Scalable Analytics Overview

Copyright © 2017 Rockwell Automation, Inc. All Rights Reserved. 2Rockwell Automation TechED 2017 @ROKTechED #ROKTechED
PUBLIC
IN15 – Scalable Analytics Overview
Data, Intelligent Aggregation, Presentation and Action

Imagine if…
 …you could plug in an appliance that discovered your devices
and alerted you of important health and status information.
 …you could diagnose problems with machines using a cloud-
based service that requires almost zero footprint in the plant.
 …you were notified of predicted system problems before
unplanned downtime or catastrophic failure.
 …your teams were told what to do to maximize performance and
profitability in an interconnected enterprise
 …it all happened without an army of data scientists…

DEVICE
DESCRIPTIVE DIAGNOSTIC PREDICTIVE PRESCRIPTIVE
Am I running ok? Why is this happening? What’s the likely next device
state? When will it occur?
What maintenance
action is required? When?
Is the system
running ok?
Why is Line 1
quality affected?
Will the process
be stable?
How do I adjust to maintain/
improve process stability?
Which plant
performed the best?
Why is Site A throughput
below plan?
Will I meet plan today?
Tomorrow?
How can I change operations
to improve Profitability?
Yield? Quality?
SYSTEMENTERPRISE
Combined Scalable Analytics Landscape

PUBLIC Copyright © 2017 Rockwell Automation, Inc. All Rights Reserved. 6
PREDICTIVE
What Will Happen?
DIAGNOSTIC
Why Did it Happen?
DESCRIPTIVE
What Happened?
PRESCRIPTIVE
What Should I Do?
Edge On-Premise Cloud
Scalable ANALYTICS
APPLICATIONS
Optimization
Orchestration / Presentation
Machine Performance
Device Health
More to Come…

PUBLIC Copyright © 2017 Rockwell Automation, Inc. All Rights Reserved. 7
AUTO DISCOVERY ZERO CONFIG DASHBOARDS ORCHESTRATION & WORKFLOW PEOPLE IN THE IIOT
INFORMATION SOLUTIONS CAPABILITIES – Cloud | On-Premise | Edge
SCALABLE EXECUTION SYSTEMS SCALABLE ANALYTICS MOBILITY & COLLABORATION CONNECTED SERVICES
The Connected Enterprise
Customer Outcomes Faster Time
to Market
Improved Asset
Utilization
$Lower Total Cost
of Ownership
Enterprise
Risk Management
ROCKWELL AUTOMATION IIoT INFRASTRUCTURE – Integrated Architecture™
Enabling the Industrial Internet of Things (IIoT)
MOBILE / DISPLAYSCONTROLLERS MACHINES & EQUIPMENT REMOTE ASSETSINTELLIGENT MOTOR CONTROLSENSORS & ACTUATORS
SMART CONNECTED ASSETS – EtherNet/IP Enabled Network

Evolving Needs… A Machine example
 I want diagnostics data from my operations (drives, controller etc.) discovered automatically and
served as guidance to help prevent downtime
 I have a machine and I want to monitor its performance
 I have machines deployed across the globe and would like to monitor their performance in a
single multitenant view
 I have machines spread across shop floor in different lines and I want to monitor not just
machine performance but line and shop performance as well. And tie them to production orders
 I want to monitor machine data along with other systems like Quality, Production, Inventory etc
in integrated way
 I would like to predict machine maintenance needs to reduce downtime in an interactive way.
 I would like to be able to model the operational process and create a predictable behavior
 I want to not just monitor performance but drive my machine/system performance in a
automated way
 I want all my teams to have frictionless real-time collaboration across

LEVEL 0
LEVEL 1
LEVEL 2
LEVEL 3
LEVEL 4
LEVEL 5
JUST
HISTORIANS
ROCKWELL
SOLUTIONS
BIG DATA
ANALYTICS
VENDORS
Control
Devices
Supervisory
SCADA
Info / MES
Enterprise
Scalable Analytics
- DECISION MAKING at Right Level
AT THE RIGHT TIME, AT THE RIGHT LEVEL.

