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© 2010 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.
Manufacturing Operations Management (MOM)
ANZ Ops Manage 2013
Tim Sowell - VP , Invensys Fellow , Global
Grant Kelly - MES Solution Consultant, APAC
MES, Batch and Quality • Manufacturing operations (MES) • Performance and efficiency (OEE) • Batch planning, execution and tracking
Intelligence • Aggregate, contextualize, visualize • Dashboards, Key Performance Indicators
Production &
Performance
Production and Performance Offerings
Mobility • Mobile workflow and decision support
• Maintenance, production and compliance
Software Solutions that
Help Ensure Your
Success in Real-Time
Environment and Safety Excellence
Asset Excellence
Productivity Excellence
Control Excellence
Collaboration / Workflow • Business Process Management
• Standard Operating Processes
Enterprise Integration • Between plant applications • Between plant and business apps.
Additional
Initiatives… Additional
Initiatives… Additional
Initiatives… Lean
Manufacturing
Quality
Regulatory
Compliance
Product
Lifecycle
Real Time
Enterprise
Total
Productive
Maintenance
Additional
Initiatives…
Financial & Performance
Focused
ERP
Product Focused
CAD, CAM,
PLM
Compliance Focused
Docs, ISO,
EH&S
Supply Focused
Procurement
SCM
Asset Reliability Focused
EAM
Resource
Tracking
& Status
Performance
Analysis
Process
Management
Data
Collection
Acquisition
Quality
Management
Product
Tracking &
Genealogy
Customer
Focused
CRM
Labor
Management
Dispatching
Production
Units
Logistics
Focused
WMS, TMS
Control
PLC, DCS
Enterprise
Control
Systems
(ECS)
Events
Bar Code
&
RFID
Manual
Data
Collection Control
Systems
Databases
& Cubes
Events Events
Historians
Control
PLC, DCS
Supply Chain Connector / Wonderware Enterprise Integrator
Performance
Performance
Analysis
Quality
Quality
Management
Operations
Resource
Tracking
& Status
Process
Management
Data
Collection
Acquisition
Product
Tracking &
Genealogy
Labor
Management
Dispatching
Production
Units
Logistics
Focused
WMS, TMS
MOM Logical Architecture in Mining
Application Object Servers (AOS)
Plant / Production Model
Operational Embedded Procedures (Workflows)
Hist
MES
Supply Chain Infrastructure
AOS
Plant / Production Model
Operational Workflows
Tier 1
Hist
Operational Infrastructure
AOS
Plant / Production Model
Operational Workflows
Operational Infrastructure
Tier 1
Hist
Standards
• Plant Equipment
• Production Activities
System Platform Configuration/ Deployment
• One Names Space
• Logically One
• Physically Distributed
• Version Mgmt
Enterprise Service Bus
Messaging Infrastructure
Message Transformation
LIMS Delay Acctng Time Usage
Logistics Scheduling
Rail Status Board
Inventory Management
Mines Planning
Supply Chain Apps
Mine Port
Un
ifyin
g In
form
atio
n
Mo
de
l
Mo
de
l Driv
en
Op
era
tion
s
Com
po
site
UI F
ram
ew
ork
Single Namespace
Managed as Logically ONE
Supply Chain
Plant Equipment Model Context
Platform
AppEngine
Plant Equipment
Model
Historian Time Series Tier 1 (local) Tier 2 (SC)
Equipment Context
Time Series Process data
Time Series Calculations Data
Time Series Events/ Alarms
Existing Systems Tags
End User Standards
• From Equipment Standards
• From Calculation Standards
• Tags are assigned to
Equipment
• Equipment Time Series is
captured
Product comes with Standard
Objects
• Standard Objects
• Domain Objects
• Toolkits to Build Further
Flexibility in Standardization
• “Infrastructure” for Real-time Management of
Operational Data
• Unified Plant Model
• Common Name Space
• Software, Systems and Devices Connectivity,
Independent of Hardware
• Management & Extensibility
• Templates Driven with Extensiation and Derivation
capabilities (Objects, Scripts and Graphics)
• Common Configuration
• Engineering Reusability
• Change Propagation
Maintainable
Integration
Application
Standardization
Future
Changeability
Easier Deployment
Easier Installation
Easier Configuration
Easier Maintenance
Easier Management
Templatized Approach
Reduced TCO
Lower Risk
System Platform is the foundation for adapting standardization to your business
Alarms & Events
Inputs/Outputs
Logic/Scripting
Historical Information Security
Equipment Centric Objects
Text & Email Alerts
Asset Performance • Downtime • Productivity •Instrument Asset
Graphic Symbols/Faceplates
Predictive Maintenance
Operational Discipline • WorkFlow •Escalation •Signoffs
How Companies Develop Standards
Leading companies are building Toolsets:
• Exxarro
• Kumba Mining
• Nestle
• General Mills
• Arcellor Mittal
• China High Speed Rail
