The document discusses the essential role of historian data in manufacturing operations, highlighting its benefits for troubleshooting and real-time performance monitoring. It emphasizes the need for accurate manufacturing operational management (MOM) information to improve efficiency and decision-making, while also advocating for a structured approach to data utilization. The text illustrates the significant advantages experienced by companies that effectively deploy historian systems for performance gain and operational insights.

1. Learning from History – Unlock your
Performance Potential
Richard Stone
Lean Manufacturing Manager

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. 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. 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. 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. Where does Historian fit in the
scheme?
http://www.wonderware.co.uk/products-and-technology/

7. The shape of the problem

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. The need to deliver Manufacturing
Information
► 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. 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. 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. Delivering MOM Information
Looking around the room …

13. Delivering MOM Information
Looking 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
► Energy
MOM information delivers information that is used as a measurement
and helps maintain sustainability

14. Integrating your Historian
System Information /
Interoperability Real-Time Manufacturing Operations Management Visibility
Devices, 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. 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. Empowering Operators
Daily & 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. Online meetings
Online Production Meeting
Point
• Hourly Short Interval Control
• Operations – Maintenance point
• Driving on time delivery
• Promotes operational collaboration
• Real time management

18. A picture of ?

19. Plant Intelligence

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
InTouch
Single-node
InTouch

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. 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. A Proven Methodology for
Success
► 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. Delivering Success of our customer’s
Goals
► 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. Delivering Success of our customer’s
Goals
► 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. Delivering Success of our customer’s
Goals
• 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. Discovery & ROI

28. Discovery & ROI
Goals
Value
Benefits
SOE

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. 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. See you in 2011?
Breakfast seminars coming to a
location near you.
1. DRIVE Manufacturing
Performance
2. DRIVE Manufacturing
Operations
3. DRIVE the SAP ERP
Connection

32. Powering intelligent plant
decisions in real time.