone 2. Business Integration ERP and SharePoint
39 Market Trends APPS: 2015 Mobile App Market $38B Sources: Morgan Stanley 2011, Gartner 2011, Forrester 2010, Pew 2011 OS DEVICES ACCESS APPS DEVICES: 2010 Shipments Tablets + Smartphones > PC 2015 shipments 1.1B Cell Phones, 300M tablets Industrial Networks: 2011: 53M Ethernet Nodes 2016: 260M Ethernet Nodes 38% CAGR
40 Why Mobile? Manufacturing CIOs reported that mobility was the 2 nd highest technology priority for their organizations between 12 and 15. #1 Benefit: Increase the productivity of their workforce The Connected Enterprise meets the Always Connected Customer
Where Are We Evolving To From: To: Tethered, centrally monitored systems, with many workers Non-wired, globally accessible systems, with fewer workers with increased production demands Subject: Do more with less
Mobile PUBLIC INFORMATION 42
Get your information! Everywhere and any time! Information to go Reports Trend Analysis KPI Dashboards
Information Delivered That is Most Relevant and Important to You
45 VantagePoint Mobile Providing Information When and Where You Need It Mobile Landing Page Content is adjusted based on screen real estate Support for all major mobile platforms (ios, Android, MS) Mobile Model Brower Mobile Favorites personalized, available on any device Ad Hoc dashboard or trend creation Mobile Content Excel Reports, SQL Server Reporting Services Reports Trend, XY Plot charts New Composer Drag and Drop Dashboard Creation Mobile Friendly Browser Experience
46 Composer Create Displays Quickly and Easily Create new displays on a Tablet or PC Device Drag and Drop Canvas for Display Creation Library of Widgets (Gauges, Indicators, Text) Save displays as favorites Sample Screen shots and video clip
48 FactoryTalk VantagePoint KPI Automatically Display & Share KPIs! A native Windows 8.1 application that visually shows off your FactoryTalk VantagePoint system in a simple but powerful way It uses KPIs (Key Performance Indicators) to focus your attention With your KPI s you can: Visually represent your data as a gauge, bar graph or indicator Collaborate by sending an e-mail with instructions and attaching a KPI Drill down to more specific detail Leverage Live Tiles to provide continuous updates by pinning a KPI on the Start page See a map view of your KPI s based on geographic location Available for download from the Microsoft Store
Eventing/Notification Receive Notifications for Increased Efficiencies An Event/Notification is comprised of a Trigger and Actions Triggers can be Any tags with a historical data provider* Time/Schedule Actions can be Generating one or more published reports Sending emails, also with attached reports Sending SMS to a mobile phone email address *Live data sources are not supported, use FT A&E!
50 Use Case: Get Notified When Events Occur Trigger emails based on historical data changes Multiple Emails Include information about trigger tag(s) any data source connected to FactoryTalk VantagePoint Embed Associated Event Data Use HTML formatting
51 Use Case: Attach Reports to Notifications Run Excel reports and attach as PDFs
52 Use Case: Attach Reports to Notifications Attach XY Plots and Trends as images
53 Use Case: Attach reports to Notifications Attach SSRS reports as PDFs
54 The End Result
Get your information! Everywhere and any time! Information to go Faster decisions based on real information No delays in case of unexpected events Always prepared for meetings and discussions Support of Performance, Quality, Sustainability and other improvement initiatives PUBLIC INFORMATION
Agenda Part 1 1. Information Portal - From Vision to Deployment 2. Historian - Big Data handling in Production Part 2 1. Mobility KPI Dashboard and Reports for your tablet or smart phone 2. Business Integration ERP and SharePoint
Empowering Stakeholders Driving Value throughout your organization Visibility into all aspects of global production Common KPIs to benchmark plants to drive performance improvement & productivity Lower Cost through network consolidation Integrated production environment with enterprise Supportable and maintainable solution Decrease shadow IT costs Control and visibility to all aspects of production environment Increase collaboration between departments Reduce and better control of costs (mfg, labor, maintenance, & inventory) VP Manufacturing IT Team (Plant & Corp) Plant Management Objective data and Decision Support to invest in & prioritize high ROI CAP X projects Measure results of CAP X projects Finance Controller Use MTTR to improve operations Top 10 report in real-time Foundation for TPM initiatives Maintenance Production & Quality reporting by shift Production & Process data in real-time Production and Line Supervisors Production Information Business Systems Track & reduce scrap thru early warning Selectively handle quarantine of finished goods thru multilevel genealogy access Prioritize & execute Lean / 6 Sigma projects Lean 6 Sigma & Quality
Integration in Microsoft-SharePoint Knowledge base Documents Collaboration Decision support Tasks & Projects Calendars Analyses Internet / Intranet Microsoft SharePoint Server Production Information Business Systems
Integration in Microsoft-SharePoint Visualization & Reports Dashboards Collaboration Advanced Analytics Microsoft SharePoint Server Production Information Business Systems
Integration in Microsoft-SharePoint VP Operations Lean/6 Sigma Plant Manager Quality Maintenance Production Sustainability Finance Microsoft SharePoint Server Production Information Business Systems
61 Collaborate on Manufacturing Information SharePoint Integration Leverage the power of SharePoint by integrating VantagePoint EMI reporting content as standard web part We believe that the value of manufacturing intelligence will only grow when software providers can integrate it with more traditional BI to provide enterprise-wide monitoring & analysis of manufacturing performance. Gartner
62 Highly Scalable Excel Reports SharePoint Integration Excel Services A faster way to create, format, and publish VantagePoint Excel reports. Users can publish VantagePoint Excel Reports to either the VantagePoint Portal or Excel Services Reports can be rendered in the VantagePoint Portal or the SharePoint Portal via Web Parts More scalable for higher volumes of Excel reports Requires SharePoint EE 2010 Increased scalability for Excel reports and updated web parts in one add-on
63 How to connect to a MES Sytem?
64 How to connect to an ERP System
65 Summary
Thank-you! PUBLIC INFORMATION Follow ROKAutomation on Facebook & Twitter. Connect with us on LinkedIn. www.rockwellautomation.com Rev 5058-CO900F