• EDF Power
S95 Standards can be modelled
Providing the Plant Model Context
Enterprise Site
Area
Sub-Area
Process Cell
ASSMANG Khumani
Iron Ore Mine (South Africa)
MOM Logical Architecture in Mining
Application Object Servers (AOS)
Plant / Production Model
Operational Embedded Procedures (Workflows)
Hist
MES
Supply Chain Infrastructure
AOS
Plant / Production Model
Operational Workflows
Tier 1
Hist
Operational Infrastructure
AOS
Plant / Production Model
Operational Workflows
Operational Infrastructure
Tier 1
Hist
Standards
• Plant Equipment
• Production Activities
System Platform Configuration/ Deployment
• One Names Space
• Logically One
• Physically Distributed
• Version Mgmt
Enterprise Service Bus
Messaging Infrastructure
Message Transformation
LIMS Delay Acctng Time Usage
Logistics Scheduling
Rail Status Board
Inventory Management
Mines Planning
Supply Chain Apps
Mine Port
Un
ifyin
g In
form
atio
n
Mo
de
l
Mo
de
l Driv
en
Op
era
tion
s
Com
po
site
UI F
ram
ew
ork
Single Namespace
Managed as Logically ONE
Supply Chain
Add Equipment Performance Context
Platform
AppEngine
Plant Equipment
Model
MESDB
Database Asset Utilization Capability Object
Raw Reason
Delay Context
Delay Time
I/O for Work Order
I/O for Production Counts
I/O for Machine State
Current Values
© Invensys 13 May 2013
Reduce Capital Expenditures by identifying the most productive assets for continued operation
Improve Asset Utilization by identifying production bottlenecks more quickly and increasing supplier accountability
Increase the Capacity of your existing assets by pinpointing the causes of unplanned downtime and improving operational efficiency
Leverage Best Practices by comparing line-to-line and plant-to-plant performance, including real-time OEE measures
Empower Operators by providing visibility to real-time asset performance KPIs that enable them to “take action”
Wonderware MES – Performance Value Proposition
Equipment Utilization
Ability to Detect and Capture Utilization Events Ability View Equipment Events Ability to Monitor and Record Equipment State Ability Automatically or Manually Assign Reason Codes
Equipment Performance
Ability to Calculate OEE for Equipment / Line Ability to Trigger Events and Display Ability to Analyze Event Frequency and Duration Ability to Assign What States Affect OEE Calculation
Production Progress
Provide a Clear Indication of Job or Production Order Progress to the Operator in Real Time
Ability to Calculate OEE Other Key Parameters Ability to Estimate Expected Completion Date and Time
Wonderware MES – Performance Features
Add Production Context
Platform
AppEngine
Plant Equipment
Model
I/O for Work Order I/O for Production
Counts
I/O for Consumption
Counts
Production Operations Capability Object
MESDB
Database
Inventory / Movement
Current Values
Asset Utilization Capability Object
Create WO
Raw Reason
Production / Consumption
Delay Context
Delay Time
I/O for Work Order
I/O for Production Counts
I/O for Machine State
Improves Manufacturing Agility by providing real-time production execution information and alerts to the right people, at the right time
Drives Consistent Production Execution through strict enforcement of electronic manufacturing procedures (process, operator, equipment & materials)
Captures Comprehensive Manufacturing Genealogy by collecting a complete production routing history (including assets), labor history and material usage history – improves compliance and governance
Improves Decision Support & Planning within the Supply Chain by providing real-time order, material (raw material & WIP), equipment and labor status
Wonderware MES - Operations Value Proposition
Product Definition
Ability to Define Raw, Semi-Finished or Finished Goods Attach Multiple BOM Definitions (versions) to a Product Attach Multiple Specifications (versions) to a Product Synchronize Products Definitions with External Systems
Bill of Material Definition
Multi-level BOM (n-tier) Define Multiple Substitutes per BOM Item Define Co-Products / By-Products Configure Specific Material Processing and Tracking
Business Rules per BOM Item (e.g. backflush, maintain inventory, must consume from previous step, etc.)
Product Definition
Wonderware MES – Operations Features
Production Management & WIP Execution
Full Production/Process Order Management Define and Execute Product Specific Production Routings Record and Track Production, Consumption and Labor WIP Status and Characteristics
Inventory Management
Configure Business Rules for Tracking Inventory (e.g. maintain composite lots, etc.)
