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AP11: Loram: Stays on Track with Mobile  Data Collection and Reporting
AP11: Loram: Stays on Track with Mobile  Data Collection and Reporting
AP11: Loram: Stays on Track with Mobile  Data Collection and Reporting
AP11: Loram: Stays on Track with Mobile  Data Collection and Reporting
AP11: Loram: Stays on Track with Mobile  Data Collection and Reporting
AP11: Loram: Stays on Track with Mobile  Data Collection and Reporting
AP11: Loram: Stays on Track with Mobile  Data Collection and Reporting
AP11: Loram: Stays on Track with Mobile  Data Collection and Reporting
AP11: Loram: Stays on Track with Mobile  Data Collection and Reporting
AP11: Loram: Stays on Track with Mobile  Data Collection and Reporting
AP11: Loram: Stays on Track with Mobile  Data Collection and Reporting
AP11: Loram: Stays on Track with Mobile  Data Collection and Reporting
AP11: Loram: Stays on Track with Mobile  Data Collection and Reporting
AP11: Loram: Stays on Track with Mobile  Data Collection and Reporting
AP11: Loram: Stays on Track with Mobile  Data Collection and Reporting
AP11: Loram: Stays on Track with Mobile  Data Collection and Reporting
AP11: Loram: Stays on Track with Mobile  Data Collection and Reporting
AP11: Loram: Stays on Track with Mobile  Data Collection and Reporting
AP11: Loram: Stays on Track with Mobile  Data Collection and Reporting
AP11: Loram: Stays on Track with Mobile  Data Collection and Reporting
AP11: Loram: Stays on Track with Mobile  Data Collection and Reporting
AP11: Loram: Stays on Track with Mobile  Data Collection and Reporting
AP11: Loram: Stays on Track with Mobile  Data Collection and Reporting
AP11: Loram: Stays on Track with Mobile  Data Collection and Reporting
AP11: Loram: Stays on Track with Mobile  Data Collection and Reporting
AP11: Loram: Stays on Track with Mobile  Data Collection and Reporting
AP11: Loram: Stays on Track with Mobile  Data Collection and Reporting
AP11: Loram: Stays on Track with Mobile  Data Collection and Reporting
AP11: Loram: Stays on Track with Mobile  Data Collection and Reporting
AP11: Loram: Stays on Track with Mobile  Data Collection and Reporting
AP11: Loram: Stays on Track with Mobile  Data Collection and Reporting
AP11: Loram: Stays on Track with Mobile  Data Collection and Reporting
AP11: Loram: Stays on Track with Mobile  Data Collection and Reporting
AP11: Loram: Stays on Track with Mobile  Data Collection and Reporting
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AP11: Loram: Stays on Track with Mobile Data Collection and Reporting

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Loram, a leading supplier of train track maintenance machinery and services, needed to better track performance of mobile rail maintenance trains. Leveraging the FactoryTalk software suite, Loram …

Loram, a leading supplier of train track maintenance machinery and services, needed to better track performance of mobile rail maintenance trains. Leveraging the FactoryTalk software suite, Loram remotely collects critical performance data from each train for real-time troubleshooting, maintenance and electronic reporting. Each train is equipped with over 100,000 data inputs,
and Loram typically collects 2,100 data tags per report. Using Historian and the Rockwell Automation GPS Time Module, Loram also tracks North American trains through wireless connection, displayed on Google Maps. Loram is implementing this feature on all new rail grinder trains.

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  • 1. ®2014 Loram Maintenance of Way, All rights reserved Speed · Performance · Reliability Loram: Stays on Track with Mobile Data Collection and Reporting Eric Manninen Principal Engineer Electrical
  • 2. ®2014 Loram Maintenance of Way, All rights reserved Speed · Performance · Reliability 2. Machine Design System Layout 4. Rockwell Software Products Overview 5. FactoryTalk Solution Implementation 6. Loram’s VantagePoint Portal Demonstration 1. Loram Company Overview 3. Business Drivers for Information Enabled Solution Agenda Overview 7. Related RSTechEd Sessions and QNA?
