WW OPS-05 Improve Production Execution Visibility, Agility & Performance with Wonderware MES

WW OPS-05 Improve Production

Execution Visibility, Agility &

Performance with Wonderware MES

Jeff Nuse

Senior Product Manager – MES Jeff Barkehanai

Product Manager – MES Quality

@InvensysOpsMgmt / #SoftwareRevolution

/Wonderware /InvensysVideos

social.invensys.com

© 2013 Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are proprietary marks of Invensys or its subsidiaries. All third party trademarks and service marks are the proprietary marks of their respective owners.

Jeff Nuse

Senior Product Manager – MES Jeff Barkehanai

Product Manager – MES Quality

/Wonderware

World-Class Manufacturing & Production

What’s the Journey??

Organization Design

 Align their organization to satisfy the needs and wants of

its customers in an effective, timely manner

 Eliminate organizational barriers to communication

Performance Measurement

 Recognize the importance of measurement in defining the

goals and performance expectations of their organization

 Relentless commitment to continuous improvement,

which cannot be achieved without measurement

Organization Design

 Align their organization to satisfy the needs and wants of

its customers in an effective, timely manner

 Eliminate organizational barriers to communication

Performance Measurement

 Recognize the importance of measurement in defining the

goals and performance expectations of their organization

 Relentless commitment to continuous improvement,

World-Class Manufacturing & Production

What’s the Journey??

Information Systems

 Leverage world-class information systems for collecting,

processing and disseminating data

Operations Capabilities

 Capable of producing the right quantity, the right quality,

at the right time, and at the right price

 Highly available production assets

Quality

 All quality costs (prevention costs, cost of defects, etc.) are

evaluated and held to the lowest reasonable sum

 “Zero defects” is the goal

Slide 4

Information Systems

 Leverage world-class information systems for collecting,

processing and disseminating data

Operations Capabilities

 Capable of producing the right quantity, the right quality,

at the right time, and at the right price

 Highly available production assets

Quality

 All quality costs (prevention costs, cost of defects, etc.) are

evaluated and held to the lowest reasonable sum

The Supply Chain…

Let’s Explore How Wonderware Production and Performance Offerings Enable Organizations to Achieve and Maintain

Wonderware’s Operational Management

Approach

_{Enabling the Journey to Operational}

Excellence Series of Functional Programs • Asset, Safety, Env, Productivity, People • Enable Horizontal Value Scenarios

• Across our Industrial Capability • Acceleration to Result Slide 6 • Foundation of Capability for Solutions • Enabling Sustainability • Enabling Evolution on Journey

Invensys’s Operational Management

In Context with the Supply Chain & Automation

ERP PLM EAM SCM L e v e l 3 M a n u fa c tu rin g E x e c u tio n S y s te m L e v e l 4 Bu s in e s s P la n n in g & L o g is tic s Production & Performance Applications

Wonderware Enterprise Integrator (WEI)

A ppl ic a ti on & R e port ing C li e nt s & 2 _ol L e v e l 3 M a n u fa c tu rin g E x e c u tio n S y s te m Production & Performance Applications

Wonderware MES Software

• Full MES Functionality according to MES/MOM

standards

– Operations (incl. Inventory) and Quality operations & Performance Management

– Enables step by step functional implementations

• Sustainable Standard Software

– Highly configurable

– Flexible, consistent enhancements in scope and size

• Integration with Customer processes

– Superior shop floor integration and execution

– Standardization support and reusability

– Enterprise Integration

Wonderware MES Software

Operations

Slide 8

• Full MES Functionality according to MES/MOM standards

– Operations (incl. Inventory) and Quality operations & Performance Management

– Enables step by step functional implementations

• Sustainable Standard Software

– Highly configurable

– Flexible, consistent enhancements in scope and size

• Integration with Customer processes

– Superior shop floor integration and execution

– Standardization support and reusability

– Enterprise Integration

Performance Operations

Wonderware

Operations

Improves Production Execution Consistency, Visibility, and Agility

Wonderware MES Operations

Overview

Business Value

• Foundation for Agile Production Processes

• Improve Production Consistency

• Empower Supply Chain Applications

• Enforce Compliance & Governance

Key Capabilities

• Open, Modular, Scalable, Extensible

• Full-Featured MES Capability – “Dock-to-Dock”