Can track bulk, lot or serialized inventory items Ability to Transfer, Split, Combine, Receive, Ship and
Reclassify Inventory Items
Production Execution
Storage Management
Ability to Define Fixed or Mobile Inventory Locations Ability to Monitor the State of Inventory Locations Track the Movements and Location of Mobile Storage
Devices
Wonderware MES – Operations Features (cont.)
Equipment / Machine Setup
Common Equipment Setup Templates Enable Consistency in Equipment setup Ability to Capture a “Golden” Setup Ability to Enforce Steps and/or Procedures
Procedure Step Manager
Guide an Operator Through a Manual or Semi-Automatic Procedure at a Particular Manufacturing Operation
Configure Required “Step Actions” (e.g. consume material, acknowledge message, view document, etc.)
Equipment Operations
Production Event Tracking
Ability to Capture Production Events Including Counts, Weights, Scrap and Reason codes
Ability to Report and Drill Through History, Enabling Genealogy, Traceability
Wonderware MES - Operations Features (cont.)
Enable Plant Document & Work Instruction Definition
Define Electronic Folders with Associated Documents and Work Instructions (multiple versions)
Configure Document Viewers to Use for Specific Document Types
Manage Links to Other Documents
x x Work Instructions & Document Management
View Many Different Document Types (e.g. PDF, MS Documents, Web Page, etc.)
Link Work Instructions and Documents to Products, Production Orders, Operations, Work Centers or Procedural Steps
Work Instructions
Wonderware MES - Operations Features (cont.)
Process/Route
Item(s) Operation(s)
Attributes Attributes
Machines
Documents
Specifications
Machine Specs
BOM Consume
Certifications
Data Collection
Steps
BOM Consume
Certifications
Documents
Data Collection
Attribute(s)
Specifications
Machine Specs
BOM Specs
BOM Specs
All Master Data Elements are Bound to a
Process/Route
Wonderware MES - Operations Process Routing
© Invensys 13 May 2013
Improved Product Quality and Consistency
• By improving quality and consistency, you increase your ability to get it right the first time; enabling you to improve scheduling accuracy and meet the delivery needs of your customer
• Enhanced product quality builds brand equity and reinforces the overall value and standing of your business to customers
Decrease Costs Through Reduction of Waste
• Monitor processes in real-time to identify quality problems or excursions, allowing you to take corrective action sooner
• Employing statistical process control techniques, you can prevent defective products from leaving the facility, reducing the impact of repair and warranty issues
Wonderware Quality Value Proposition
Item and Item Class Definition Entity and Entity Class Definition Variable/Attribute Definition Specification Definition Import Specifications from External Source (ERP/PLM)
Wonderware Quality Features
Item and Item Class Definition Entity and Entity Class Definition Variable/Attribute Definition Specification Definition Import Specifications from External Source (ERP/PLM)
Specification Management
Item and Item Class Definition Entity and Entity Class Definition Variable/Attribute Definition Specification Definition Import Specifications from External Source (ERP/PLM)
Sample Plan Definition Sample Naming Scheme Sample Plan Frequency Definition Import Sample Plan from External Source (ERP/PLM)
Sample Plan Definition Mgt.
Item and Item Class Definition Entity and Entity Class Definition Variable/Attribute Definition Specification Definition Import Specifications from External Source (ERP/PLM)
Wonderware Quality Features (cont.)
View/Record Sample Details Sample Collection Notification Additional Sample Request Generation Automatic Sample Collection
Sample Plan Execution Mgt.
Item and Item Class Definition Entity and Entity Class Definition Variable/Attribute Definition Specification Definition Import Specifications from External Source (ERP/PLM)
Standard Run Rule Selection SPC Charts – Xbar Range and Sigma, Moving Average, X
Individual, p/np/c/u/DPMO Run Rule Violation Trigger Additional Operator Data Collection (e.g. Comments)
Statistical Process Control
Case Study: Esperance Port MES
Existing System: • InTouch SCADA and a
custom built Access Data
Base to capture production
data
• Considerable manual
entries were needed with
room for errors
• Hard to maintain and
unreliable
Requirements for New System: • Remove customization adding a robust and
reliable commercial solution
• Address limitations by having a fully
scalable solution able to expand
• Compliment its existing SCADA investment
and enhance operator access
• Optimize production throughput and reduce
Down Time
• Product tracking and access to product
stages when loading or in storage
• Generate plant wide production reports
accessible to all users
“Management was pressed to increase efficiency, visibility of data, expand operator effectiveness and monitor accurately load throughput through the port and in to ships.”
