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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MaintenanceDelivering Appropriate Intelligence

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• 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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Top Downtime Reasons – By Asset

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Event Details

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Notifications – Based on Rules and Alerts to Specific Personnel

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MTBF and MTTR

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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

Process Area – HMI Display Allows Navigation to Packaging Area

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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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Filler HMI Screen Showing PackML State

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Production of Different Products

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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

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Site to Site Comparison

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Shift to Shift Comparison

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Mobile Dashboards – Larger Screen

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Mobile Dashboards – Phone Screen

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

QUESTIONS?