Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
PUBLIC INFORMATION
American Colloid Company: Boost Accurac...
Agenda
 Introductions/Technologies Used
 Customer Information
 Situation/Goals
 Project specifics
 Wrap Up/ Q&A
AGENDA
Introduction
 Wendy Armel – Principal MES Analyst
 Audience – How Many…
 End Users
 Systems Integrators
 Rockwell Aut...
What is FactoryTalk Metrics?
 OEE and Downtime Tracking
 Overall equipment effectiveness (OEE) can provide you
with crit...
What Business Intelligence Tools Were Used and Why?
 SAP Business Objects
 Provides for ad hoc analysis at a strategic l...
Customer Information
 Plant is located in Lovell, WY. American Colloid Company
(ACC) is one of the world’s leading produc...
Goals
 Reduce Downtime
 Increase production rates
 Gain visibility into plant operations
 Needed more accurate informa...
Challenges
 Focusing everyone on the right (biggest) issues
 There are four crews running 12 hour shifts.
Communications...
Project Approach
 Implemented small pilot
 Refined pilot to provide for base configuration
 Expanded base configuration...
Pilot
 Stone Technologies and FactoryTalk Metrics were put on
trial to deliver a solution that could improve our reliabil...
Pilot – Root Cause Analysis
AGENDA
Pilot – Production Summary
AGENDA
Pilot – 24 Hour Downtime Summary
AGENDA
Pilot Refinement
 Refined machine states and down time reasons
 Linked data into MSAccess to allow ad hoc analysis by
re...
Expansion
 Expanded data collection to the following:
 3 Mills
 2 Dryers
 3 Screening Systems
 Geosynthetic clay line...
Data Warehousing/Ad Hoc Analysis
 After analyzing data in MSAccess, it was determined what
data was needed at the strateg...
Asset Availability
AGENDA
Availability by Work Cell
 Shows Final compiled data warehouse data
 Packaging data is manual data that was merged into ...
Detailed Events For Selected Bar
AGENDA
Downtime Hours
This chart allows allocation of resources
AGENDA
Downtime Occurrences
Selected the “shock switch” bar and the following details are
displayed.
AGENDA
Production Rate
Actual vs MAC (Maximum Achievable Capacity)
AGENDA
Results
 American Colloid Company realized results
 Focused resources on the correct areas
 78% - 94% Asset Availabilit...
Benefits
 While the project was successfully implemented by Stone, it
is critical to the customer that they not be relian...
Benefits of FactoryTalk Metrics - Customer
 Support is easier if new people are introduced to the project
 TIME – standa...
Lessons Learned
 People cannot accurately estimate what is taking place in a
production environment.
 Prior to implement...
Take Away
 When you are on an effort to improve, if you solve the
wrong problem, you wind up with two problems. The
origi...
Summary
 Goals
 Get new data acquisition solution up and running quickly
and efficiently
 Keep the solution cost effect...
COMPANYOVERVIEW
Stone Technologies
 $15M 2013 revenue
 54 full time employees
 Average 20% year over year
growth for pa...
CONTACTUS
Contact Information
30
Wendy Armel - Principal MES Analyst
warmel@stonetek.com
Office: (972) 395-1627 Cell: (727...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
We care what you think!
 On the mobile app:
1. Locate ses...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
www.rsteched.com
Follow RSTechED on Facebook & Twitter.
Co...
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American Colloid Company: Boost Accuracy and Use of Reliability Data from HMI to C-suites

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Understanding hard data on availability and uptime is a prerequisite to tackling production issues or opportunities. When Amcol International, a company that transforms Bentonite clay into 200+ SKUs, needed to better measure bulk powder continuous processes it turned to FactoryTalk Metrics. Combining highly-accurate time-based data from control systems with manually entered data across locations, the system sends automatic alerts for immediate tactical improvements and trend reports for strategic insight. Easy integration with SAP’s business objects adds analytics for easier decision making.