Case Study: Esperance Port MES
Solution • InTouch Upgraded and Extended with ArchestrA System
Platform and Wonderware MES
• Sustainable Solution based on Products that can upgrade
• Central access to information via Information Server
accessible real time reports
Operational Benefits • Product base – removing performance and maintainability
risk
• Using a centralised and scalable repository, one Operator
interface
• Distributed and compliments existing WW and IIS
infrastructure
• Up to the minute Reports. From Wagon to Ship
• Report downtime and performance KPI’s, OEE
• Rapid expansion to add in existing equipment
• Potential to expand with workflow / ERP integration etc
• After 3 months in use the ROI indicates 3-6 months.
MOM Logical Architecture in Mining
Application Object Servers (AOS)
Plant / Production Model
Operational Embedded Procedures (Workflows)
Hist
MES
Supply Chain Infrastructure
AOS
Plant / Production Model
Operational Workflows
Tier 1
Hist
Operational Infrastructure
AOS
Plant / Production Model
Operational Workflows
Operational Infrastructure
Tier 1
Hist
Standards
• Plant Equipment
• Production Activities
System Platform Configuration/ Deployment
• One Names Space
• Logically One
• Physically Distributed
• Version Mgmt
Enterprise Service Bus
Messaging Infrastructure
Message Transformation
LIMS Delay Acctng Time Usage
Logistics Scheduling
Rail Status Board
Inventory Management
Mines Planning
Supply Chain Apps
Mine Port
Un
ifyin
g In
form
atio
n
Mo
de
l
Mo
de
l Driv
en
Op
era
tion
s
Com
po
site
UI F
ram
ew
ork
Single Namespace
Managed as Logically ONE
Supply Chain
Production & Performance
Context
Add Operational Procedure Workflows
Platform
AppEngine
Plant Equipment Model
Escalation - of events and conditions to required people
Enforce - SOP’s, enable collaboration, lean/six sigma, dynamic change mgt
Real time - end-to-end institutionalization of Operational Processes Management
Knowledge management - through standard responses to normal & unscheduled events
Historian Time Series
MES DBase Transactional
ArchestrA Workflow Extending System Platform with transactional Capability
Business Value
• Enable Operational Improvements
• Improve Procedural Quality, Consistency
• Adhere to and enforce Regulatory Compliance
Key Capabilities
• Native extension to ArchestrA
• Ability to handle human interaction
• Digitally capture, institutionalize Best Practices
• Preconfigured Workflows
• Business to Mfg. Connectivity (human
centered)
• Sustainable Interoperability
Empower Expert Operators & Workers to perform the right tasks at the right time using
procedural enforcement, documents, best practices
Model-Driven Operations Management Key Elements
Business Rule/Process Management
Composite solution business rules managed in an intuitive, visual workflow-modeling environment
Out-of-the-box configurable workflow activities for common MES, Quality, Labor, Maintenance, etc. transactions and tasks
Ability to add and manage custom workflow activities for our legacy applications
Ability to build libraries of templates of workflow activities and tasks adapted to your respective business segments
Single Framework to Manage “Solution Business Rules” that Cross-Over Production Application and Organizational Boundaries
MOM Logical Architecture in Mining
Application Object Servers (AOS)
Plant / Production Model
Operational Embedded Procedures (Workflows)
Hist
MES
Supply Chain Infrastructure
AOS
Plant / Production Model
Operational Workflows
Tier 1
Hist
Operational Infrastructure
AOS
Plant / Production Model
Operational Workflows
Operational Infrastructure
Tier 1
Hist
Standards
• Plant Equipment
• Production Activities
System Platform Configuration/ Deployment
• One Names Space
• Logically One
• Physically Distributed
• Version Mgmt
Enterprise Service Bus
Messaging Infrastructure
Message Transformation
LIMS Delay Acctng Time Usage
Logistics Scheduling
Rail Status Board
Inventory Management
Mines Planning
Supply Chain Apps
Mine Port
Un
ifyin
g In
form
atio
n
Mo
de
l
Mo
de
l Driv
en
Op
era
tion
s
Com
po
site
UI F
ram
ew
ork
Single Namespace
Managed as Logically ONE
Supply Chain
Model-Driven Operations Management User Interface Elements
UI Management
Model simple or complex forms to collect or visualize data in support of composite business rules/processes
Out-of-the-box forms for standard MES, Quality, Labor, Maintenance, etc. functions
Support composite application development (e.g. forms can host data from multiple data sources, etc.)
Forms accessible via many channels (e.g. web client, mobile client – multi platform, ArchestrA graphics, etc.)
