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Manufacturing Performance


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Wonderware has joined forces with EmsPT to bring you a webinar that discusses how to make more of your Historian installation and DRIVE a Programme of Continuous Improvement.

Wonderware recently surveyed a select number of Historian customers and there were some common themes that emerged. It is apparent that users want to:

Understand their production process by using historical data to analyse process and production issues

DRIVE Continuous Improvement activities and obtain data for production KPI's

Expand their system to drive performance improvements

Together Wonderware and EmsPT have already worked with many Wonderware Historian customers to ensure their goals were fully understood and beneficial use was realised. We would like to share these advantages of optimising a Historian installation to DRIVE Continuous Improvements with you.

Webinar Content:

Summary of Wonderware Customer Research

The need for Manufacturing Information to enable Continuous Improvement

Expanding on your Wonderware Historian Investment

Who uses Manufacturing Information?

Delivering Manufacturing Information for enhanced:




-Schedule Adherence



A proven Methodology for Success

Published in: Education
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Manufacturing Performance

  1. 1. Learning from History – Unlock your Performance Potential Richard Stone Lean Manufacturing Manager
  2. 2. Historian customer research► 2 types of Historian user ▪ Process trends, archives, reports (80%) • Process trends are vital to many companies for trouble shooting, batch production analysis, and many other areas of insight ▪ Also Business benefits – reporting KPI (20%), doing more than trending, validation of process parameters etc► We wish to explore the second group’s usage and discuss what is required to deliver more from Historian data.
  3. 3. Quoted...1. “The Historian is currently logging every bit of PLC information from the 4 lines it is in operation on the data it captures includes.. ▪ Time, Operators, Temps, Pressures, Speeds, Alarms etc”2. “Historian is used to provide short term historical data to the InTouch screens for Trends as the built in InTouch trends are not capable of handling the volume of data, the solution collects all data from 3 lines using InTouch the data includes... ▪ Temps, Pressures, Signals, Speeds, Motors, Alarms”3. “currently capture SPC data at the SCADA level identified through the Lasers on the line which determine Diameter of the product (due to set standards from the recipe) but this data is not looked at unless a Non Conformance is raised by a customer after delivery, the QA team may require more information...”
  4. 4. And quoted...1. “Historian is used in the Injection Moulding department. It collects data from the drying process/injection process/part counting process. It also collects data from resin supply/handling system”2. “It is collecting information from 31 machines. We could/would not run without Historian. We would have no reporting facility thus no KPI data. We would be producing product but would have no method of recording how we were doing - which is how we are compared to our European sister plants. We would also be running blind - which would be going back to how we ran 5+ years ago. We would also struggle to carry out root cause analysis of complaints.”3. “If correctly deployed, Historian is a veritable gold mine of information that can be very easily accessed. If you have got used to Historian and it was taken away, you could live without it but it would be like living without two or three of your fingers”
  5. 5. And quoted...1. “It would make the job more laborious for those that use it. At present faults can be identified from the office. They would have to go out on to the plant to investigate issues.”2. “Was purchased to validate the process in real-time – they use it as a validation aid to ensure that their operators have processed a batch as intended”3. “... don’t directly report from Historian, they export information into an excel spreadsheet and use this information with data from other sources to compile a production report.”4. “one practical example of how Historian has helped is that using it they were able to notice that when the CHP part of the plant was drawing water other processes within the plant began to slow down. Without the Historian they never would have known this but due to it being highlighted they installed an extra water tank and this helped them make considerable performance gains.”...
  6. 6. Where does Historian fit in thescheme?
  7. 7. The shape of the problem
  8. 8. Beyond the process► The feedback tells us that our customers have had significant benefit from their Historians, understanding Process Data► The need to understand Manufacturing Challenges
  9. 9. The need to deliver ManufacturingInformation► Evidence that Historian data does provide data for improvements for the Engineers.► The curve of improvements► Request for information Operational & Production Management► It is the Engineers that know what is going on. But others are reliant on engineering for other production KPI’s
  10. 10. Developing your investment► “Manufacturing Operational Management (MOM)” Information► How is this achieved ?► Your investment in Historian could deliver more when used with associated technologies► Without accurate MOM information: ▪ Ask 20 people get 20 answers ▪ Needs to be in real-time to allow the shift to react ▪ It needs to be in the right context for the right people► It’s also important to understand the ROI of any investment current and future.
  11. 11. Who uses MOM Information ?All your internal customers► Operation Manager► Production Manager► CI Manager► Quality Manager► Plant Manager► Works Manager► Engineering Manager► Business Unit Manager►…► How are we doing NOW !!
  12. 12. Delivering MOM InformationLooking around the room …
  13. 13. Delivering MOM InformationLooking around the room ?Looking at your data from the factory ?The same data for different uses:► Manufacturing Efficiency► Quality► OEE► Manufacturing KPI’s► Schedule Adherence► Yield► Production Progress► Utilisation► EnergyMOM information delivers information that is used as a measurementand helps maintain sustainability
