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Stone Technologies: Manual Data Modification Makes Getting Accurate Information Easier
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Stone Technologies: Manual Data Modification Makes Getting Accurate Information Easier

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Stone Technologies: Manual Data Modification Makes Getting Accurate Information Easier Stone Technologies: Manual Data Modification Makes Getting Accurate Information Easier Presentation Transcript

  • Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Rev 5058-CO900DStone Technologies: Manual DataModification Makes Getting AccurateInformation EasierAlan StanfillMES Project ManagerJune 2013
  • Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Introductions Alan Stanfill, Stone Technologies – MES Project Manager Audience – how many: End Users SI’s OEM’s Distributors Rockwell Automation Others? Survey on audience experience with: OEE data FactoryTalk Metrics Microsoft SQL databases Manual data modification LAB SESSION MI16
  • Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved. 3AgendaWrap Up / Q&ACustomer SolutionWhat’s New in FactoryTalk® Metrics?History of Stone Custom SolutionsBad Data Happens – Need for Modification
  • Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.• What do we mean by “bad data” …• Have you ever had data that appears accurate when it’s captured?• BUT …• You later discover that it is not?• How about incomplete data that could use some context or comments to clarify?Bad Data Happens• Why does this happen?• Controls and automation systems can’t know everything• Sometimes the first event captured isn’t the real cause• Root issue often needs to be determined by a human• This happens AFTER the event rather than in real time
  • Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.History of Stone Solutions• Client requirements forced a custom solution Multiple clients over several years (10+ years) Data modification wasn’t in the product but was required for a complete solution• Stone approach Try to minimize customization Allow data modification to mirrored data Maintain look / feel of product solutions• Input to Rockwell Automation The Stone team has over the years and continues to work closely with the productdevelopment team to suggest product enhancements
  • Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Stone – Event Categorization
  • Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Stone – Event Splitting / Notes
  • Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Stone – Event Categorization
  • Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Stone – Shift Notes
  • Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Stone – Reporting
  • Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Limitations of Stone Solutions• Separate data• Mirrored key data to non FactoryTalk Metrics tables for modification• Only event data changed – no good / bad / total part counts, etc.• No re-calculating of OEE (Overall Equipment Efficiencies) andother KPI’s (Key Performance Indicators)• Gave updated event information but did not change OEE• Custom reporting is required• Upgrades potentially impacted• SUPPORT!
  • Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.FactoryTalk Metrics New Release FactoryTalk Metrics v10.5 Customers can now edit events/part counts in the system Web pages integrated with Report Expert for data entry Web services provided for integrators Covers MANY scenarios customers need out-of-the-box You can NOT create a workcell that has no control system FactoryTalk Metrics v11 Adds full manual data entry A workcell can be created with no control system required All production and event data can be entered manually
  • Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.FactoryTalk Metrics v10.5 New/Improved Manual Data Modification Edit Events, split Events Edit Part Counts and Scrap Counts Data integrity automatically maintained between data tables Web UI integrated with Report Expert UI uses workcell/event configuration information Integrators may create their own UI using published web services Infrastructure FTSP 5.1 supported Includes FT VantagePoint 4.513
  • Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.FactoryTalk Metrics: Editing Data withReport ExpertNew “Editor” buttonin Report ExpertSelect EditOperationand savedparameter setModifyparametersto filter datato edit(optional)Click “View Data”to view selectedevents.
  • Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.FactoryTalk Metrics 10.5Manual Editing of Events15List offilteredeventsappears.Click“Details”to showeventdetailsabove.Click one of thebuttons to Editselected event.
  • Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.FactoryTalk Metrics 10.5Manual Splitting of Events16Originaleventinformation. Enter splittime and click“Split”Enter changed eventinformation for the two partsof the split event and “Save”.
  • Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.FactoryTalk Metrics 10.5Manual Editing of Part Counts17Choose “Edit PartCounts” and aParameter Set, orset parametersmanually. Click“View Data”A filtered,grouped andsorted set ofpartnumbers isdisplayed.Click“Edit”toshowdetailsaboveandedit arow.Edit Good and Scrap partcounts. Click “Save” toupdate the database.
  • Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Benefits of Productized Solution• No duplication of data• Calculations updated• OEE is refactored• Data integrity is maintained• Standard reports• Standard interface• Integrated into Report Expert• Leverages security• Still customizable to user requirements• Uses standard parameter sets• SUPPORTED!
  • Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Client Situation• Large food / beverage facility• Not traditionally a Rockwell information software user• Large OEE centered data collection system (186 workcells)• Multiple year implementation• Functionality to include more than just FactoryTalk Metrics• Checklists, custom reports, flexible routing, etc.• Needed plant floor UI• Touchscreen, tablet friendly version• Tailor to plant floor users• Requirement for data modification• Operator Stops needed to tie to TPM loss tree with multiple levels• Support is a huge key to their success
  • Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Client Plant Floor Under the Hood• Created an ASP.NET page to leverage new API (web services)• Key web services used• Find data• GetEventByOccurenceId• GetEventConfigById• GetLookupListById• Modify data• ChangeEvent• SplitEvent• Web services require parameter sets but we didn’t want to force the usersto select these• Parameter set built programmatically based on known filter criteria• Give appearance of multiple levels of reasons
  • Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Plant Floor UI – Select Location
  • Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Plant Floor UI – Initial State
  • Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Plant Floor UI – Event Splitting
  • Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Plant Floor UI – First Split Event
  • Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Plant Floor UI – Second Split Event
  • Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Plant Floor UI – Edit Reason Code
  • Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Plant Floor UI – Notes Entry
  • Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Plant Floor UI – After Modifications
  • Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Client Results• Plant floor compatible UI• Windows 8 tablet used for design compatibility• Some functionality supported on iPad per client request• Large buttons, no drop downs, etc.• Users do not have to know parameter sets to find / modify data• Off the shelf software utilized as much as possible (SUPPORT)• System allows data modification while still maintaining standard product• Currently in phase 1 of 5• Rollout to additional lines is very simple• Total of 186 workcells
  • Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Company Background30• Stone Technologies, Inc. founded in 1996– Long term relationships built on performance, trust, & promise keeping.– Of our top 20 clients since the inception of the company in 1996:• Doing business with ALL of them today• Average relationship is over 9 years• Average of 50 projects per client• Average adding 2 – 3 new clients a year– Focused on the F&B, Consumer Products Industry, Fine Chemical, Medical Device,Power Generation industries• Technology Focus and experience– 22 engineers focused on process and other controls systems– 18 engineers focused on MES and information solutions– 10 dedicated project managers– The technical staff has an average of 22 years of experience.– Our least experienced employee has 12 years industry experience
  • Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Expertise
  • Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Rev 5058-CO900DQuestions?Remember to Check out Lab Session MI16Alan StanfillMES Project Managerastanfill@stonetek.com
  • Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Rev 5058-CO900DThank you for participating!Please remember to tidy up your work area for the next session.We want your feedback! Please complete the session survey!