Single Framework to Manage “Solution User Interfaces” that Cross Over Production Application Boundaries
Standard form provided
with MES for configuring
Line Classes
Form supports
displaying data from
multiple data sources
(e.g. MES and Galaxy)
Form is extensible
within Forms
Designer
Form button is
linked to workflow
Model Driven Configuration and UI 2013 Release
Visibility/ Reporting / Analysis Presentation
Operations
SQL Server Databases
OLE DB Sources
Other Historians
& OPC-HDA
WW Historian
Real-Time Galaxy
Galaxy Plant Model
Oracle Databases
Reports, Dashboards,
etc.
Analytics
Dashboards Reports Process
Displays
Analytics OverView Mobile
Information Model
Presentation Model
Content
Meta-data
Intelligence
Dimensional
Data Store
Pass Thru Model
Runtime Metrics
Data Source Mappings
Types
Relationships
Rules
• Enables Performance Improvements
– Visibility of Operational metrics provide visibility of improvement potentials in efficiency and cost across responsibilities
– Near real-time monitoring enable corrective actions to running production to minimize losses and cost impact
• Optimize Profit
– Take decisions which provide the best use of capacity and/or lowest cost of delivery
• Improve Collaboration and Leverage Employee Expertise
– Self service access to drill down dashboards and analyses tools enable process improvements
Real-time Operations Metrics Drive Higher Performance
MOM Logical Architecture in Mining
Application Object Servers (AOS)
Plant / Production Model
Operational Embedded Procedures (Workflows)
Hist
MES
Supply Chain Infrastructure
AOS
Plant / Production Model
Operational Workflows
Tier 1
Hist
Operational Infrastructure
AOS
Plant / Production Model
Operational Workflows
Operational Infrastructure
Tier 1
Hist
Standards
• Plant Equipment
• Production Activities
System Platform Configuration/ Deployment
• One Names Space
• Logically One
• Physically Distributed
• Version Mgmt
Enterprise Service Bus
Messaging Infrastructure
Message Transformation
LIMS Delay Acctng Time Usage
Logistics Scheduling
Rail Status Board
Inventory Management
Mines Planning
Supply Chain Apps
Mine Port
Un
ifyin
g In
form
atio
n
Mo
de
l
Mo
de
l Driv
en
Op
era
tion
s
Com
po
site
UI F
ram
ew
ork
Single Namespace
Managed as Logically ONE
Supply Chain
© Invensys 13 May 2013
Reduces Integration Cost
• Reduces the cost of ownership for integrating Wonderware software to enterprise systems, supporting industry standards such as ISA-95 and B2MML
Increases Inter-Operability
• Enables existing business and manufacturing systems to work in a complementary fashion that is loosely coupled, yet extremely reliable
Enables Business Continuity
• Enables WW MES application to run disconnected from ERP, with the ability to re-synchronize transactions after ERP has come back online
Wonderware Enterprise Integrator Value Proposition
Wonderware Enterprise Integrator
Key Capabilities
Facilitates exchange of information between systems
Maintains message history for fast recovery
Provides store & forward capability to support disconnected operations
Receives & delivers messages to multiple shop floor applications
Provides advanced message management & administration capability
Wonderware MES/MOM Software
• Operations, Performance, Quality management
– Reduces project scopes, risks, shorter time to value
– Enables step by step functional implementations
• Model Driven Operations
– Embedded Operational Practices
– Enable Consistency of action/ procedure
• Highly sustainable standard software
– Fast adoption of individual customer requirements
– Flexible, consistent enhancements in scope and size
• ArchestrA System Platform Integration
– Leverages investments in System Platform and HMI
– Superior shop floor integration and connectivity
– Standardization and reusability
– Wonderware Applications real-time integration layer
Wonderware
MES Software
Performance
Operations
Quality
Mod
el
Driv
en
(W
orkfl
ow
)
Com
po
sit
e
Presen
tati
on
Model-Driven Operations Management
Value Proposition:
Process Governance
Knowledge Management
Process Agility
Dynamic Change Mgt.
Process Responsiveness
Rapid Innovation
Continuous Improvement
People & System-Centric Collaboration
Real-time Decision-Support
Transforming Software into “Process-Oriented” Applications
SCADA/HMI
Scalable / Adaptive Object Architecture
Asset
Condition
Mgmt
Operation/Log
Book
Task Mgmt
Simulation Alarming
History
Equipment
Object
(Service)
Hist
Mill
Loc
Template Library
ArchestrA Service Bus (iSOA)
Physically Distributed can grow as you need
Application Abstracted from Physical
Mill 1 Mill 2 Mill 3 Mill 4 Mill 5 Diesel Power MES
DBases
Mining Library
• Lonmin
• Exxaro