Upload
copa-data
View
310
Download
1
Tags:
Embed Size (px)
DESCRIPTION
Dynamic Production Reporting is what we call our approach to analyzing production data – as it happens. The reports generated reflect even the most recent events and production data. Now you can create comprehensive reports containing both process data and historical data, which was previously only available after significant time delays. This enables you to diagnose underperformance and immediately take corrective actions. Realtime production reports enable you to make immediate decisions on how to enhance your production efficiency and output. By dynamically optimizing production in this way you can achieve significant savings in costs and resources and match supply and demand far more closely.
Citation preview
dynamic production reporting
zenon Analyzer Use clever reports, identify hidden potential and advance your production.
Why wait to get the most out of your production
data? In times of volatile raw materials prices,
unpredictable demand and the cost pressure of
global markets it is essential that your production
facility is constantly finely tuned to produce as
efficiently and effectively as possible. Having
exact information on how well your equipment is
performing is essential to help you take the
right action.
Dynamic Production Reporting is what we call our
approach to analyzing production data – as it hap-
pens. The reports generated reflect even the most
recent events and production data.
Now you can create comprehensive reports con-
taining both process data and historical data, which
was previously only available after significant time
delays. This enables you to diagnose underperfor-
mance and immediately take corrective actions.
Realtime production reports enable you to make
immediate decisions on how to enhance your pro-
duction efficiency and output. By dynamically op-
timizing production in this way you can achieve
significant savings in costs and resources and match
supply and demand far more closely.
zenon Analyzer dynamicproductionreporting.
2
zenon OperatorEmbedded HMI System
zenon LogicIntegrated PLC System
zenon SupervisorIndependent SCADA System
zenon AnalyzerDynamic Production Reporting
productoverviewzenon Analyzer is the reporting tool that enables
Dynamic Production Reporting.
It is extremely easy to configure and install and
has the capability to process and analyze data from all
automated production equipment within your facility
and other sources of data (e.g. manual data input). So
you not only get immediate information, but also a
complete picture of the status of productivity within
your facility.
So you know exactly and immediately ...
... where you are losing money
...where you can increase output
... where you can save resources.
And much more.
3
zenon Analyzer processes data
both online – directly from
your equipment – and/or
offline from a central database.
This means you can combine
the advantages of both online
and offline reporting. Analyze
up-to-date production data
and do analyses of different
production time frames.
usingthesystemzenon Analyzer delivers ready-made report templates and allows new
reports to be created with an advanced graphic design. In addition the
system is multi-lingual – you can implement your language of choice.
Reports can be specified to reflect the needs of the individual produc-
tion team member. Operations and maintenance staff get operational
and maintenance data; management get management-relevant data,
and so on.
Advanced filtering functions allow you to analyze data inter-
actively according to multiple parameters, such as:
by equipment: area, line, machine etc.
by time: month, week, day, shift, hour, from/to
by production entities: article, batch, order
by length or numer: of e.g. breakdowns or alarms
by consumption of media
In all cases you can drill down and through to the details to get to
the bottom of specific events.