  • 3. ®2014 Loram Maintenance of Way, All rights reserved Speed · Performance · Reliability Office Headquarters are located in Hamel, MN Employs over 850 people Builds Leased and OEM Machine Equipment Outstanding Safety Record Provides Railway Maintenance Services to Major Commercial Railroads and Passenger Rail Markets across North America and the World through: ► Rail Grinders ► RailVacs ► Ditchers ► RailTrains ► Track Lifters ► Track Undercutters ► Rail Inspection Vehicles ► Shoulder Ballast Cleaners Loram - Company Overview
  • 4. ®2014 Loram Maintenance of Way, All rights reserved Speed · Performance · Reliability For more information, visit us at: www.loram.com RailVac Light-Rail Grinder Shoulder Ballast Cleaner Rail Grinder Loram – Representative Machine Types
  • 5. ®2014 Loram Maintenance of Way, All rights reserved Speed · Performance · Reliability Loram Rail Grinder Video Demonstration
  • 6. ®2014 Loram Maintenance of Way, All rights reserved Speed · Performance · Reliability Physical Layout of typical Rail Grinder Machine ►Typical Length of 800 feet (244 m) ►43 Liter Diesel Engine Generator Set ►4920 KW Power Generated on Machine ►Power Bus draws up to 4000 Amps ►120 - 30 HP Grind Motors ►Travels up to 70 miles/hour (113 km/h) ►Operates at 20 miles/hour (32 km/h) ►10,300 Gallons of Diesel Fuel stored ►50,000 Gallons of Water stored on Machine for Fire Suppression System ►26,400 feet (8047 m) of total wire used
  • 7. ®2014 Loram Maintenance of Way, All rights reserved Speed · Performance · Reliability Controls Layout of typical machine: RG400 Series Rail Grinder ►5 ControlLogix 1756-L73 Processors located in the Control Car & 4 Grind Cars ►5 ControlLogix (1756) Distributed Input/Output 17-Slot Remote Racks ►4 Flex (1794) Distributed Input/Output Remote Racks in the Control & Support Cars
  • 8. ®2014 Loram Maintenance of Way, All rights reserved Speed · Performance · Reliability Rail Grinder Rockwell System Architecture Controller System 1,000,000 Controller Tags 145,000 HMI Tags 2,100 Data Historian Tags EtherNet/IP Network HMI Communication Data Collection ControlNet Network Distributed I/O PLC Messaging DeviceNet Network Motor Protection
  • 9. ®2014 Loram Maintenance of Way, All rights reserved Speed · Performance · Reliability Machine Operators – Crew is not technically trained with Automation skill-set – Troubleshooting information from crew is not reliably Accurate Mean Time to Repair – Diagnosis of component failure was a slow multiple day process – Failure analysis was not real-time capable Historical Data Logging – Legacy datalogs only stored locally on machine for 30 days – Datalogs must be manually removed and sent to engineering – Format is not easily readable, customizable, or searchable Machine Diagnostic Logs – Manual hand-written logs off Chart recorders, Metering, and Gauges – Predictive Maintenance was not able to be implemented Reliability Data and Remote Diagnostics are limited – Most downtime situations require a remote site visit by field service personnel Loram’s Business Challenges: Pre-Machine Historian implementation
  • 10. ®2014 Loram Maintenance of Way, All rights reserved Speed · Performance · Reliability Software Solution Needs Overview What we needed to add to the architecture Enterprise Data Historian Server Machine Historian Machine Historian Machine Historian Machine Historian Machine Historian Web Dashboard Reporting Interface for Diverse Clients Operations Field Service Controls Engineering
  • 11. ®2014 Loram Maintenance of Way, All rights reserved Speed · Performance · Reliability Engineering and Controls: Information System Requirements Engineering • Long-Term Corrective action planning for component failures – Diagnosis of historical component product life – Real-time failure analysis of current system • Key Performance Indicator Data – Electronic Historical Datalogs provide machine performance data remotely – Data that is easily accessible, sortable, and searchable in a variety of reports – A system that can handle multiple months worth of local storage before upload – Historical Trending verification of Machine Runtime Performance to Design Controls • Controller Tag Data Reporting – Electronic Historical Datalogs provide sequence of event data remotely – Data is easily accessible, sortable, and searchable in a variety of reports – Determination of root cause analysis of complex machine control faults – Diagnostics reports determine operator, code, or machine component issues
