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Introducing a breakthrough in Business Intelligence and Data Visualization for the Manufacturing Environment: Information – to – Intelligence (i2i)

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  1. 1. Process understanding is only a few clicks away We are proud to offer the i2i Manufacturing Information Management & “DataVis” Platform transforming Information-2-Intelligence at the speed of “Click” Introducing a breakthrough in Business Intelligence and Data Visualization for the Manufacturing Environment: Information – to – Intelligence (i2i) These days it’s all about speed – the advent of the Internet coupled with a high-speed connected society has completely transformed the way all of us want [and need] to interact with the data we use to increase our productivity: Not only do we want information right away, but we demand it on our terms as well – and we couldn’t agree more. With over 20 years Manufacturing Engineering and Integration experience we’ve answered the Information Management needs of our customers with a data management solution that can be deployed Authorized Partner Integrator and validated quickly to provide the entire organization with access to the critical data they need – now and on their own terms. See for yourself by scheduling an on-line test drive of a complete i2i solution. copyright © 2009 exoCite Manufacturing Solutions, Inc.
  2. 2. Bringing over 15 Years Process & Industrial Control Expertise to the Enterprise Specializing in building Industrial Automation Systems from the Plant-floor to the Enterprise our engineers have built a solid reputation for delivering World-Class Manufacturing Solutions Authorized Partner Integrator copyright © 2009 exoCite Manufacturing Solutions, Inc.
  3. 3. The key to a successful Enterprise Data Solution is to Simplify your Architecture Reducing discrete data stores to a well-designed Relational Database and Plant-wide Historian Architecture will ease deployment and validation efforts and increase project success rates substantially – at a significantly reduced Total Cost of Ownership (TCO) Plant Batch RDBMS Plant PAT OEE & Other “Results” Efficiency Data Data Plant Historians Plant or (Primary / Corporate Redundant) Domain Manufacturing & Packaging Areas PAT Spectral Raw Materials Data & LAB & QC Data copyright © 2009 exoCite Manufacturing Solutions, Inc.
  4. 4. A Single Interface designed for a Multi-Purpose World Leverage the power of the RDBMS to satisfy the data requirements of those who need it most Technology Group & Regulatory Quality Control & Quality Assurance Group/ Reporting Laboratory • • Manufacturing Investigations Batch and Product Investigations • • Recipe Configuration Verification Recipe Editing & Tracking configurations to production • • Raw Materials Usage Reports Batch-to-Batch Compare Facility • • Alarm History by Batch Process trends by Batch • • Extended Batch & Production Reports Alarms & Events by Batch • • Process Risk Reports for Product Release Raw Materials Usage Reports • • Regulatory Compliance Reporting PAT & Human Sample Data Manufacturing & Packaging Groups Corporate Management, IS & Efficiency Systems • • Alarm & Batch Frequency Reports Real-Time Process Trends • • Production Down-Time & OEE Reports Recipe Configuration Usage • • SIX Sigma/Batch Statistical Information Work Instructions & 21CFR Part 11 Electronic Signatures • • Batch and Production Cost Analysis Audit Trails by Date & by Batch • • Human Resource & Training Tracking Alarm & Batch Frequency Reports • • Headcount Planning Batch & Production Reports • • System Performance Reports Equipment Down-time & OEE Reports • Regulatory Reporting Maintenance & Engineering Group Materials, Inventory & Resource Planning • Real-Time Process Trends for PID and Process Tuning • Batch & Production Reports • Alarm Histories & Alarm Frequency Reports • Production Down-Time Information • Preventative Maintenance (PM) Reports (by Time / Usage) • Raw Materials usage Reports • Recipe Configuration tracking to production • Batch Frequency Reports by Product • 21CFR Part 11 Audit Trails & Audit Histories • Raw Materials Genealogy • Alarm Frequency Reports (Occurrence, Time-to-Resolve) • Annual Summary Reports • Batch Frequency Reports (Batch & Step Time-to-Complete) • Monthly Equipment Utilization Reports • Historical Trends by Time/Date • Batch-to-Batch Compare Facility copyright © 2009 exoCite Manufacturing Solutions, Inc.
  5. 5. Process Improvements through modern Data Management and Information Layering Combining traditional Historian Data with a rich S88 compliant Manufacturing Data Model Comparing a known good “Golden Master” batch against another batch Q: How do our customers utilize a comprehensive manufacturing relational data model coupled with visualization and reporting tools to better understand their processes? A: Through Data Layering from many data sources tied together through our highly intuitive visualization tools. The image on the left demonstrates our powerful and highly intuitive batch comparison tools. The image below combines traditional process historian data with many other pieces of information related to each particular batch including Alarms & Audit Trail Events, S88 Recipe Configurations, product details, process steps, and logged-in operator information. Don’t just view data, interact with it The latest industry and regulatory agency trends call for improving process understanding through the use of innovative technologies. But to improve our processes requires that we do more than simply view the copious amounts of raw data produced by today’s modern, complex manufacturing processes. Other industries are moving towards interactive data management & visualization tools (“DataVis”) and applications, yet this technology is still largely out of reach in the world of real-time manufacturing systems – that is until now. Through the use of a powerful S88/S95 Manufacturing Relational Data Model coupled to highly interactive “data layering” visualization tools, our customers are able to know and understand S88 Recipe Data Model, Batches & Steps, Alarms & Events & Historical Trends their processes faster than was ever before possible. copyright © 2009 exoCite Manufacturing Solutions, Inc.
  6. 6. Use the power of the rich data model to make sense of your historical process data View S88 Recipe Configurations, 21CFR Audit Trails, Alarm Histories and Batch Data at a glance copyright © 2009 exoCite Manufacturing Solutions, Inc.