Powerful, flexible andeasytouse
Consumption analysis of
different media
Occurence Number per Alarm
Total Duration per Alarm (seconds)
Copa-Data (www.copadata.com)zenon Analyzer Page 1 of 3
Report generated by CD\Phillip.Werr at 19.09.2011 08:46:02
ALARM ANALYSIS ON FREQUENCY AND DURATION
10 ALARMS19.09.2011 07:46:02 - 19.09.2011 08:46:02Period Nr. of alarms
OEE Indicator
Availability Performance Quality Total Units Good Units
19,98% 69,58% 29,14% 98,56% 182512 179875
OEEAvailability
PerformanceQuality
COPA-DATA (www.copadata.com)zenon Analyzer Page 1 of 1
Report generated by COPA-DATA\DEMO at 13.05.2011 09:58:05
OEE Indicator
Filler11.05.2011 08:57 - 12.05.2011 09:57Period Equipment
Analysis on frequency
and duration of alarms
OEE Indicators to analyze
Overall Equipment Effectiveness
4
Alarm analysis on frequency and duration OEE Indicator
B 68 - 76
C 76 - 84
< 68 A
D 84 - 92
E 92 - 100
F 100 - 108
G> 108
1,00
69,08
More efficient
Less efficient
Current ClassEnergy Scale (kWh in 1 h)
Current Value (kWh in 1h):
Time Duration [h]:
Copa-Data (www.copadata.com)zenon Analyzer Page 1 of 2
Report generated by COPA-DATA\EmilianA at 05.07.2011 09:27:56
ENERGY CLASS
1/4 h05.07.2011 08:27 - 05.07.2011 09:27Period Aggregation
Energy consumption per machine
Energy consumption per machine
Variable nameAbsolute
consumptionRelative
consumptionGlass Bottle Line#Bottle Washer 122.848 kWh 10.70 %
Glass Bottle Line#Crate Washer 114.978 kWh 10.01 %
Glass Bottle Line#Depalletizer 124.384 kWh 10.83 %
Glass Bottle Line#Filler 113.192 kWh 9.86 %
Glass Bottle Line#Inspector 101.364 kWh 8.83 %
Glass Bottle Line#Labeller 98.822 kWh 8.60 %
Glass Bottle Line#Packer 81.508 kWh 7.10 %
Glass Bottle Line#Pallet Conveyor 70.705 kWh 6.16 %
Glass Bottle Line#Palletizer 93.150 kWh 8.11 %
Glass Bottle Line#Pasteurizer 123.104 kWh 10.72 %
Glass Bottle Line#Unpacker 104.496 kWh 9.10 %
Energy
10/16/2013 4:56:00 PMFrom
Equipment model
To
10/17/2013 4:56:00 PM
Variables
Glass Bottle Line#Bottle Washer, Glass Bottle Line#Crate Washer, Glass Bottle Line#Depalletizer, Glass Bottle Line#Filler, Glass Bottle Line#Inspector, Glass Bottle Line#Labeller, Glass Bottle Line#Packer, Glass Bottle Line#Pallet Conveyor, Glass Bottle Line#Palletizer, Glass Bottle Line#Pasteurizer, Glass Bottle Line#Unpacker
zenon Analyzer | www.copadata.com Page 1 / 1
Your production line is producing a large batch, but how efficient are you compared to your benchmarks?
With zenon Analyzer you can find out while production is still running and take corrective measures where necessary.
“ “
5
Media Absolute Consumption Unit PercentBottle Washer: Additive 0,78 kg 18,75%Bottle Washer: Conditioner 0,52 kg 12,50%Bottle Washer: Disinfectant 0,26 kg 6,25%Bottle Washer: Lye 2,60 kg 62,50%
TOTAL 4,16 kg 100,00%
COPA-DATA (www.copadata.com)zenon Analyzer Page 1 of 1
Report generated by COPA-DATA\DEMO at 13.05.2011 10:03:23
13.05.2011 09:02 - 13.05.2011 10:02
Media Bottle Washer: Additive, Bottle Washer: Conditioner, Bottle Washer: Disinfectant, Bottle Washer: Lye
PeriodChemicalsMedia Group
Absolute consumption distribution per media
The Reports informationinaconcise andunderstandableform
With zenon Analyzer you have complete data
transparency across your entire production.
This wealth of production data and meta data
(e.g. shifts, alarms, prices) is made accessible and
understandable by the concise reports that the
system generates.
typicalexamplesofthereportsare Production reports, which aggregate different
kinds of information (efficiency, consumption,
alarms, etc.) per batch, article, or time filters, e.g.
per shift
Consumption optimization reports showing con-
sumption evolution, cost distribution and correla-
tion with the production, for media such as water,
energy, compressed air, chemicals etc.
Reports for Energy Data Management. zenon
complies with the prerequisites of the TÜV SÜD
Standard “Efficient Energy Data Management” and
meets therefore the requirements of chapter 5.6.1
Monitoring, measurement and analysis of the ISO
50001 standard.