  • 12. ®2014 Loram Maintenance of Way, All rights reserved Speed · Performance · Reliability Operations and Field Service: Information System Requirements Operations • Collection of Reliability Data and Remote Monitoring – Electronic Datalogs of totalizer data on engine run hours, historical generator loads, and other important KPIs. – Predictive maintenance using remote diagnostics (MTTF) • Historical Machine Efficiency available for comparison study • Real-time feedback using Ad-Hoc tag reporting on current machine issues Field Service • Collection of Reliability Data and Remote Monitoring – Machine Location tracking for travel and component replacement scheduling – Real-time failure analysis through Web Portal – Remote Diagnosis time reduction from 1 or 2 days to hours improving MTTR – Remote Real-time failure analysis to replace field service travel – Predictive Maintenance improvement to reduce downtime, save expensive component failure, and decrease field service call volume needs
  • 13. ®2014 Loram Maintenance of Way, All rights reserved Speed · Performance · Reliability What Rockwell Software can be used to meet all these diverse application needs? Factorytalk® Historian Site Edition FactoryTalk® VantagePoint Factorytalk® Historian Machine Edition
  • 14. ®2014 Loram Maintenance of Way, All rights reserved Speed · Performance · Reliability FactoryTalk Historian Machine Edition In-rack On Machine Historian Data collection at the machine level More granular data Data at higher speeds Single machine historian Reduce network dependency Improved Reliability Solid-state data collection No computer / OS to maintain No moving parts Remote data capture Collect data where a computer is not available or desired Distributed / modular configuration Configure one machine at a time
  • 15. ®2014 Loram Maintenance of Way, All rights reserved Speed · Performance · Reliability FactoryTalk Historian Site Edition Enterprise Level Historian Server 15 Market Leading Historian Technology – Optimized time series data storage and retrieval – Advance Calculations & Data Access capabilities Quick to Deploy and Easy to Own – Integrated with Logix and FactoryTalk Technology – Auto Discovery & Configuration – Low Total Cost of Ownership Rich Set of Clients – FactoryTalk View Site Edition – HMI trending integration with Historian – VantagePoint EMI – bundled with Historian SE Package Distributed Historian Architecture – Includes a 1756 chassis based Historian – Data can be aggregated at the site and Enterprise level – Seamless integration and common client access throughout the portfolio
  • 16. ®2014 Loram Maintenance of Way, All rights reserved Speed · Performance · Reliability FactoryTalk VantagePoint a powerful client interface for Factorytalk Historian: – Advanced trend tool – XY Plotter – Excel Add-in – Advanced Dashboards – Portal for thin client access Provides Client Access to Historical, Real-time and Alarm & Events Data. Aggregating and Correlating Data Sources with Common Reporting Tools FactoryTalk VantagePoint Web-based Client Report Server
  • 17. ®2014 Loram Maintenance of Way, All rights reserved Speed · Performance · Reliability FactoryTalk VantagePoint: Notifications and Reporting on Mobile platforms Reporting available on mobile devices: – Enterprise Reports – Charts – Status Indicators – Grid Reports Report Notification – Event Triggers Email or Text Message with Event Data with Pre-Built Report Loram has tested Microsoft Surface Pro Tablets on machine to view data using the FT VantagePoint Mobile Client Application
  • 18. ®2014 Loram Maintenance of Way, All rights reserved Speed · Performance · Reliability Putting it all Together: Loram’s FactoryTalk Implementation FactoryTalk Historian Site Edition Server FT Historian ME FT Historian ME FT Historian ME FT Historian ME FT Historian ME FactoryTalk VantagePoint Web Reporting Server Operations Field Service Controls Engineering FT Historian ME Modules added to Rail Grinders FactoryTalk Historian SE Server Consolidates Historical Tag Data FactoryTalk VantagePoint Turns Historical Tag Data into Actionable Reports Each Group uses Web Interface to View their Unique Report Tool Set
  • 19. ®2014 Loram Maintenance of Way, All rights reserved Speed · Performance · Reliability In-Rack Machine Historian logs data locally even when network is not available. Historian Server provides centralized long term data storage when network becomes available. Historical Database Collection Server and Remote Data Machine Edition Historian Module In-Rack Historian: A FactoryTalk Historian Machine Edition module collects data from a PLC using compression and exception algorithm storage. It collects data from the controls system even when network is not available. Store and Forward: Collected Data in Historian ME module is Uploaded to FT Historian Site Edition Server when network is available for long-term storage and reporting.