  7. 7. From a good data model springs practically unlimited Reporting opportunities Move beyond simple batch reporting to produce rich process optimization and efficiency reports copyright © 2009 exoCite Manufacturing Solutions, Inc.
  8. 8. Data may come from many sources, but now one tool can make sense of it all Combining traditional Historian Data with a rich Manufacturing Data model Combine Alarm History information with Historical Trends to demonstrate relationship between those events 21CFR Part 11 Audit Trails combined with Trends demonstrates direct relationship of user activities S88 Recipe Configuration Data per process step situated adjacent to Historical Trends – Helps demonstrate the effectiveness of each recipe revision copyright © 2009 exoCite Manufacturing Solutions, Inc.
  9. 9. Quickly visualize the differences between large numbers of batches Summarize large quantities of data using powerful built-in Charts and Graphs tailored to each process Q: How do our customers quickly scan many batches to find the ones with the greatest potential risk? A: Through the use built-in charts and graphs to visually pinpoint areas of interest within the data. Once identified, users can switch to the process compare utilities to quickly perform “Golden Master” comparison studies. The image below demonstrates a chart that is currently used to determine which coating batches required extra shots of solution. This report was previously created by hand through a labor-intensive data entry procedure using Microsoft Excel, but was easily and quickly re- produced using the data available in the RDBMS. The image above is an example of two separate coating batches from the same coating pan: one that required several additional final coating steps to complete and another that executed normally (the “Golden Master’). Viewing the batches side-by-side and combining Audit Trail Event data with the Historical Trends, investigators were able to quickly identify the root cause of the problem batch and implement changes to critical procedures to reduce future occurrences saving valuable time, materials and potentially lost batches. copyright © 2009 exoCite Manufacturing Solutions, Inc.
  10. 10. Process Understanding through effective data management techniques Combining traditional Historian Data with a rich Manufacturing Data model Comparing and entire batch against another – good for getting the whole picture in a single mouse click Q: How can our customers leverage their investment in existing plant historians to improve process understanding? A: By combining RDBMS batch information with the Plant Historian Process Data to produce unprecedented navigation and data layering capabilities. Historians offer highly configurable views of process data that cannot be easily attained with an RDBMS alone, so it was a natural fit to combine the information from these very distinct and rich data stores. The example above illustrates traditional process data obtained directly from the plant’s existing historian database. Process Alarms, Audit Trails, S88 Recipes, Process Steps, User Information, batch and step times, etc. are retrieved from the RDBMS and overlaid directly on top of the historian data to create a level of detail that could not be achieved in any other way. The example on the right demonstrates batch comparisons using RDBMS data only. In this case process data is sent to the relational database during batch operations as well as continuously to the plant historian providing an extra layer of protection against data loss. Comparing Individual Process Steps between multiple batches copyright © 2009 exoCite Manufacturing Solutions, Inc.
  11. 11. Retrieving your process data by time is fine, but why not navigate by batch as well? The S88 data model does far more than just store data – it can also help you to navigate through it Retrieve critical batch data directly from RDBMS Retrieve data directly from your Plant Historian (Proficy Historian, OSI PI, Aspen, etc) Coating information (from Historian) PAT Datasource Granulation and Drying Process (from RDBMS) then – Combine data from multiple data sources including relational databases, PAT data sources, Building Management Systems (BMS) & Environmental and Plant Historians copyright © 2009 exoCite Manufacturing Solutions, Inc.
  12. 12. Use the Data Model for what it was originally designed to do, summarize data Direct your efforts using rich charting tools specifically designed to identify costly process problems Q: How do our customers determine if their batches are running consistently over time? And how can we quickly convey which areas need immediate attention to keep each process running smoothly? A: We continually strive to identify new ways to present batch and process data to users that quickly lead them to problem areas that will reduce process efficiencies and cause down-time and lost batches. Effective charts and graphs can very quickly convey a great deal of information in a very small amount of space The example above demonstrates the amount of time each batch and process step took to complete. Extended batch or step times time can be an indicator of process or equipment problems or even operator error. A reduction in batch or step times can also be an indicator of potential product quality issues and may warrant additional investigation during the product release process. The chart at right shows which alarms occurred most often and which ones took the longest to resolve. Those that took longest to resolve and/or occurred most often would indicate a good place to make process improvements to reduce costs and improve process efficiency. copyright © 2009 exoCite Manufacturing Solutions, Inc.
  13. 13. Fully integrated Adobe® Acrobat™ Reader enables organization-wide collaboration Share critical manufacturing data using Adobe PDF file format. Enable full-text searches of any report Built-In Adobe ® PDF Viewer provides extensive Report Searching Capabilities Integrated Adobe® Acrobat™ PDF Reader The power of the built-in Adobe PDF (Portable Document Format) reader makes saving and sharing reports a very simple process. The PDF reader plug-in also includes extensive full-text search capabilities that eases the batch investigation process by quickly locating key information in large Alarm & Audit Trail Histories and Production and Batch reports. Searching a batch report (above) for “Inlet” reveals every Inlet parameter entry including both “Airflow” and “Temperature”. This feature is often used to determine if all procedures were faithfully followed during each phase of the batch process. The days of manually pouring Quickly Build any report by Date over hundreds of pages of batch and production report data to find a specific piece of critical information Range or by Batch are finally coming to an end. Number copyright © 2009 exoCite Manufacturing Solutions, Inc.
  14. 14. Bring i2i to the plant-floor by integrating with any modern SCADA/HMI Application Integrate our powerful Data Visualization tools on the plant-floor to improve any Manufacturing Process Actual Production GE Proficy SCADA/HMI Software with i2i Visualization Tool Integration 21CFR Part 11 Compliant Electronic Signatures S88 Recipe Integration copyright © 2009 exoCite Manufacturing Solutions, Inc.