Efficiency reports that calculate KPIs such as
OEE (Overall Equipment Effectiveness) over a se-
lected period of time and production equipment
Alarm breakdown Analysis
and much more...6
zenon Analyzer | www.copadata.com Page 1/1Report generated by CD\Phillip.Werr at 16.09.2011 09:51:01
26.01.2011 13:00 - 26.01.2011 16:00Period Bottle Filler, Bottle Orientor, Bottle Washer, BT1, BT2, BT3, BT4, BT5, BT6, Crate magazine, Crate Packer, Crate Unpacker, Crate-Inspector1, Crate-Inspector2, CT1, Depalletizer1 , Depalletizer2, Empty Bottle Inspector, Filled Crate Inspector, Input, Labeling Machine, Output, Palletizer, Sniffer, Sniffer Block, Unlabeling Machine, Unplausible
Machines
Gantt Chart Report
GANTT Chart processing data according
to Weihenstephan standards
reporttemplateszenon Analyzer provides ready-to-use templates. Alternatively, the report templates
can be custom-designed regarding content and graphical appearance. User-defined
algorithms can be implemented to allow company– specific KPIs to be generated – so
you get exactly the information you need. Both report generation and archiving can
be configured to be carried out automatically.
exportformatsReports can be exported in many formats, depending on how and where you wish to
present them or further process the data.
regulatorycomplianceThe reports also function as a digital protocol for traceability and future reference,
for example to prove compliance to legal requirements.
Your management wants complete KPI analyses for every shift? No Problem – zenon Analyzer can
create the reports automatically after each shift and send them to specified recipients.
“ “
7
zenon runtime 6.51 and higher
hmi or scada
3rd party hmi
directly from machines
(PLCs)
sql databases
opc ua
manual data input
otherdatabases
3rd party scada systems
zenon analyzer
dynamic production reporting
zenon runtime 5.50 and higher
hmi or scada
excel files
energy meters
access all kinds of historic and real-time data
zenon Analyzer is extremely easy to implement –
connecting to various data sources e.g. to zenon
HMI/SCADA systems or PLC Systems. It can be
integrated into any existing automation and IT
environment with no or only minor changes to
the infrastructure.
The system works with both centralized databases
such as Microsoft SQL, as well as decentrally, sourc-
ing data directly from the production equipment,
thus collecting online and offline data. In the latter
case, no additional database is needed. Manual data
input is also possible.
Both data structure and interfaces are well-
documented, enabling you to more easily integrate
your own customer-defined features. The latest en-
cryption technology ensures the highest level of
data security.
Getting started – settingupthesystem easy,fastandcostefficient
A wizard to import meta data into zenon Analyzer
is included. Meta data can also be automatically
updated through the wizard. Integrated connectors
collect the necessary data.
zenon Analyzer generates reports from many
different types of data e.g. Alarm, shift-related,
user-related, historical, real-time, batch. The ad-
vantage to you: a reduction in complexity, as only
one system needs to be installed rather than need-
ing multiple systems to acquire and convert these
different types of data.
zenon Analyzer has a web-based interface. This
means that no additional maintenance of clients is
needed and no revalidation of the existing environ-
ment is necessary. This is particularily helpful for
heavily regulated industries such as Food & Bever-
age or Pharmaceutical. The users have flexible ac-
cess to reports from any workplace in the network.
8
Struggling with volatile raw material prices? Why not include price information from external
sources into your production reports? Close the gap between production and business reporting!
“ “
Fast Facts
zenon Analyzer is a web-based tool for dynamic production report-
ing. It can operate completely independently or be fully integrated
into the zenon product family.
zenonanalyzer improves your production by increasing production effectiveness
supports monitoring, measurement and analysis of energy data
(like the ISO 50001 standard)
eliminates waste by optimizing energy and material consumption
enables up-to-date benchmarks with historical production data
supports quality control
supports daily activity of production teams with reports
focused on production entities (batch, articles, shifts, etc.)