• Real-Time Visibility to Production Activities

• Comprehensive Manufacturing Genealogy

Slide 10

Business Value

• Foundation for Agile Production Processes

• Improve Production Consistency

• Empower Supply Chain Applications

• Enforce Compliance & Governance

Key Capabilities

• Open, Modular, Scalable, Extensible

• Full-Featured MES Capability – “Dock-to-Dock”

• Real-Time Visibility to Production Activities

Wonderware MES Operations

Features

Product Definition

Order Management

WIP & Inventory Management

Step Execution

Setpoint Management

Work Instructions

Product Definition



Import Product Definitions from External Applications



Configure Multiple BOMs (e.g. versioned) for each Finished or Semi Finished Material



Define Multi-Level BOMs



Define Multiple Substitute Materials for each BOM Item



Attach Work Instructions to Materials

Order Management



Create Work Orders Manually or Import from an External Application (e.g. ERP)



Attach Routing Instructions, BOMs, BORs, Setpoints, SOPs, and Data Collection Requirements to a Work Order



Capture Work Order Events (e.g. Status Change, Production, Consumption) at each Operation on a Process Route



Sequence Work Orders Manually or through a Finite Capacity Scheduling (FCS) Application

WIP & Inventory Management



Define a Hierarchy of Storage/Stock Locations to Track Materials – Fixed or Moveable



Track Materials as Bulk and/or Lot Based



Assign Configurable “Grades” and “States” to all Materials



Calculate and Enforce Expiry Dates



Capture Complete Genealogy Trail of all WIP and Inventory Activities

Step Execution



Configure Steps (or Tasks) for each Operation within a Route



Configure and Enforce Step Execution Order



Attached Work Instructions to a Step



Assign BOM Items to a Step



Assign Machine and BOM Setpoints to a Step



Configure Step Activity (e.g. Collect Data, Consume Material)

Setpoint Management

.



_{Define Values (e.g. Min., Max., Nominal), Instructions,}

Comments and Work Instructions for each Setpoint



Associate Setpoints with a Particular Work Center/Machine, a Material or a Procedural Step



Download Setpoints to Automation Devices

Work Instructions



Define Electronic Folders with Associated Documents and Work Instructions (Multiple Versions)

 View Many Different Document Types (e.g. PDF, Microsoft

Documents, Web Pages, etc.)

 Link Work Instructions and Documents to Products, Work

Orders, Operations, Work Centers or Procedural Steps

Product Definition

Order Management

WIP & Inventory Management

Step Execution

Setpoint Management

Work Instructions

Product Definition



Import Product Definitions from External Applications



Configure Multiple BOMs (e.g. versioned) for each Finished or Semi Finished Material



Define Multi-Level BOMs



Define Multiple Substitute Materials for each BOM Item



Attach Work Instructions to Materials

Order Management



Create Work Orders Manually or Import from an External Application (e.g. ERP)



Attach Routing Instructions, BOMs, BORs, Setpoints, SOPs, and Data Collection Requirements to a Work Order



Capture Work Order Events (e.g. Status Change, Production, Consumption) at each Operation on a Process Route



Sequence Work Orders Manually or through a Finite Capacity Scheduling (FCS) Application

WIP & Inventory Management



Define a Hierarchy of Storage/Stock Locations to Track Materials – Fixed or Moveable



Track Materials as Bulk and/or Lot Based



Assign Configurable “Grades” and “States” to all Materials



Calculate and Enforce Expiry Dates



Capture Complete Genealogy Trail of all WIP and Inventory Activities

Step Execution



Configure Steps (or Tasks) for each Operation within a Route



Configure and Enforce Step Execution Order



Attached Work Instructions to a Step



Assign BOM Items to a Step



Assign Machine and BOM Setpoints to a Step



Configure Step Activity (e.g. Collect Data, Consume Material)

Setpoint Management

.