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American Colloid Company: Boost Accuracy and Use of Reliability Data from HMI to C-suites

  1. 1. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. PUBLIC INFORMATION American Colloid Company: Boost Accuracy and Use of Reliability Data from HMI to C-suite Wendy Armel, Stone Technologies Principal MES Analyst
  2. 2. Agenda  Introductions/Technologies Used  Customer Information  Situation/Goals  Project specifics  Wrap Up/ Q&A AGENDA
  3. 3. Introduction  Wendy Armel – Principal MES Analyst  Audience – How Many…  End Users  Systems Integrators  Rockwell Automation  Distributor  Other  Experience with  FactoryTalk® Metrics  Business Objects AGENDA
  4. 4. What is FactoryTalk Metrics?  OEE and Downtime Tracking  Overall equipment effectiveness (OEE) can provide you with critical insight into how well you are managing your production operations.  Downtime - identify specific causes of inefficiency, including sophisticated methods of analysis that allow you to measure or compare the performance of plants, lines, machines or even individual production teams. AGENDA
  5. 5. What Business Intelligence Tools Were Used and Why?  SAP Business Objects  Provides for ad hoc analysis at a strategic level  Why use SAP Business Objects?  American Colloid Company already uses SAP and owned the BI stack.  Using this product made the data available to a wide audience  The IT Department at American Colloid Company was able to support this solution internally by using a technology they already owned  American Colloid Company needed a way to do strategic level analytics on the data being captured from the FactoryTalk Metrics product AGENDA
  6. 6. Customer Information  Plant is located in Lovell, WY. American Colloid Company (ACC) is one of the world’s leading producers of bentonite clay.  Make products for the following:  oil drilling  consumer products good (cat litter)  Pharmaceutical  taconite steel  Agriculture  industrial applications  Process: bring in crude bentonite, dry and process and load into rail cars and trucks AGENDA
  7. 7. Goals  Reduce Downtime  Increase production rates  Gain visibility into plant operations  Needed more accurate information for strategic and tactical decisions for allocating resources toward continuous improvement.  The goal was to improve efficiency and reduce costs. AGENDA
  8. 8. Challenges  Focusing everyone on the right (biggest) issues  There are four crews running 12 hour shifts. Communications between the crews were difficult to keep updated. Each crew had a different perspective on what the issues were.  Needed to change the culture from using tribal knowledge to using data from an automated collection system - FactoryTalk Metrics  A previously installed automated data collection system was ineffective. The end users were skeptical of another solution.  Integrating manually recorded data from both domestic and international locations. AGENDA
  9. 9. Project Approach  Implemented small pilot  Refined pilot to provide for base configuration  Expanded base configuration  Implemented data warehouse to allow for high level analytics AGENDA
  10. 10. Pilot  Stone Technologies and FactoryTalk Metrics were put on trial to deliver a solution that could improve our reliability.  Implemented on one Mill process line (work cell)  Began receiving automated emails of key reports to become aware of the data.  Root Cause Analysis report – reviewed end of each shift. Reviewed to see if there are indication of unexpected issues.  Production Summary– reviewed daily. Provided information on productivity  Downtime Summary – reviewed daily. Provided insight into downtime. AGENDA
  11. 11. Pilot – Root Cause Analysis AGENDA
  12. 12. Pilot – Production Summary AGENDA
  13. 13. Pilot – 24 Hour Downtime Summary AGENDA
  14. 14. Pilot Refinement  Refined machine states and down time reasons  Linked data into MSAccess to allow ad hoc analysis by reliability team  Refined automatic notifications  Added email notification to key personnel when a downtime reason changed  Determined the only automatically delivered report needed was the Root Cause Analysis report AGENDA
  15. 15. Expansion  Expanded data collection to the following:  3 Mills  2 Dryers  3 Screening Systems  Geosynthetic clay liner AGENDA
