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www.plantconnect.net
An ISO 9001:2008 company
PlantConnect ® SFactory
Smart Factory Solution
PlantConnect®
SFactory
About AIPL
What is Smart
Manufacturing
Smart Manufacturing
LET US EXPLORE ‘HOW’& ‘WHY’ IN THIS PRESENTATION
What?
A manufacturing
system that is
optimised,
demand driven,
agile and
sustainable
Why?
Produce ‘more’
and ‘better’ with
‘less’
Business Drivers
Source : CII – ARC Survey on ‘Smart Manufacturing in India’, 2015
Business Drivers
Productivity
Quality
Compliance
Competitiveness
PROFITS
Downtime
Energy Consumption
Time to Market
Finished Goods Inventory
COSTS
Business drivers for manufacturing enterprises
Smart Manufacturing Landscape
Smart manufacturing landscape encompasses several entities –
Smart Factory, Supply Chain, OEMs, Smart Grid and many more
Presenting
PlantConnect ® SFactory
A Smart Factory solution
PlantConnect® SFactory
Smart Factory solution for discreet manufacturing facilities
Your tool to conquer the business drivers
Data acquired from machines, utilities
Easy to configure, deploy and use
Can be integrated with ERP and other systems
SFactory Deliverables
• PlantConnect DAM
acquires data from
machines, energy
meters, utilities etc. in
real time
• PlantConnect Server
on customer premises
/ cloud
• Data from each DAM
is sent to
PlantConnect server
over intranet / internet
• PlantConnect server
processes the
data…tops it up with
intelligence…and
presents it to different
types of users like
Supervisors,
Engineers, Managers,
Top Management
• Each user sees what
is relevant to him/her
Deployment
Functional Modules
Data Acquisition
Dashboards & Analytics – OEE, Machine utilization etc.
Asset Maintenance
Energy Monitoring
Reporting
SFactory Setup
Integration with enterprise systems
Data Acquisition
• Option I - Acquiring data from PLC
– PlantConnect Data Acquisition Module (DAM) collects data in real time
from machine PLC / Controller
• Option II – Acquiring data from sensors
– If machine does not have connectivity, required sensors are installed
– Minimum data acquired is 1 pulse for every production cycle. This is
available in all machines and can provide critical outputs of production
count, downtime etc.
• Energy data
– Energy data is collected from energy meters installed for each machine
or as suitable
• Other utilities
– Data of other utilities like Chiller, Compressor etc. is also acquired
Dashboards
• Tree view of devices with current device status
• System level and device level dashboards
• Standard / custom widgets
• Widgets displayed based on user role
• Drill down to individual devices from the dashboard
SFactory System Dashboard
• System Dashboard shows performance at a glance for current day /
shift updated in real time.
• Two levels – Plant and Machine
• Only those machines accessible to user are included
• Plant level - data for entire plant
– OEE
– Energy Consumption
• Machine level, shows
– OEE
– Energy Consumption
– Product name
– Number of parts produced
– Machine status – running / idle / off
SFactory Machine Dashboard
• Machine dashboard is related to one machine
• It has a number of widgets depending on machine type
as well as role of logged in user
• Some widgets are
– OEE widget
– Standard cycle time Vs actual cycle time trend
– Downtime analysis by reason
– Machine utilization analysis
– Rejection analysis by reason
– Energy consumption
– Power factor trend
Condition Based Processing
Define conditions
• Based on multiple parameters
• Multiple conditions joined by AND / OR
• Attach periodicity / number of occurrences to the
condition
Examples -
(Pressure1 < 68 AND Valve1 = OFF )
If this occurs 5 times in 30 minutes, then set condition true
(Abs(Zone1Temp – Zone1SetTemp) >= Zone1TempTolerence OR
Abs(Zone2Temp – Zone2SetTemp) >= Zone2TempTolerence )
If this condition occurs and stays for 10 seconds, set condition true
This is a powerful module that can be used in different ways
Condition Based Processing
Condition ProcessingAttach condition to one of following
Condition
Based Alarms
Generates an alarm
when condition
occurs
Condition Based
Maintenance
Generates
maintenance workflow
State change
Records a state
change for device /
process when
condition occurs.