Scalable Analytics
– FactoryTalk Analytics for Devices
We have hundreds of smart devices spread across our
plant, why can’t we easily discover these devices and
automatically make the diagnostic info available to
our maintenance team? We’re tired of custom
engineered solutions that aren’t repeatable…
I want diagnostics data from my operations
(drives, controller etc.) discovered
automatically and served as guidance to help
prevent downtime
DECREASE
DOWNTIME
REDUCE
MAINTENANCE
AVOID UNPLANNED
OUTAGES
PAIN POINTS: ASK

WHAT DOES IT DO?
Automation Devices
Analytics Appliance
Browser + Mobile Access
•Monitors and improves MTTR (Mean Time to Repair)
•Detects Ethernet/IP devices automatically
•Performs analysis on device data
•If there is any issue with a device, notifies customers
•Learns what devices are important for a specific customer
•Performs system level health & diagnostics to solve hard-to-
discover issues
•New and intuitive ways to interact with analytics

SUPPORTED
 Any Ethernet/IP device responds with a high level diagnostic status
 Our appliance has detailed dashboard driven by “digital driver” for
specific devices
 Allows our smart devices to add extra data
 Allows our appliance to perform more complex analysis
 Example: PowerFlex® 755 has over 80 points of data and then an extra
30 created by our analyzers
 Our most popular families will have coverage (Logix, PowerFlex, Kinetix)
 This is an area for future expansion, both in devices supported, 3rd party
devices supported and customizability for end users
WHAT DEVICES WILL BE

Scalable Analytics
– FactoryTalk Analytics for Machine
I have a machine and I want to monitor its performance
As a OEM, I have machines deployed across the globe and
would like to monitor their performance in a
single multitenant view and provide value add
services to End Users
DECREASE
DOWNTIME
REDUCE
MAINTENANCE
AVOID UNPLANNED
OUTAGES
PAIN POINTS:
We have been struggling to improve
performance on our new filling machines.
As a OEM you need the machine best and I would like
to keep an eye on OEE and ensure it running
at best efficiency
ASK

Data structures
in the Logix Secure transfer of
data to the cloud
Storage and
processing of data
Pre-defined
dashboards
and analysis tools
Easy as 1-2-3-4!

Scalable Analytics
– Performance Management
I have machines spread across shop floor in
different lines and I want to monitor not just
machine performance but line and shop
performance as well and tie them to
production order.
DECREASE
DOWNTIME
REDUCE
MAINTENANCE
AVOID UNPLANNED
OUTAGES
PAIN POINTS:
I want roll up of machine performance to line
and shop and should be able to look in respect to
production orders, etc.
ASK

Performance Management
BUSINESS VALUE
START
Lean & Continuous
Improvement
Preventive
Maintenance
Improved Asset
Utilization
Operational
Excellence
MACHINE EVENT
TRACKING
Equipment state is recorded
at all times for analysis
and troubleshooting
DOWNTIME DATA
COLLECTION
A complete picture into
what was happening when
equipment goes offline
OVERALL EQUIPMENT
EFFECTIVENESS
Understand how effectively
manufacturing assets are
utilized by tracking
availability, performance
and quality
MEAN TIME
BETWEEN FAILURE
Detail on MTBF
makes preventive
maintenance possible
MEAN TIME
TO REPAIR
Make better use of staff
and reduce downtime
by understanding
maintainability of
equipment/systems
DATA COLLECTION
CONFIGURATION
Tag browsing requires no
changes to automation
OPERATOR
CONSOLE
OEE analytics and
event editing & reporting in
one simple user interface
DRIVES
OPERATIONS
EXCELLENCE
Enable lean and continuous
improvement efforts

Line Performance Operator Console
The work instruction is
added to the workflow.
User Configurable events
windows allows operator to
view high priority events
Visualize machine and line state,
Job status and high priority events.