_{Define Values (e.g. Min., Max., Nominal), Instructions,}

Comments and Work Instructions for each Setpoint



Associate Setpoints with a Particular Work Center/Machine, a Material or a Procedural Step



Download Setpoints to Automation Devices

Work Instructions



Define Electronic Folders with Associated Documents and Work Instructions (Multiple Versions)

 View Many Different Document Types (e.g. PDF, Microsoft

Documents, Web Pages, etc.)

 Link Work Instructions and Documents to Products, Work

Wonderware MES Operations

Seamless Integration to Automation

Operations Capability Object (OCO)

Supports the following automated transactions:

 Create & execute jobs/orders

 Record production & consumption

 Create & transfer inventory

 Load specifications

 Record production events

Slide 12

© Invensys 23 October 2013

Supports the following automated transactions:

 Create & execute jobs/orders

 Record production & consumption

 Create & transfer inventory

 Load specifications

Wonderware

Performance

Improves Asset Utilization, Increases Capacity

Business Value

• Improve Asset Utilization (OEE)

• Reduces Capital Expenditures

• Increases the Capacity of Existing Assets

• Empowers Operators

Key Capabilities

• Detect, Capture & View Utilization Events

• Manual & Automated Data Collection

• Real-Time Visibility to Production Performance

• Bottleneck and Root-Cause Analysis

Wonderware MES Performance

Overview

Slide 14

Business Value

• Improve Asset Utilization (OEE)

• Reduces Capital Expenditures

• Increases the Capacity of Existing Assets

• Empowers Operators

Key Capabilities

• Detect, Capture & View Utilization Events

• Manual & Automated Data Collection

• Real-Time Visibility to Production Performance

Equipment Utilization

Equipment Performance

Production Progress

Wonderware MES Performance

Features

Equipment Utilization

 _{Detect and Capture Utilization Events}  View Equipment Events

 _{Monitor and Record Equipment State}

 _{Automatically or Manually Assign Reason Codes}

Equipment Performance

 _{Calculate OEE for Equipment / Line}  Trigger Events and Display

 _{Analyze Event Frequency and Duration}  _{Assign What States Affect OEE Calculation}

Production Progress

 _{Provide a Clear Indication of Work Order Progress to the}

Operator in Real-Time

 _{Calculate OEE and Other Custom KPIs}

 Estimate Expected Completion Date and Time

Equipment Utilization

Equipment Performance

Production Progress

Equipment Utilization

 _{Detect and Capture Utilization Events}  View Equipment Events

 _{Monitor and Record Equipment State}

 _{Automatically or Manually Assign Reason Codes}

Equipment Performance

 _{Calculate OEE for Equipment / Line}  Trigger Events and Display

 _{Analyze Event Frequency and Duration}  _{Assign What States Affect OEE Calculation}

Production Progress

 _{Provide a Clear Indication of Work Order Progress to the}

Operator in Real-Time

 _{Calculate OEE and Other Custom KPIs}

Wonderware MES Performance

Seamless Integration to Automation

Utilization Capability Object (UCO)

Provides the following capability:

 Configure utilization events to collect for each asset

 Automatically captures event data (start/stop time, etc.)

 Automatically collects

production performance data

Slide 16

© Invensys 23 October 2013

Provides the following capability:

 Configure utilization events to collect for each asset

 Automatically captures event data (start/stop time, etc.)

 Automatically collects

Wonderware

Quality

Improves Product Quality and Consistency Through Real-Time SPC and Analysis

Business Value

• Improve Quality and Consistency, Reduce Process Variation

• Identify, Correct Deviations in Real-Time

• Meet Regulatory, Customer Compliance

Key Capabilities

• SPC Alarms, Alerting and Charts

• Integrated Specification Management

• Sample Plan Definition and Execution

Wonderware Quality

Overview

6

6σ

σ

Slide 18 Business Value

• Improve Quality and Consistency, Reduce Process Variation

• Identify, Correct Deviations in Real-Time

• Meet Regulatory, Customer Compliance

Key Capabilities

• SPC Alarms, Alerting and Charts

• Integrated Specification Management

Wonderware Quality

Features

Specification Management

Sample Plan Definition Mgt.

Sample Plan Execution Mgt.

