wonderware performance software dawid sadie wonderware sa

Wonderware Performance Software

Dawid SadieWonderware SA

Agenda

IntroductionIntroductionIntroductionIntroduction

Building the FoundationBuilding the FoundationBuilding the FoundationBuilding the Foundation

Wonderware SolutionWonderware SolutionWonderware SolutionWonderware Solution

ConsiderationsConsiderationsConsiderationsConsiderations

SummarySummarySummarySummary

Introduction

Why should I be interested In performance management? My machines run just fine …

Is the capex for the new lineapproved yet? We struggle toget orders out the door.

The machine is producing at maximum – there is nothing more I can do … exceptif I could find a reliable replacement forPart-X …

Why does Line A always produce lessscrap than Line B? The operator ensuredme the setup is identical …

When will order X beComplete?

Agenda






Building the Foundation for Repeatable Process Improvement

1. Determining operational goals and requirements

2. Specifying business metrics and key performance indicators

3. Measuring, visualising, analysing and acting upon information

Determining Operational Goals and Requirements

► First step in improving ANY production process is to understand the Business Drivers

► Improving Productivity and Asset Utilisation▪ Reduce capital expenditures▪ Get the most from your existing equipment▪ Get more from less lower budgets, fewer personnel

► Increase Efficiency to preserve (and even increase) bottom-line▪ Can’t make more Capacity limited▪ Can’t increase prices Price limited

► So … Make it right the first time !!!

Specifying Business Metrics and Key Performance Indicators (KPI’s)

► Several KPI’s can provide substantial insight into improving operational results -

► Overall Equipment Effectiveness (OEE)▪ Includes Availability, Performance and Quality

► Equipment Uptime▪ Time running compared to scheduled time

► Others, including TEEP, TAKT, MBTF► Key is having a consistent way to

measure, visualise, analyse and act upon these metrics

Overall Equipment Effectiveness

OEE = Availability * Performance * Quality

Example: (.77)*(.65)*(.98)*100% = 49% OEE

Availability =Net Operating Time

Running Time * 100%

Performance =Target Output

Actual Output * 100

Quality =Actual Output

Good Output * 100

(Key Efficiency Metric)(Key Efficiency Metric)

OEE Analysis is a Key Tool for Improving the Bottom Line► OEE – The percentage of time that equipment is

actually producing quality goods ► Improving OEE will directly lead in increased

production, and can significantly impact the bottom line, especially in these cases - ▪ High speed - (CPG, bulk products, electronic parts)▪ High value - (automotive, aerospace, electronics

finished goods)▪ High capacity - (oil and gas, water and wastewater,

mining & metals)► Most companies have far lower baseline OEE

than accepted industry-standard► Improving OEE by even a small incremental

amount can result in Big Bottom Line Impact

Impact on Financials

Scheduled Hours (SH) 7680 hoursUnits Produced (UP) 1 MillionUnit Price 100 RandsAverage Asset Value (AV) 90 Million

Detail Debit Credit OEE 0.60Net Sales 100.00 Million Availability 0.65

Speed 0.97Direct Costs Quality 0.95Direct Materials 25.00 Direct Labour 24.00 OEE SH

Theoretical Runtime (TR) 0.60 x 7680 4600 hoursFactory OverheadDepreciation 2.50 UPUtilities 3.40 Ideal Speed Rate 1000000 217 units/hour

Insurance 1.50 SH OEEProperty Tax 2.80 7680 x 0.60Indirect Labour 3.90 Factory Supplied 2.10 UP / SHOther 1.80 Actual Rate 1000000 / 7680 130.2 units/hourTotal 18.00

EBIT / AV

Operating Expenses ROA 9.00 / 90 10.00 %Selling Expenses 16.00 Administration Expenses 8.00

Operating Income (EBIT) 9.00 Million

Scheduled Hours (SH) 7680 hoursUnits Produced (UP) 1.1 MillionUnit Price 100 RandsAverage Asset Value (AV) 90 Million

Detail Debit Credit OEE 0.66Net Sales 110.00 Million Availability 0.72

Speed 0.97Direct Costs Quality 0.95Direct Materials 27.50 Direct Labour 26.40 OEE SH