Dashboards and Reports for Analytics
Dashboards and reports provide
overview by machine, line, area.

Scalable Analytics
- FactoryTalk VantagePoint EMI
I want to monitor machine data along with other
systems like Quality, Production, Inventory in an
integrated way
I want self service visualization
I need a common Platform to visualize data from
different applications.
:
CONNECT ORGANIZE VISUALIZE
PAIN POINTS:
I have multiple focused applications across my
plant, its always difficult to get insight from
different applications in integrated way!
ASK

FactoryTalk VantagePoint EMI
Capability Overview
CONNECT
• Premier Integration with
Rockwell Data Sources
• 3rd Party Historians, 3rd Party
Systems via OPC / OPC DA
• Database Connectivity (Oracle
and SQL)
ORGANIZE
• Organize the data in a way that
makes the most sense for your users
• Combine multiple data sources into
one logical unit
• Reuse model content for increased
productivity
VISUALIZE
• Mobile: Mobile First Design Model
Browser and Display Creation
• Ad Hoc / Self Service Tools: Excel,
Trend, XY Plotter
• Enterprise Reporting Tools: SQL
Server Reporting Services and
Sharepoint Web Parts

Logix and Process Solutions
 Automatically ‘discover’ known User-defined Data Type (UDT) structures in Logix
 Pre-defined type packages & dashboards aligning with the PlantPAx process library
Premier Integration with FactoryTalk products
 FactoryTalk Historian SE and ME for
monitoring process parameters
 FactoryTalk Metrics for machine performance and downtime events
 FactoryTalk View SE for embedded reporting
and advanced trending
 FactoryTalk Alarm and Events for alarm reporting
 FactoryTalk EnergyMetrix for correlation of energy data
 FactoryTalk ProductionCentre for Manufacturing Execution Systems (MES)
connectivity
3rd Party Plant Systems Connectivity (Real-time, Historian, Databases)
FactoryTalk VantagePoint EMI
What data sources can I connect to?

The Unified Production Model
Key to standard and reusable reporting solutions!
Physical Model
Connect data sources
Logical Model
Organize for Presentation
Desktop
Mobile

Copyright © 2017 Rockwell Automation, Inc. All Rights Reserved.#connectedenterprise@RAInfoSolutions #IIoT
PREDICTIVE
MAINTENANCE
UTILITY
OPTIMIZATION
PROCESS
INSIGHT
PREDICTIVE
QUALITY
PROCESS
VALIDATION
PRESCRIPTIVE
ASSURANCE
Machine Learning
Descriptive | Diagnostic | Predictive | Prescriptive

…I need to make product every day. I can’t
forecast orders and production if I can’t rely
on critical machines. But when I insist on
reliability my machine availability drops in
half because we are checking and
maintaining incessantly.
I have hundreds of measurements on and
around key equipment, why can’t we drive
maintenance to requirements. Last year when
a machine failed, it needed to be completely
rebuilt. It doesn’t happen often, but its costly
MAINTENANCE AND OPERATIONS COLLABORATION TO:MAINTENANCE OPERATIONS
DECREASE
DOWNTIME
REDUCE
MAINTENANCE
AVOID UNPLANNED
OUTAGES
PAIN POINTS:
Predictive Maintenance

Predictive Maintenance
Machine Learning
1. Import Historian data
2. Import Computerized Maintenance
Mgmt. System (CMMS) or other
asset downtime data
3. Person trains the system overlaying
CMMS downtime markers on
historian (server is where training &
learning happens)
4. Agents are deployed to “listen” for
patterns
Also has concept of retraining
when new patterns are found
5. If prescriptive alert is found, issue
work order
Historian MMS Person
1 2 3
Server
4
Agent
5
Work Orders

