Alan Stanfill, MES Group Manger

Transcription

1 LINE INTEGRATION - TURNING PLANT FLOOR DATA INTO ACTIONABLE INFORMATION Alan Stanfill, MES Group Manger

2 Agenda Introductions Common Industry Challenges Organizational Data Perspectives Maintenance Operators Management Results Realized Wrap Up / Q&A BACKGROUND

3 Introductions Audience How Many End Users System Integrators Rockwell Automation Other BACKGROUND Experience with RAPID PlantPAx FactoryTalk Historian SE FactoryTalk Metrics

4 Common Industry Challenges Uncovering hidden potential within a manufacturing organization Removing emotion and opinion from the data Using automation and software to simplify and deliver timely information Providing actionable information to multiple levels of an organization Standardizing information gathered across machines, lines, and facilities BACKGROUND

5 Stone Manufacturing Contains two sites: Processing creates bulk liquid material Packaging creates finished goods BACKGROUND - STONE MANUFACTURING DEMO

6 Maintenance Delivering Appropriate Intelligence PERSPECTIVES

7 Background Understands PLC and HMI Programming Measured on machine uptime Needs to improve machine uptime and MTBF / MTTR Challenges Identify top 5 downtime reasons for a specific period of time Determine exactly when my downtime is happening and for how long Notification when my machine is down for longer than 2 minutes Accurately measure MTBF and MTTR MAINTENANCE SUPERVISOR Solutions Verify there are control layer tags to provide automated downtime events High performance HMI Screens to allow operator interaction with pertinent data and reduce reaction time to critical/high priority alarms Smart alarming capability to catch first out alarms enabling personnel to quickly determine what initiated machine shutdown Automatically capture data needed to support challenges

8 Top Downtime Reasons By Asset MAINTENANCE SUPERVISOR OUT OF THE BOX

9 Event Details MAINTENANCE SUPERVISOR OUT OF THE BOX

10 Notifications Based on Rules and Alerts to Specific Personnel MAINTENANCE SUPERVISOR STONE EXTENSION

11 MTBF and MTTR MAINTENANCE SUPERVISOR OUT OF THE BOX

12 Background Understands how to operate the equipment Measured on throughput Initial eyes on Machine faults Challenges Understanding production impact by the different products that are being run Visibility across multiple areas Comparing my shift production with other shifts Determining what the filler is doing Keeping the machine producing sellable product MACHINE OPERATOR Solutions Integrate PackML information into an HMI Screen to provide more visibility into the process Production how is my shift producing vs another shift Utilize Rockwell Automation solutions for HMI, data acquisition and reporting, feedback of relevant KPIs back to the HMI display High Performance HMI to reduce reaction time to critical/high priority alarms

13 Process Area HMI Display Allows Navigation to Packaging Area OPERATOR

14 Ability to View Packaging Information from Process Site Rockwell s RAPID Solution Allows Navigation to Filler Detail (PackML Screen) OPERATOR ROCKWELL RAPID WITH STONE EXTENSIONS

15 Filler HMI Screen Showing PackML State OPERATOR STONE EXTENSION

16 Production of Different Products OPERATOR OUT OF THE BOX

17 Background Focused on increased capacity within the packaging area Charged with ensuring the proper systems are in place to improve plant performance Measured by production achieved Challenges Needs support from maintenance and operations to improve production numbers Cultural adoption of new systems Maximize existing asset capacity Minimize retraining needs Encourage positive interaction between departments MANAGEMENT Solutions to Solve Challenges Educate all levels of the organization to the importance of accurate information Ensure the newly automation system is providing actionable information Determine areas of improvement Revisit production numbers after changes in the process have been implemented Morning huddles with operators/maintenance to focus efforts on current action items

18 Site to Site Comparison MANAGEMENT STONE EXTENSION

19 Shift to Shift Comparison MANAGEMENT STONE EXTENSION

20 Mobile Dashboards Larger Screen MANAGEMENT

21 Mobile Dashboards Phone Screen MANAGEMENT

22 Client Testimonial American Colloid Company Focused resources on the correct areas 78% -> 94% Asset Availability Increase Increased MAC across the plant by 30% People cannot accurately estimate what is taking place in a production environment Typically prior to implementation of automated data collection ~60% accuracy Automated solution - ~95% accuracy (time is 100% accurate) Data to support the issues allows proper focus instead of solving what they think the problem is Having the correct data takes the emotion out of decisions RESULTS

23 QUESTIONS?