  16. 16. Data Warehousing/Ad Hoc Analysis  After analyzing data in MSAccess, it was determined what data was needed at the strategic level  Categorized the machine states and events into buckets that impacted the asset availability  Total hours of downtime  Number of occurrences  Production rate  Corporate IT implemented a data warehouse  Identify the data and define the summarization criteria  Set the automated routine to extract the data to keep data fresh  SAP Business Objects applied for ad hoc analysis AGENDA
  17. 17. Asset Availability AGENDA
  18. 18. Availability by Work Cell  Shows Final compiled data warehouse data  Packaging data is manual data that was merged into the data warehouse AGENDA
  19. 19. Detailed Events For Selected Bar AGENDA
  20. 20. Downtime Hours This chart allows allocation of resources AGENDA
  21. 21. Downtime Occurrences Selected the “shock switch” bar and the following details are displayed. AGENDA
  22. 22. Production Rate Actual vs MAC (Maximum Achievable Capacity) AGENDA
  23. 23. Results  American Colloid Company realized results  Focused resources on the correct areas  78% - 94% Asset Availability  Increased MAC across the plant by 30% AGENDA
  24. 24. Benefits  While the project was successfully implemented by Stone, it is critical to the customer that they not be reliant on Stone for future support  Stone personnel (even ones new to the system) can support the standard configuration  Should the customer ever need it – there are MANY other integrators who can support the standard FactoryTalk Metrics implementation  Not stuck with a single provider as they were with the prior solution AGENDA
  25. 25. Benefits of FactoryTalk Metrics - Customer  Support is easier if new people are introduced to the project  TIME – standard objects shorten implementation time frames significantly  MONEY  Out of box cost  Ongoing support  Integration AGENDA
  26. 26. Lessons Learned  People cannot accurately estimate what is taking place in a production environment.  Prior to implementation – ~60% accuracy  Automated solution - ~95% accuracy (time is 100% accurate)  Having data to support the issues, allows operations, maintenance and quality to focus on the same issue instead of working against one another, solving what they think the problem is.  Interdepartmental communications are more efficient and having the correct data takes the emotion out of decisions. When the teams start to succeed, people are more eager to work together. Success is contagious AGENDA
  27. 27. Take Away  When you are on an effort to improve, if you solve the wrong problem, you wind up with two problems. The original, plus the one you created.  FactoryTalk Metrics provides the data to focus on the right problem AGENDA
  28. 28. Summary  Goals  Get new data acquisition solution up and running quickly and efficiently  Keep the solution cost effective  Approach  Stick to standard configuration as much as possible  Results  Streamlined, repeatable solution that provides valuable data to multiple levels of the organization AGENDA
  29. 29. COMPANYOVERVIEW Stone Technologies  $15M 2013 revenue  54 full time employees  Average 20% year over year growth for past 10 years 29 Stone Technologies, founded in 1996, is a national system integrator providing automation/control, information (MES) and operational consulting solutions. Based in St. Louis, MO with resources in 15 states/ 1 province. Employee Business Satisfied people deliver successful projects and provide long term continuity Stone Technologies long term relationships built on performance, trust, & keeping promises. Average 95% employee retention rate for the last 10 years The technical staff has an average of 22 years of experience Of our top 20 clients (by services revenue) since the inception of the company 15 years ago: 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 We have paid employee bonuses every year since inception Our best revenue generating tool is the successful delivery of projects
  30. 30. CONTACTUS Contact Information 30 Wendy Armel - Principal MES Analyst warmel@stonetek.com Office: (972) 395-1627 Cell: (727) 244-5588
  31. 31. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 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 31 Please take a couple minutes to complete a quick session survey to tell us how we’re doing. 2 3 4 1 Thank you!!
  32. 32. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. www.rsteched.com Follow RSTechED on Facebook & Twitter. Connect with us on LinkedIn. PUBLIC INFORMATION Thank you for attending our session!

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