  • 20. ®2014 Loram Maintenance of Way, All rights reserved Speed · Performance · Reliability FactoryTalk VantagePoint visualizes the data from the Historian Server and provides a Web Portal Reporting Interface Reporting Server The data collected by FactoryTalk Historian System is reported upon through Excel and Trending Tools. These reports are then published to and visualized by FactoryTalk VantagePoint Web Portal. Reporting Clients FactoryTalk VantagePoint makes these reports available via a web client dash-board interface. Allowing a range of reporting client user groups to have their different data wants and needs met. FactoryTalk VantagePoint Web Reporting Server Operations Field Service Controls Engineering Web-based Dashboard Reporting Server and Client User Groups
  • 21. ®2014 Loram Maintenance of Way, All rights reserved Speed · Performance · Reliability History and Progress of this Rockwell Solution GPS Dashboard Map for Machine Reporting and Tracking in 2011
  • 22. ®2014 Loram Maintenance of Way, All rights reserved Speed · Performance · Reliability What we learned and where we’re going The Results of this solution implementation today: – Faster troubleshooting resulting in: • Shorter downtime • Increased productivity • Real-time diagnostics – Able to decrease field service deployment of technicians – Implement pro-active maintenance procedure timelines • Before critical component failures occur • Saving downtime and decreasing replacement costs – Provide built-in warranty / legal protection through reporting of machine service record We are continuing to invest in this technology with its proven results: – We’ve increased our reporting tag usage as we have identified new KPI data – Expanded our fleet install to retrofit existing machines and deploy on new start-ups – We are designing this system into new machine types for the latest generation builds – Exploring building a customer reporting cloud portal for future OEM machines Productivity Downtime
  • 23. ®2014 Loram Maintenance of Way, All rights reserved Speed · Performance · Reliability This unique GPS enabled google maps interface allows tracking of machine progress at a glance and drill-down to machine reports Since implementing the first machine historian in 2011, more information-enabled machines have been retro- fitted or started up with this solution and new machine types plan to upgrade. RG402 - 01/19/2012 RG403 - 02/27/2013 RG406 - 03/03/2013 RG405 - 04/04/2013 RG404 - 04/20/2013 RG401 - 06/11/2013 RG408 - 11/15/2013 RG410 - 05/05/2014 RG409 - Planned RG411 - Future
  • 24. ®2014 Loram Maintenance of Way, All rights reserved Speed · Performance · Reliability Web Dashboard and Reporting Demonstration Loram’s VantagePoint Web Portal Home Page Each Machine has a set of pre-built reports based on troubleshooting experience Each Machine has a set of pre-built reports based on troubleshooting experience
  • 25. ®2014 Loram Maintenance of Way, All rights reserved Speed · Performance · Reliability Loram’s Machine Reporting Dashboard Machine Selection Machine Overview Grind Diagnostics Power Generation Traction Data Dust Collection Hydraulic System
  • 26. ®2014 Loram Maintenance of Way, All rights reserved Speed · Performance · Reliability Machine Efficiency Data Reports – Proactive Improvement Tracking and Comparison
  • 27. ®2014 Loram Maintenance of Way, All rights reserved Speed · Performance · Reliability Framing Historical Data into Event-based Reports provides Warranty / Legal Protection
  • 28. ®2014 Loram Maintenance of Way, All rights reserved Speed · Performance · Reliability Report Tracking Ambient Machine Temperatures can Correlate Potential Heat-related Component Failure