Statistical Process Control

(SPC)

Specification Management

 _{Import Specifications from an External Source (ERP/PLM)}  Define Product and Process Specifications in the Context of

Materials, Equipment, and Operations

 _{Define and Attach Characteristics (Variable & Attribute)}  _{Define Specification Overrides}

Sample Plan Definition Management

 _{Import the Sample Plan from an External Source (ERP/PLM)}  Configure “What” Characteristics to Collect

 Configure “When” the Characteristics Should be Collected  _{Select from Multiple Frequency Types: Time, Qty, Event, etc.}  _{Attach Multiple Frequency Types to a Sample Plan}

Sample Plan Execution Management

 _{Sample Collection Notification}

 View Sample Details & Recorded Data  _{Additional Sample Request Generation}  _{Manual or Automatic Sample Collection}

Statistical Process Control (SPC)

 _{Standard Run Rule Selection}

 _{SPC Charts – XBar Range and Sigma, Moving Average, X}

Individual, p/np/c/u/DPMO

 _{Feedback of Control Rule Violations}

 Additional Operator Data Collection (e.g. Comments)

Specification Management

Sample Plan Definition Mgt.

Sample Plan Execution Mgt.

Statistical Process Control

(SPC)

Specification Management

 _{Import Specifications from an External Source (ERP/PLM)}  Define Product and Process Specifications in the Context of

Materials, Equipment, and Operations

 _{Define and Attach Characteristics (Variable & Attribute)}  _{Define Specification Overrides}

Sample Plan Definition Management

 _{Import the Sample Plan from an External Source (ERP/PLM)}  Configure “What” Characteristics to Collect

 Configure “When” the Characteristics Should be Collected  _{Select from Multiple Frequency Types: Time, Qty, Event, etc.}  _{Attach Multiple Frequency Types to a Sample Plan}

Sample Plan Execution Management

 _{Sample Collection Notification}

 View Sample Details & Recorded Data  _{Additional Sample Request Generation}  _{Manual or Automatic Sample Collection}

Statistical Process Control (SPC)

 _{Standard Run Rule Selection}

 _{SPC Charts – XBar Range and Sigma, Moving Average, X}

Individual, p/np/c/u/DPMO

 _{Feedback of Control Rule Violations}

Wonderware MES Product Roadmap

Performance 2014

© 2013 Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are proprietary marks of Invensys or its subsidiaries. All third party trademarks and service marks are the proprietary marks of their respective owners.

Wonderware Performance 2014

• New Line Management functionality

– Bottlenecks

– Parallel Entities

• New Web Client

– Configuration

•Line Management

•Entity Standards / Configuration

– Runtime Production Operations

– Historical Utilization and Production Information

• New Line Management functionality

– Bottlenecks

– Parallel Entities

• New Web Client

– Configuration

•Line Management

•Entity Standards / Configuration

– Runtime Production Operations

Line Functionality

The “Line”

• Has a Utilization Reason

– Set manually / automatically at the Line level or set based on Reason from child entities in the Line

• Has Current Job(s)

– Multiple Work Orders, Item, “Operation” for the Line, Quantities

– Production Counters (Good / Reject) – for ERP reporting

– Performance Counters – for “performance”

– KPI’s of the same type as the individual Entities in the Line

Slide 22

• Has a Utilization Reason

– Set manually / automatically at the Line level or set based on Reason from child entities in the Line

• Has Current Job(s)

– Multiple Work Orders, Item, “Operation” for the Line, Quantities

– Production Counters (Good / Reject) – for ERP reporting

– Performance Counters – for “performance”

Line Functionality

Parallel Entities as Bottleneck

• The Bottleneck in a Line is the Entity with the slowest Production Rate. The rate of the Bottleneck Entity or Segment in a Line

determines the production rate of the Line.

• If Parallel Entities are the Bottleneck, then the production rate of the Line is the sum of the rates of the Entities making up the Bottleneck.

• The Bottleneck in a Line is the Entity with the slowest Production Rate. The rate of the Bottleneck Entity or Segment in a Line

determines the production rate of the Line.

• If Parallel Entities are the Bottleneck, then the production rate of the Line is the sum of the rates of the Entities making up the Bottleneck.

