line integration - turning plant floor data into ... · line integration - turning plant floor data...
Post on 05-Jun-2018
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LINE INTEGRATION -TURNING PLANT FLOOR DATA INTO ACTIONABLE INFORMATION
Alan Stanfill, MES Group Manger
Agenda
•Introductions
•Common Industry Challenges
•Organizational Data Perspectives
•Maintenance
•Operators
•Management
•Results Realized
•Wrap Up / Q&A
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Introductions
•Audience – How Many …
• End Users
• System Integrators
• Rockwell Automation
• Other
•Experience with
• RAPID
• PlantPAx
• FactoryTalk Historian SE
• FactoryTalk Metrics
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Common Industry Challenges
•Uncovering hidden potential within a manufacturing organization
•Removing emotion and opinion from the data
•Using automation and software to simplify and deliver timely information
•Providing actionable information to multiple levels of an organization
•Standardizing information gathered across machines, lines, and facilities
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Stone Manufacturing
• Contains two sites:
• Processing – creates bulk liquid material
• Packaging – creates finished goods
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RBackground
• Understands PLC and HMI Programming
• Measured on machine uptime
• Needs to improve machine uptime and MTBF / MTTR
Challenges
• Identify top 5 downtime reasons for a specific period of time
• Determine exactly when my downtime is happening and for how long
• Notification when my machine is down for longer than 2 minutes
• Accurately measure MTBF and MTTR
Solutions
• Verify there are control layer tags to provide automated downtime events
• High performance HMI Screens to allow operator interaction with pertinent data and reduce reaction time to critical/high priority alarms
• Smart alarming capability to catch first out alarms enabling personnel to quickly determine what initiated machine shutdown
• Automatically capture data needed to support challenges
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Notifications – Based on Rules and Alerts to Specific Personnel
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Background
• Understands how to operate the equipment
• Measured on throughput
• Initial eyes on Machine faults
Challenges
• Understanding production impact by the different products that are being run
• Visibility across multiple areas
• Comparing my shift production with other shifts
• Determining what the filler is doing
• Keeping the machine producing sellable product
Solutions
• Integrate PackML information into an HMI Screen to provide more visibility into the process
• Production – how is my shift producing vs another shift
• Utilize Rockwell Automation solutions for HMI, data acquisition and reporting, feedback of relevant KPIs back to the HMI display
• High Performance HMI to reduce reaction time to critical/high priority alarms
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PID
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Ability to View Packaging Information from Process Site – Rockwell’s RAPID Solution
Allows Navigation to Filler Detail (PackML Screen)
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Background
• Focused on increased capacity within the packaging area
• Charged with ensuring the proper systems are in place to improve plant performance
• Measured by production achieved
Challenges
• Needs support from maintenance and operations to improve production numbers
• Cultural adoption of new systems
• Maximize existing asset capacity
• Minimize retraining needs
• Encourage positive interaction between departments
Solutions to Solve Challenges
• Educate all levels of the organization to the importance of accurate information
• Ensure the newly automation system is providing actionable information
• Determine areas of improvement
• Revisit production numbers after changes in the process have been implemented
• Morning huddles with operators/maintenance to focus efforts on current action items
RESU
LTS
Client Testimonial – American Colloid Company
Focused resources on the correct areas 78% -> 94% Asset Availability Increase Increased MAC across the plant by 30% People cannot accurately estimate what is taking place in a
production environment Typically prior to implementation of automated data
collection – ~60% accuracy Automated solution - ~95% accuracy (time is 100% accurate) Data to support the issues allows proper focus instead of
solving what they think the problem is Having the correct data takes the emotion out of decisions
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