  • 29. ®2014 Loram Maintenance of Way, All rights reserved Speed · Performance · Reliability AdHoc Report created to Troubleshoot Machine and Solve Field Issue Remotely
  • 30. ®2014 Loram Maintenance of Way, All rights reserved Speed · Performance · Reliability Excel Report to Track Fuel Consumption
  • 31. ®2014 Loram Maintenance of Way, All rights reserved Speed · Performance · Reliability Related Sessions at RSTechEd 2014 Introduction to FactoryTalk VantagePoint 1 hour You’ve heard about Manufacturing Intelligence, but do you have a good base understanding for what the FactoryTalk VantagePoint EMI reporting and analytics product can really do? Come take a quick tour of FactoryTalk VantagePoint EMI and learn more about what it has to offer. FactoryTalk VantagePoint EMI: 50 Minutes to Value 1 hour If you had 50 minutes, a computer running FactoryTalk VantagePoint, and an information engineer, what could you do? In this session, the instructor will lead you through solution creation on the fly. What types of ad-hoc analysis can you do? What types of content are easiest to develop? Could you really do a full report-package solution with FactoryTalk VantagePoint in the allotted time? Come see. Mobility and Portability with Today’s Rockwell Software 1 hour Bring your own device to work? Need to support mobile workers? Production and operations management solutions today require various forms of access to their Manufacturing Intelligence systems including mobile devices and web clients. In this session, see how Rockwell Software can begin to accomplish these goals with access to FactoryTalk View Site Ediction, FactoryTalk VantagePoint EMI and eventing on any mobile platform.
  • 32. ®2014 Loram Maintenance of Way, All rights reserved Speed · Performance · Reliability Related Sessions at RSTechEd 2014 Introduction to FactoryTalk Historian 1 hour A distributed historian strategy produces strong advantages. Learn how FactoryTalk Historian delivers a scalable, modular, synchronized methodology for collecting, maintaining and analyzing process data at each level of manufacturing operations. New features and functionality will be highlighted and compared to similar products in the marketplace. FactoryTalk Historian Machine Edition 2 hours Hands-on lab with FactoryTalk Historian Machine Edition covers typical configuration and data collection in a ControlLogix chassis. The lab will cover the web configuration of the module, simple web reporting, and the use of thick clients for reporting and analysis of the data in the historian module. You will also learn about store and forward architecture between Historian Machine Edition and Historian Site Edition and integration with Rockwell Software Studio 5000 through Add-On Profiles. FactoryTalk Historian Siting Edition: Data Collection and Reporting Lab 2 hours Introductory FactoryTalk Historian Site Edition lab covers basic elements of system confi guration, data collection and reporting tools. Learn how FactoryTalk Historian Site Edition provides an engine of unmatched performance and scalability. See the power of autoconfiguration and diverse control system/HMI connectivity.
  • 33. ®2014 Loram Maintenance of Way, All rights reserved Speed · Performance · Reliability33 Questions? For more information, visit us at: www.loram.com
  • 34. ®2014 Loram Maintenance of Way, All rights reserved Speed · Performance · Reliability We care what you think! • On the mobile app: 1. Locate session using Schedule or Agenda Builder 2. Click on the thumbs up icon on the lower right corner of the session detail 3. Complete survey 4. Click the Submit Form button 34 Please take a couple minutes to complete a quick session survey to tell us how we’re doing. 2 3 4 1 Thank you!!

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