Theoretical Runtime (TR) 0.66 x 7680 5060 hoursFactory OverheadDepreciation 2.50 UPUtilities 3.40 Ideal Speed Rate 1100000 217 units/hour

Insurance 1.50 SH OEEProperty Tax 2.80 7680 x 0.66Indirect Labour 3.90 Factory Supplied 2.10 UP / SHOther 1.80 Actual Rate 1100000 / 7680 143.2 units/hourTotal 18.00

EBIT / AV

Operating Expenses ROA 12.50 / 90 13.89 %Selling Expenses 17.60 Administration Expenses 8.00

Operating Income (EBIT) 12.50 Million

OEE Impact on Financial Results

ROA directly effects the ROE (Return on Equity) which inturn effects the share price.

► Improving OEE by even a small incremental amount can result in Big Bottom Line Impact

► 10% increase in OEE results in 38% increase in Operating Income

Producing more product

Production Cost (direct)

Increase availability

► Improving OEE by even a small incremental amount can result in Big Bottom Line Impact

► 10% increase in OEE results in 38% increase in Operating Income

Measuring, Visualising, Analysing and Acting upon Information► KPI’s and Business Metrics can be useful for

improving a process, but only if they can be –► Measured and Recorded

▪ Needs to be consistent and repeatable▪ Must take advantage of automatic data capturing

rather than manual entry► Delivered in easy-to-understand visual format

to all relevant personnel▪ Plant dashboards targeted to specific groups of users▪ Easily configurable and customisable

► Analysed in real-time▪ Before bad products are made or production goals are

missed► Made actionable

▪ Allow users to drill down for more detail and to determine root cause

Agenda


BuildingBuilding the Foundationthe FoundationBuildingBuilding the Foundationthe Foundation




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AssetManagement

LIM Systems

Devices

ERP(SAP, Oracle, Microsoft..)

Wonderware MES & EMI Software Solutions Built on Strong Platform

Information / Visibility

SystemInteroperability

Real-Time Manufacturing Operations Management

Microsoft Technology & Industry Standards

System Platform

Clients

EnterpriseIntegration

Wonderware MES & EMISoftware Solutions

Operations PerformanceQualityBatch

Asset Monitoring

Industry Applications

&IndustryPacks

Food &Beverage

Adopting a Flexible Approach to Improving Your Manufacturing Operations

Enable an incremental, low-risk deployment of increased application functionality, one step at a time.

Enable an incremental, low-risk deployment of increased application functionality, one step at a time.

Get to the Bottom of your Unplanned Downtime Issues

Wonderware Performance Software v3.5► Leverages existing automation system

▪ Provide more accurate, reliable & granular downtime data than manual systems

► Highly flexible capture of downtime events with Unlimited downtime reasons per piece of equipment

► Enhanced operator involvement with highly configurable .NET based Operator interface

► Information delivery via standardised and pre-configured reports and KPI-displays

Reduce Costs with Equipment Efficiency TrackingWonderware Performance Software v3.5► Real-time Overall Equipment

Effectiveness (OEE) Monitoring▪ Monitor equipment, line or plant OEE▪ Compare machine to machine, line to line,

plant to plant▪ Leverages existing automation system for

accurate and timely OEE data

► Unlimited number of OEE calculations

► Include real-time OEE on Operator HMI screens and web-based plant information portals

Wonderware Performance Software

Monitors, analyses and reports on asset efficiency & equipment

downtime - resulting in improved productivity and asset utilisation.

Monitors, analyses and reports on asset efficiency & equipment

downtime - resulting in improved productivity and asset utilisation.

Capabilities

Equipment Utilisation• Real-time Tracking/Display/Analysis of

Unplanned Equipment Downtime

Equipment Utilisation

Equipment Efficiency

Reporting

What is Equipment Performance?