…I can’t buy proactively when we don’t know
how much we will consume. If I had insight
into fuel consumption and how much we
would really use, I could get us a great deal.
We centralized utilities to enable flexible
dispatch, which can increase availability and
efficiency. But the benefits were smaller than
expected. Our operators can’t decide what to
run to save on our energy bill.
DRIVE DISPATCH TO CUT ENERGY SPEND:UTILITIES ENERGY BUYER
REDUCE
ENERGY SPEND
SIMPLIFY
COMPLEX DISPATCH
STABILIZE &
PREDICE DEMAND
PAIN POINTS:
ENERGY Optimization

 Easy optimization with & graphical configuration &
model library
 Data reconciliation and scheduled retraining for good
models
 Optimizes dispatch against current & predicted load &
operating limits. Includes library forecast model.
 Tested up to 400 units.
 Auto discovered UDT to set up optimization problem
 Automatically models unit operation using data
 Optimizes current dispatch against current load and
operating limits.
Streaming Optimization Interactive Optimization
Minimize Costs, Maximize Profit
Optimization
What is the best thing to do?

…We live and die by product quality, but I
only get a sampling every four hours. In
between results we are blind. I have an
idea, but don’t think we really know how to
drive quality or giveaway. When that meter
is wrong, we don’t know right away and
make a lot of bad product.
Lab costs are always a challenge. We want a
more proactive way to drive operations, but
struggle to capture all requested results and
don’t have enough time to push quality-based
performance.
OPERATIONS AND LAB COLLABORATION TO:LAB OPERATIONS
INCREASE
PRODUCT QUALITY
IMPROVE
YIELDS AND EFFICIENCY
UNDERSTAND
PLANT INTERACTIONS
PAIN POINTS:
DIGITAL TWIN

 Configured automated modeling
 Show most significant influences
 Adapt online
 Server-based or in chassis
 Engineered flexible modeling
 Powerful data processing
 Visualize trained relationships
 Server-based or Logix-embedded
Virtual Online Analyzer
Sensor Validation, Influences
Streaming Insights Interactive Insights
Digital Twin (Predict)
What will the process be with these inputs?

Predict
Optimize
Classify
Low Deployment & Maintenance Cost – No Data Scientist – Fast Results
Streaming Insights
Digital Twin
Automatic
Install
Identify
Inputs Monitor
Product &
Configuration
Confirm/Improve
& Deliver ValueWhat’s Important

Powerful Models – Leverage Knowledge – Achieve Higher Value
Interactive Insights
Gather Clean Digital Twin Deploy
Batch Data from
SYSTEMS
Data, Time
Outliers & Gaps
Identify Relationships
Learn
Predict
Optimize
Classify
Control

FactoryTalk TeamONE
I want all my teams to have frictionless real-
time collaboration
:
CONNECT VIZUALIZE COLLABORATE
PAIN POINTS:
Friction in real-time communication between
maintenance and operations team,
between quality and production team
TEAM AND MANAGEMENT COLLABORATION TO:MANAGEMENT TEAM MEMBERS

The app for team productivity
 Why? Reduce mean time to repair (MTTR)
 How? Enable every industrial worker to investigate, collaborate and troubleshoot
plant floor issues faster (when they are at work in the plant) instantly with no setup
with very little changes to their infrastructure.
 What? A team based iOS and Android App that integrates worker knowledge and
automation data. An app platform for Rockwell Automation to continue to build
more modular content into and deliver connected enterprise solutions to
customers.

Now you can…
 …get alerts on machines that contain useful information
with minimal effort.
 …simply integrate accessible best practice reporting for
your OEM machines.
 …leverage accurate predictive models of quality,
performance and key measurement reliability.
 …forecast machine failures and steer maintenance to
troubled machines before significant damage occurs.
 …drive operations to efficient performance across parallel
non-trivial decisions without experts struggling to get it right

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Copyright © 2017 Rockwell Automation, Inc. All Rights Reserved. 38Rockwell Automation TechED 2017 @ROKTechED #ROKTechED
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