  14. 14. Integrating your Historian System Information / Interoperability Real-Time Manufacturing Operations Management VisibilityDevices, Applications, Enterprise Integration Empowering All Roles in the Plant ERP (SAP, Oracle, Microsoft..) Enterprise Wonderware® MES & EMI Software Solutions Integration CEM Intelligence Database Energy Applications Asset Operations Performance Quality Batch Asset Monitoring Management Wonderware® System Platform Wonderware® Wonderware® Wonderware® Application Historian Information Server Server LIM Systems Device Integration Devices
  15. 15. Manufacturing Performance► Software needs to be Proven – Mature – a Future► Historian is proven for logging data against a time line► Users need to be able to be self sufficient: ▪ Complex reports and queries from non-process data ▪ Mixed with information such as shifts, batch number, product type ▪ Interactive drill down reports ▪ Root cause analysis► Historian is major component of System Platform which is part of a Manufacturing Operations Management solution► An example - Wonderware “Performance Module “ provides: ▪ Real time KPI’s Reports ▪ Operator / Supervisor interfaces ▪ Real-time data collection ▪ Production Dashboards ▪ Management KPI’s ▪ Links to Scheduling Systems
  16. 16. Empowering OperatorsDaily & Shift Focus Real - Time • Daily Production Plans • Line bottle neck identification • Shift OEE information • Product and Batch performance • Shift Downtimes • Integration with planning systems • Daily KPI Displays • Empower operational staff
  17. 17. Online meetings Online Production Meeting Point • Hourly Short Interval Control • Operations – Maintenance point • Driving on time delivery • Promotes operational collaboration • Real time management
  18. 18. A picture of ?
  19. 19. Plant Intelligence
  20. 20. Hierarchy Of Information Solutions Intelligence HMI Reports Server Information ActiveFactory / Historian Client Multi-site Site InTouch & Build on your existing InTouch & System information infrastructure Historian Platform Multi-node InTouchSingle-node InTouch
  21. 21. Wonderware Intelligence • For your multi-site or multi-database deployments • Build KPIs (Key Performance Indicators) to view your critical manufacturing metrics in near real-time Site • Leverage data that exists in your automation, MES, business systems, or legacy applications • View rich dashboards with “drill down” capabilities into analytics and source data for better cause and effect analysis Multi-site Dashboards Analytics Reports
  22. 22. Culture & Change► We are all involved in change and effected by culture► Focus on the Positives► Important to use proven Methodology► Software Products alone don’t deliver – they must be supported to deliver the value identified in by a ROI statement.► Goals – ROI – Success – Training – Enable► DRIVE - emsPT
  23. 23. A Proven Methodology forSuccess► At emsPT we use DRIVE► Starts with a Discovery phase and stays engaged to deliver the manufacturing benefits.► Understanding your challenges and what success looks like► A Proven Program
  24. 24. Delivering Success of our customer’sGoals ► Efficiency ▪ “Easy access to the information” ▪ “To provide a day-to-day performance measure“ ▪ “To be able to identify 3% production efficiency gains“ ▪ “ To understand our Downtimes on our whole site as this is affecting overall OEE ▪ “ A Solution offering accurate understanding of bottlenecks “ ▪ “Providing real-time information to analyse downtimes and causes “ ▪ “Supporting efficiency improvement initiatives with detailed reports & analysis” ▪ “Understanding the real effect of minor stoppages “ ▪ “Detecting reduced performance early, based on historical data” ► Capacity ▪ “To be able to understand where we are today with a view to looking at spare capacity available” ▪ “Support the desire to improve asset utilisation (production downtime & performance) and improve the OEE” ▪ “Releasing additional production capacity through better understanding of our processes “ ▪ “To see how different products effect our line output and effect overall capacity”
  25. 25. Delivering Success of our customer’sGoals ► Time & Culture ▪ “Spend less time on paper work and more time in the production area.” ▪ “A system that assists with the evolution of the productivity and improvement culture within the business” ▪ “Allowing more effective capital budget planning” ► Daily Production KPI’s & Quality ▪ “Have access to information to drive a CMMS solution.” ▪ “A system that is used by the business” ▪ “To deploy a unified solution across all lines to ensure like for like comparison and Benchmarking for improvements in line with KPI’s” ▪ “Improve Quality and ensure consistency” ▪ “To understand how process variables effect production quality” ▪ “Improvement of product yield” ▪ “Reduced energy consumption”
  26. 26. Delivering Success of our customer’sGoals • MES – “Have an ongoing initiative to work towards a paperless environment as currently there is wasted time within the process to collate information from the shop floor and feed this into SAP and other systems” – “Reduce your labour costs and improve quality of information by moving towards full Automation & MES” • Standards – “Ability to deliver the requirements of such a system, faster, more flexibly, in a more standard way across sites” – “A system that enables a lower TCO (as there are „ever-changing requirements)” – “A solution that is maintainable and configurable” – “Using existing factory automation infrastructure to reduce time and cost of implementation “
  27. 27. Discovery & ROI
  28. 28. Discovery & ROIGoals Value Benefits SOE
  29. 29. Conclusion► Many software products are a solution looking for a problem► Customers have been tempted to buy for instant result and from the heart► You need a combination of powerful products and a proven methodology with demonstrable benefits
  30. 30. What next► What next ▪ Call EmsPT ▪ Take a DRIVE Audit or Workshop► Register your interest in further events ▪ Bringing the information to you ▪ Regional breakfast seminars
  31. 31. See you in 2011?Breakfast seminars coming to alocation near you.1. DRIVE Manufacturing Performance2. DRIVE Manufacturing Operations3. DRIVE the SAP ERP Connection
  32. 32. Powering intelligent plant decisions in real time.