supports “continuous improvement” processes
easeofuse easy-to-use reports
easy access to sophisticated production information
interactive reports with “drill through” capabilities
modern and clear report layouts
integrationandsetup unintrusive installation
easy integration of different data sources
convenient design and update of new reports etc.
built-in Microsoft SQL Server 2012
connectivityandintegration integration of offline and online data sources
high connectivity to many different kinds of
machines and hardware
easy integration of new equipment
direct connection to automation infrastructure
integration of meta-data from HMI/SCADA Systems
possibility of manual data input
zenon OperatorEmbedded HMI System
zenon LogicIntegrated PLC System
zenon SupervisorIndependent SCADA System
zenon AnalyzerDynamic Production Reporting
10
from sensor to erp I food & beverage
One consistent Product Family from Sensor to ERP.
zenon OperatorEmbedded HMI System
zenon LogicIntegrated PLC System
zenon AnalyzerDynamic Production Reporting
zenon SupervisorIndependent SCADA System
zenon OperatorEmbedded HMI System
zenon LogicIntegrated PLC System
zenon AnalyzerDynamic Production Reporting
zenon SupervisorIndependent SCADA System
zenon OperatorEmbedded HMI System
zenon LogicIntegrated PLC System
zenon AnalyzerDynamic Production Reporting
zenon SupervisorIndependent SCADA System
zenon OperatorEmbedded HMI System
zenon LogicIntegrated PLC System
zenon AnalyzerDynamic Production Reporting
zenon SupervisorIndependent SCADA System
Platform-independent Dynamic Production
Reporting tool, which processes and presents
data from the process to the ERP in real time.
Full visualization and control of complex
equipment with a connection to other systems
like SAP ERP.
Specialized simple and ergonomic machine
and equipment control.
zenon integrated PLC system with IEC 61131-3
programming environment.
Four products for creating top-of-the-line automati-
on solutions. All products work seamlessly together,
covering everything from sensors to ERP.
The entire Product Family is built around the
zenon philosophy of providing perfect ergonomics
through:
integrated, native networking
horizontal and vertical connectivity
hardware independence
automatic engineering
individualization of user interfaces
and interaction
setting parameters instead of programming
zenonissettingindustrystandardsinergonomics.
11
zenon has been used for over 25 years by many
companies worldwide and in various industries.
zenon is firmly positioned in automation, particu-
larly in the Automotive, Food & Beverage, Energy
and Pharmaceutical industries.
globalpresence-localsupportWith nine subsidiaries in Europe, North America
and Asia and an international network of around
15 distributors and over 100 partners, COPA-DATA
is active in more than 40 countries.
completeautomationsolutionsTogether with the competent partners of the
COPA-DATA Partner Community, COPA-DATA
offers tailor-made solutions for your complete
automation.
zenon
zenon shines with excellent performance and comfortable maintenance, even in a project
with over 6,000 process screens.“ “
partnersfromvariousindustries
© Copyright 2013, Ing. Punzenberger COPA-DATA GmbH. All rights re-served. This document may not be reproduced or photocopied in any form (electronically or mechanically) without a prior permission in writ-ing from Ing. Punzenberger COPA-DATA GmbH. The technical data con-tained herein have been provided solely for informational purposes and are not legally binding. Subject to change, technical or otherwise. Reg-istered trademarks zenon® and zenon Analyzer ® are both trademarks registered by Ing. Punzenberger COPA-DATA GmbH. All other brands or product names are trademarks or registered trademarks of the re-spective owner and have not been specifically earmarked. We thank our partners for their friendly support and the pictures they provided.
Publication number: CD-ZAF-13-10-02
COPA-DATA Headquarters
Ing. Punzenberger COPA-DATA GmbHKarolingerstraße 7B, 5020 SalzburgAustria
t +43 (0) 662 43 10 02-0f +43 (0) 662 43 10 02-33
Find your regional contact at: www.copadata.com/contact
dynamic process solutions
Even though we have generated more fills and could increase our turnover in the last year, we have
managed to achieve a large savings in individual consumption through our Energy Management
System with the support of zenon.
“ “
rudolfkropfhead of eet
adelholzener alpenquellen gmbh