MES Performance 2014

Utilization Capability Object (UCO)

• Performance / Utilization / OEE / Utilization Object (UCO)

– OEE Calculations exposed in the UCO

– Imports / Export of Configuration into UCO

– Simplification of “Performance” for easy deployment

– High Speed Status changes

MES Operations 2014

Operations Objects

• Operations Object (OCO)

– High Speed transactions

– Split off Specifications from the OCO – new Specifications Object SCO

Wonderware MES Roadmap

MES 2014 Operations Q1 2015 MES 2014 Performance Q1/Q2 2014 Slide 26 CY2014 MES 2014 Operations CY2013

! Dates are for guidance only and will change

Wonderware MES Product Roadmap

Cause and Cause Group Definition

MES Client Configuration - Categories

Add ability for

Categories to contain cause groups and characteristics Used to limit list of assignable causes shown in an SPC Chart Add ability for Categories to contain cause groups and characteristics Used to limit list of assignable causes shown in an SPC Chart

SPC Chart to Add Cause

SPC Chart Control Enhancements

• Enable/Disable Display statistics on the chart

–Individual values, mean, and range

–Cp / Cpk / Pp / Ppk

• Populate Header Fields and options of what to show (none, minimal, most, all)

–Characteristic / Chart type / Item (Minimal)

–Item Description / Operation / Entity (Most)

–Operator / Test Equipment (Most)

–Specification Limits / Unit of Measures (All)

• Right Click Option

–Assign / Unassign Cause to a Point

–Mark a Sample as Ignored

–Mark a Sample as Control Move

–Comments / Notes Management

• Enable/Disable Display statistics on the chart

–Individual values, mean, and range

–Cp / Cpk / Pp / Ppk

• Populate Header Fields and options of what to show (none, minimal, most, all)

–Characteristic / Chart type / Item (Minimal)

–Item Description / Operation / Entity (Most)

–Operator / Test Equipment (Most)

–Specification Limits / Unit of Measures (All)

• Right Click Option

–Assign / Unassign Cause to a Point

–Mark a Sample as Ignored

–Mark a Sample as Control Move

Sample Frequency Definition Added

• New Frequency Type - Production Unit Count

–Generate new sample after X units of production have been reported

–Will predict into the future based on job/entity standard production rate

–Production count reset options on job change, main item change, shift change, or never

• New Frequency Type - Production Unit Count

–Generate new sample after X units of production have been reported

–Will predict into the future based on job/entity standard production rate

–Production count reset options on job change, main item change, shift change, or never

Additional MES Quality Items

• Automatic Calculation of Control Rules to include

– Number of samples to use

– How many samples must exist before calculating limits

• Archive / Restore

– Quality data from the Sample table and dependent tables

• Sample Plan can be marked as requiring verification of the user

– User must reenter password when saving manual data

• System Parameters for setting maximum number of samples or time period when calculating process statistics

• Sample Recording Object trigger command for creating a new sample

• Evaluation of Control Rule Violations for Attribute Characteristics

– Includes p, np, c, u, and DPMO chart evaluation of rule violations

• Sample Viewer Control Improvements

– Configurable Refresh Rate

– Added Priority and Severity to grids

– Next / Previous button in Results Editor

Slide 34

• Automatic Calculation of Control Rules to include

– Number of samples to use

– How many samples must exist before calculating limits

• Archive / Restore

– Quality data from the Sample table and dependent tables

• Sample Plan can be marked as requiring verification of the user

– User must reenter password when saving manual data

• System Parameters for setting maximum number of samples or time period when calculating process statistics

• Sample Recording Object trigger command for creating a new sample

• Evaluation of Control Rule Violations for Attribute Characteristics

– Includes p, np, c, u, and DPMO chart evaluation of rule violations

• Sample Viewer Control Improvements

– Configurable Refresh Rate

– Added Priority and Severity to grids

Wonderware MES Quality Management

Roadmap

MES Quality Management Release (MES 2012 v4.5) September 2012 QI Analyst V 8.0 SP3 Nov 2013 QIA to MES QM Migration 2015 WW MES QM MES 2012 P1 March 2013 CY2014 CY2012 QIA to MES QM Migration CY2013 WW MES 2014 Q2 2014 WW MES QM MES 2012 P1 CY2015