Drive Better Equipment Utilisation…through Operator Awareness

Customisable Operator Interface

► User definable utilisation states ► Define an unlimited number of

reason codes to establish the utilisation state

► Reason code triggered automatically from I/O or manually input by operator

► Define a target Utilisation & OEE for each asset

► Configure if utilization reasons affect OEE values

ReasonReason StateState

Powerful Utilisation ControlReal-time Visualisation & Input

Capabilities

Equipment Efficiency• Real-time Tracking/Display/Analysis of




Reporting




Higher Equipment Efficiencies with Operator Involvement

Capabilities



Reporting


Equipment Efficiency• Real-time Tracking/Display/Analysis of




Reporting• Real-time Web Reports or Paper Reports

“Zero Footprint” Web-Based Reporting

►Flexible Report Templates▪ OEE & Downtime▪ Production Event Summary

►Extensible▪ Easily create report

instances for specific users

►Wired for Analysis▪ Drill through by passing

parameters ▪ Determine root cause of

production problems

Web-Based ReportingDrill Down to Root Cause

What’s in Performance 3.5?

► Simplified Configuration▪ New Utilization Capability Object▪ New Performance Configuration Client

► Improved Visualisation▪ New ArchestrA Graphic Templates

• OEE, Downtime & Production Progress

▪ Improved Operator Interface• New Utilisation Grid .NET Control

► Enhanced Reporting▪ New Web based ArchestrA reports

► New Migration Utility▪ Easier upgrades

Object Based Configuration

► New Utilization Capability Object▪ Configure downtime events & OEE

calculations▪ Define production attributes for production

progress tracking▪ Associate with ArchestrA Graphic templates▪ Extend with custom scripts

► Benefits▪ Facilitates corporate standards ▪ Template approach promotes engineering

reuse▪ Faster configuration & reduced maintenance

New Performance Configuration Client► Helps configure:

▪ Users & Groups▪ Utilisation States,

Reason Groups & Reasons

▪ Shifts & Shift Schedules▪ General System

Parameters

► Helps simplify system configuration

New Performance Graphics Templates► OEE KPI Control

▪ Displays OEE value and/or the OEE components (Availability, Performance, Quality

► Count/Duration KPI Control▪ Displays the number & duration of events for the current entity

► Production Progress Control▪ Displays the current progress of production for the current shift

compared to a provided target

OEE KPI Control

► Shows OEE or OEE components▪ Dial or Bar chart

► Configure▪ All standard graphic properties are available

for setup.

Counts and Duration Control

► The control will display either counts or duration for Utilisation States, Reason Groups, or Reasons on the graph

► Filtered for the time period specified by the Filter properties for the current entity

Production Progress Control

► Used to display progress towards a production target for the current shift▪ The projected production is based on the current rate

of production for the current job running on the current machine

New .NET Control – Utilisation Grid

► Allows enhanced operator displays► Employs advanced filtering capabilities

► Time based• Last N events, this/last shift,

last N hours

► State based• Unacknowledged• Minimum Duration

► Status based• Utilization state

► Any combination of filters

Reporting

► New ArchestrA Utilisation Reports

Information at your fingertips

Web based or Paper Reports, You Web based or Paper Reports, You choosechoose

Efficiency Information for Decision Makers

Agenda






Considerations

► Wonderware Performance Software is the key to achieving consistency in equipment performance▪ Consistently measure and record▪ Single or multiple “lines”

► Modular solution for adding functionality▪ Grow towards Operational Excellence (start with

Performance)► Start small, get benefit, and grow bigger

▪ Eliminates the “big-bang” approach► Can integrate with your existing investment

… co-exist

Agenda






Summary

► Business Benefit – ▪ Reduce operational costs▪ Delay the need for investing in new equipment

► Business metrics and KPI’s▪ Required to track and measure performance▪ Measure (consistently) to improve

► Wonderware builds the foundation▪ Modular functionality▪ Re-usable, repeatable, consistency

► Making the “1st time right” approach not just a vision but a reality!

Wonderware Ease of Use

► Single development environment ▪ Wonderware Integrated Development

Environment (IDE)

► Single configuration object ▪ Utilization Capability Object

► Pre-built visualization graphics ▪ Downtime, OEE, Production Progress▪ ArchestrA graphic template

technology

► Pre-configured Web Reports▪ Out of the box value

Powering intelligent plant decisions in real time.

wonderware performance software dawid sadie wonderware sa

Documents

oee results

financialsimproving

business metrics

lower baseline oee

key performance indicators3

production goals

production process

line impact10