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Rapid Line Integration

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  • 1. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Rev 5058-CO900DRAPID Integrated Line Controland Performance ManagementName – Ryan LeppDate – June 2013
  • 2. Copyright © 2012 Rockwell Automation, Inc. All rights reserved.COMPANY CONFIDENTIAL - Internal Use Only 2Typical Configuration of Finishing/Packaging LinesPallets of EmptyCans or Bottlesto be FilledNew or Used ordirect feed fromBlow molderWashing of thecontainerLiquid productfrom upstreamprocess plantFilling of thecontainer thensealing it with alid or capConveyingSystem tocontrol bufferstocksHeating theproduct to killoff unwantedorganismsLabeling of thecontainerPackaging intoCases, 6pack,24 pack etc.Palletisationready fortransport
  • 3. Copyright © 2012 Rockwell Automation, Inc. All rights reserved.COMPANY CONFIDENTIAL - Internal Use OnlyChallenges in Line Control &Management3Too Customized - No Modular IPCost to Integrate OEMsComplexity – Time to StartupPerformance Managementan Afterthought
  • 4. Copyright © 2012 Rockwell Automation, Inc. All rights reserved.COMPANY CONFIDENTIAL - Internal Use OnlyTypical Line Integration ApproachDiscreteManufacturingCustom engineered line controls- Peer to peer interlocking -or-- Supervisory controller• Investment (1) – Develop , install, and verify line controls during startup. (Capital Project Investment)• Investment (2) – Implementation MES after capital project acceptance. (Plant Systems Budget)Custom designed MES- Not part of linecontrol- Additional machineinterface21 Problems with this approach: Separate line control and lineperformance systems bothrequire custom equipmentinterfacing work to be done. The majority of engineering workis custom and therefore isrepeated on each startup The performance managementsystem is not available duringinitial startup of the line
  • 5. Copyright © 2012 Rockwell Automation, Inc. All rights reserved.COMPANY CONFIDENTIAL - Internal Use OnlyWhat is RAPID?5• RAPID is a configurable line control solution with built in line performancemanagement.• RAPID provides a flexible approach to integrating discrete manufacturinglines, allowing for a single location to setup, control, and analyze theperformance of an entire line.• This approach lowers the total cost and time of deploying and optimizingmanufacturing equipment while providing a platform that interfaces withproduction machines and operations management systems in a consistentmanner.- One investment for Line Control and Line Performance applications- Decreases time & cost to startup new lines (stretches capital)- Line optimization can begin during startup (improves “vertical startups”)- Can be implemented on new or existing lines with varying control systems
  • 6. Copyright © 2012 Rockwell Automation, Inc. All rights reserved.COMPANY CONFIDENTIAL - Internal Use OnlyWhat is RAPID’s Value? RAPID uses a “Bottom up” machinecentric approach to line control andperformance management Greatly reduces the impact onthe OEM’s equipment. Simplifies the work performedby system integrators Provides immediate andactionable feedback to operatorand maintenance personnel.Custom SystemIntegration…
  • 7. Copyright © 2012 Rockwell Automation, Inc. All rights reserved.COMPANY CONFIDENTIAL - Internal Use OnlySupervisory PACSupervisory HMI     PerformanceManagementRAPID Line Integration SystemFault & Event Definition ToolsFault & Event Definition ToolsEquipment Configuration ScreensEquipment Configuration ScreensEquipment Interface ToolsEquipment Interface Tools EMI Software ConnectionEMI Software ConnectionLine Level Root Cause ReportingLine Level Root Cause ReportingLine Configuration ScreensLine Configuration ScreensDynamic Event ConfigurationDynamic Event ConfigurationPre‐Configured  Work CellsPre‐Configured  Work CellsProgram by OEM BProgram by OEM CProgram by OEM CEquipment InterfaceRAPID InterfaceEquipment InterfaceEquipment InterfaceOEM CODE :S88/PackMLv3Program by OEM AOEM CODE :Custom CodeEquipment InterfaceOEM CODE :End User StdOEM CODE :S88/PackMLv2Equipment #4Equipment #1 Equipment #2 Equipment #3RAPID System Overview7Solution:
  • 8. Copyright © 2012 Rockwell Automation, Inc. All rights reserved.COMPANY CONFIDENTIAL - Internal Use Only Import AOI into equipment program Map Commands and Status data to equipmentcontroller tags Create code to process line control commands ifnecessary. Use ViewME verification tool to test the interface. When complete / verified – Export the interface(rung/routine) to save the mappings for future use.EquipmentStatusEquipmentCommandsEquipment Interface SummaryImplementation Steps
  • 9. Copyright © 2012 Rockwell Automation, Inc. All rights reserved.COMPANY CONFIDENTIAL - Internal Use OnlyRAPID Supervisor Code templateRepeated CodeFunctions perMachine:- Communications- EquipmentInterface- Data Mapping- Root Cause- Peer Mapping- SequencingControl- Conveyor ZoneAccumulationControls
  • 10. Copyright © 2012 Rockwell Automation, Inc. All rights reserved.COMPANY CONFIDENTIAL - Internal Use OnlyEquipment Configuration10
  • 11. Copyright © 2012 Rockwell Automation, Inc. All rights reserved.COMPANY CONFIDENTIAL - Internal Use OnlyLine Level Root Cause Determination11“Root Cause Analysis” provides:Equipment & Line Level Root Cause:Each Machines Blocked and Starve Conditionis reported as a status.The Bottleneck / Critical Asset Root Causeis reported as a line downtime reason.
  • 12. Copyright © 2012 Rockwell Automation, Inc. All rights reserved.COMPANY CONFIDENTIAL - Internal Use OnlyAdhoc Reporting – Report Expert12
  • 13. Copyright © 2012 Rockwell Automation, Inc. All rights reserved.COMPANY CONFIDENTIAL - Internal Use Only Summary:• Provides a simple, configurable, and integrated line control & line performance solution to:1. Coordinate and control the flow of materials through a discrete manufacturing line2. Manage the collection of specific equipment data and associated network communications3. Report equipment and line level key performance indicators (OEE, MTBF, MTTR, ETC)4. Collect equipment and line level events for downtime and root cause analysis5. Based on Logix, FTViewSE, and FTMetrics Supervisory System – Line Configuration, Control, and Line Performance• Provide configurability of upstream/downstream interlocks and start/stop behaviors• Manage each line configuration on a product type / SKU basis• Display real-time status and performance information• Display Line level KPI’s and root cause analysis• Equipment downtime reason reporting by duration and frequency• Reason code descriptions programmatically created from event messaging structure• Adhoc reporting – Ability to create/organize reports against SKU, Shift, Work Order, User, etc Equipment Interface (AOI)• Simple and verifiable interface implementation• Provides commands and parameters to equipment• Receives status and event data from equipment• Equipment states (PackML preferred)• Production counts (processed, defective)• ‘First Out Fault’ events (downtime events)Rapid Core Features (Sample Code & Configurations)13
  • 14. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Rev 5058-CO900DQuestions?

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