Used for accurate
analysis of
machine utilization
Execute logic
Executes custom logic
when condition
occurs. Used for
performance /
efficiency calculations,
control device etc.
Asset Maintenance
• Maintenance scheduling – condition based / running hours based / periodic
• Maintenance workflow
• Maintenance alerts
Asset Maintenance
• Maintenance Due Report
• Maintenance Logs
Maintenance Reports
• Define asset health conditions
• Raise alerts when the condition occurs
• Send SMS / Email for each alert
Energy Monitoring
• Monitor energy consumption at
different levels – from machine
to entire plant
• Establish correlation between
machine performance and
energy consumption
• Generate alerts if consumption
above benchmarks
• Real time power factor trend
• Energy monitoring reports
Reporting
Reports & Charts
Standard(Standard reports &
charts)
Custom(Custom reports &
charts developed for you)
Report Builder
(A powerful tool to create reports)
Reports accessible to users based on their role
Can be generated from any client machine in network
Reports are generated on user demand
Reports can be scheduled and distributed via email, printed, stored
SFactory Standard Reports
• Production report
• Machine utilization report
• Rejection analysis report
• Production cycle detail report
• Alarm summary report
• Energy consumption report
• Define custom reports using our Report Builder
Mobile App for Operators
• Get alarm alerts on mobile app
• SFactory makes it easy for operators to provide inputs
using a mobile app
• Various data entry forms
– Product change form
– Downtime reason form
– Rejection reason form
– Production remark form
• All these forms are available in browser client as well
Integration with Enterprise Systems
• Integration with ERP, CMMS, MES and other systems
• Standard integration using csv files which are exported
based on a defined schedule
• Custom integration with SQL database, web service etc.
is possible
SFactory Output
SFactory Use Cases
Use Cases: how you can get returns on investment
Know exact
downtime and idle
time of machines
and its reasons
Analyze reasons
|
Take Action
|
Reduce downtime
Rejection reason
analysis
Find root causes of
rejections and fix them
|
Improve quality
Get real time alerts
for Cycle Time
Variation beyond
tolerance
Take immediate
action on this critical
input
|
Stop further rejections
SFactory Output
SFactory Use Cases
You can think of many more such areas
Material
consumption
forecast
Helps in raw material
inventory management
Condition Based /
Predictive
Maintenance
Reduce cost by
|
50% compared to
Preventive maint.|
90% compared to
Reactive maint.
Real time OEE
(Overall Equipment
Effectiveness)
Know pulse of the
production
|
Take informed
decisions
SFactory Case Study 1 - Plastics
A plastics company in India
Production Monitoring
- 3 plants – total 40 injection moulding machines
- Plant / machine performance monitoring
- Machine overview widget
- Rejection widget
- Machine level OEE widget
- Condition based processing
- Conditions for machine status
- Rejected parts
- Machine maintenance conditions
- Reporting
- Production report
- Cycle time report
- Rejection report
- Machine utilization report
SFactory Case Study 2 - Energy
Power Plant Sub-Station
Energy Management
- Energy consumption
analysis
- Peak load management
- Circuit overload / trip
alerts
PlantConnect®
SFactory
What is Smart
Manufacturing
About AIPL
Ascent Intellimation Pvt. Ltd.
Ascent Intellimation Pvt. Ltd. or AIPL is a Pune
based boutique IT solutions company focused on
Industrial Automation
Thought leader in convergence of Industrial
Automation & Information Technology
Has provided solutions to several global customers
like Siemens, Thermo Fisher, Newport, Honeywell
etc.
Customers
Thank You!
Dr. Arvind Tilak, CEO
Mr. Anand Taparia, Manager – Business Dev.
Or call us at +91 20 6500 4608
Ascent Intellimation Pvt. Ltd.‘Dnyanamayi’, 1, Shreeniketan Society,
Kothrud, Pune 411038, India
www.plantconnect.net