IN14 - FactoryTalk Metrics: Showing Value in 50 Minutes

Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED

PUBLIC INFORMATION

FactoryTalk® MetricsConfigured Performance Management in 50 minutes or less.


Agenda

What is FactoryTalk® Metrics?

Scope / Session Overview

First Pass – required steps – 10 minutes

What is ReportExpert?

Second Pass – optional steps – 10 minutes

Summary


What is FactoryTalk® Metrics?

A performance management solution that out of the box enables you to track and trace manufacturing operations now.

FactoryTalk® Metrics is machine centric – you do not pay for a tag count you pay for a work cell and configure as many tags as you need.

KPIs – OEE, Availability, Performance, Quality, MTBR, MTTR +

Supports Machine States Running, Faulted, Blocked, Starved, Changeovers etc.

Context-based support using an S95 plant model and user-defined context fields.

Event Tracking including energy, batch and mass balance.

Report Engine that supports weighted average roll up across the plant model, user-defined context and time dimensions like shift or hour.

Vantagepoint Enabled / Connector Link.


Scope

Show the work step by step.

First Pass Configuration Basic steps to meet requirements for FactoryTalk® Metrics

Cycle Time (in seconds), good part counter and a running bit.

Define two states Running and Down.

Report Overview

Second Pass Configuration Recommended steps that increases detail and delivers information to improve operations

now.

PartId – not just 10,000 parts but by type

12oz / Bottle / x13 / SAP Id / Complex Id – link to MES / MOM.

Detect Scrap – add a scrap part counter

Add Starved, Fault and Operator reason codes.

Report Overview


Session Overview

We have about 40 minutes

Simple worksheet of basic performance data / tags

Transform these data points into actionable information Part Counts by type – Good / Scrap / Total Parts

Define Machine states that measure your assets your way.

Comprehensive reporting that enables you to make changes right now. Decrease Down time and complete production in 5 days not 7.

A two pass scenario

First Pass Configuration – delivering key KPIs quickly.

Second Pass Configuration – delivering additional detail that will enable you to focus on key operation targets providing the root cause reasons for downtime.


First Pass – Required Steps

S95 Plant Model

This is quick, simple and industry standard.

Provides structure to the data and adds roll-up. Example: My Company (Enterprise) | My Site(Site / Location) | Production (Area) |

Line 1 (Line) | L11 Filler (Workcell). You can use this model to summarize your data (KPIs, downtime and others) at any S95 Level.

Key to organizing plant operations and provides a saleable link to enterprise software.

Software Schedule

Assign a basic schedule to store you data by shift to support time date reporting.

Metrics supports variable length shifts but we are not covering that feature in this lab.


First Pass Configuration

You need three tags.

Running Indication This should be a Boolean bit that is high (= 1) when running. Running means you are producing

parts.

Down State when the run bit is low (= 0) – configure on First Pass then delete on Second Pass.

Good Part Counter This should be an accumulated value that does not reverse or go negative but can reset

automatically.

Cycle Time In seconds how long does it take to make one part / pound / case – you pick the unit of measure.

Cycle time can be a tag, derived from a lookup or typed in.


Using the Configuration Console ….

Add the tags to support this configuration.


First Pass Configuration complete…

After less than 9 minutes and 3 tags.

Production Reporting

Good part counts

Detect downtime

Down time versus Fault Time?

OEE, Availability, Performance and Quality.

Dashboards including a white board with dynamic time

Lets take a look!

ReportExpert


What is ReportExpert?

ReportExpert is a Rockwell Automation® (RA) application that simplifies SQL Server Reporting Services (SSRS) to configured steps using templates and parameter sets.

Anyone can learn how to configure reports.

No SQL training required.

Not required to be a Database administrator

Configure report templates using easy to define parameter sets.

Configuration versus Programming

Create custom reports in seconds.

Demo


Do it …….

Load ReportExpert and view the following reports.

Water Fall

Production Overview

Whiteboard


Second Pass Tag List - **Optional**

Track parts by type

Track performance by operator or any other criteria

Add scrap part counter to measure waste / calculate Quality.

Detect Starved conditions / protect OEE while Starved.

Add Boolean faults – most common

Integrated event driven by an Operators input – Trigger / String

Tag List -


Using the Configuration Console …

Complete the Second Pass Configuration.

Add PartId

Add Operator

Add a scrap part counter

Add a fault event Drive Stop

Add Starved as a machine state.

Add an event that captures operator added comments.


After 10 minutes and 10 tags

Every thing we just showed is based on a configured application

S95 Model

Plant Schedule Assignment (variable schedule support not covered

here)

Configuration shown with only the most basic tags – anyone with a run

bit, part counter and cycle time can deliver OEE now.

Configuration shown with additional tags that drive advanced topics.

Default Report Options using ReportExpert

VantagePoint Linked with connector that ships with the product.


Using ReportExpert …

Load ReportExpert

Waterfall

Production Overview

By Part

By shift, hour and rolled record

Rolled record is user-defined by workcell selection summarizing performance

data from every 5 minutes to once an hour.

White Board enhanced

Top Ten (user defined) Event Chart.


Summary Results -

Scalable performance management that grows with you

Self Service Reporting

Dashboards, whiteboards totaling 69 standard reports

Report packs available via samplecode.rockwellautomation.com

Operator Ranking

Production reporting with part counting by type including good/scrap/total parts.

Blocked and starved detection – machine states.

Root cause support.

Simultaneous events limited only by server resources.

All KPIs including OEE, Availability, Performance, Quality, MTBF and MTTR to name a few.

www.rockwellautomationteched.com

Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.

PUBLIC INFORMATION

Rockwell Automation TechED 2015 @ROKTechED #ROKTechED

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IN14 - FactoryTalk Metrics: Showing Value in 50 Minutes