Post on 11-Mar-2018
YNY TECHNOLOGY
Solutions TowardsOperational Excellence
CONTENTMANUFACTURING OPERATIONS MANAGEMENT (MOM)
ENTERPRISE ASSET MANAGEMENT (EAM)
CONDITION MONITORING
AVANTIS CMMS MOBILITY SUITE
MANUFACTURING EXECUTION SYSTEMS (MES)
HOW EFFICIENT DO YOU THINK YOUR PLANT IS?
OPERATIONS & PERFORMANCE OPTIMIZATIONOPTIMIZE YOUR POWER NETWORK WITH DATA-DRIVEN DECISIONS
BUSINESS PROCESS MANAGEMENT (BPM)
KEY INFOGRAPHICS: INDUSTRIAL BENCHMARK
ARTESIS MOTOR CONDITION MONITORING (MCM)
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When this solid foundation is established, the organization is well positioned to progress through a path of continuous improvement towards the
goal of operational excellence.
Recognizing these facts, YNY Technology follows a proven solution delivery methodology which facilitates system implementation in conjunction
with complementary improvements to business processes and organization, while transferring system knowledge and ownership to the user
community. The proven solution delivery methodology is the foundation to our consultancy expertise in helping our clients to identify the right
opportunity for improvement as well as implementing the right solutions to align to their business goals. This proven methodology consist of:
1. Structured consulting engagements to:- Understand project objectives from client perspective
- Work with client to uncover opportunities
- Identify & document other hidden value and ROI
- Justify implementation projects
- Co-define our client’s operation and performance optimization
strategies to reduce downtime and increase production
2. Highly experienced, multifunctional teams- Providing depth, breadth, capability, experience
- Holistic approach to propose a solution via integration
from plant floor to enterprise level
3. Proven approach whose goal is to deliver value- Identify initiatives with fastest ROI and highest impact
- Share responsibility to determine client’s success
- Support continuous improvement
OPERATIONAL EXCELLENCE
EXPERIENCE
TECHNOLOGY
SKILL
SOLUTIONS TOWARD OPERATIONAL EXCELLENCECONSULTANCY EXPERTISEAt YNY Technology, we understand that the path to improving asset effectiveness and productivity must be based on a
firm foundation created from the interaction of three essential elements:
Sound business practices and procedures
Empowered and skilled employees supported by the appropriate training, organization, and culture
A well-deployed system from plant floor all the way up to the enterprise level
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ABOUT USYNY Technology Sdn Bhd is a technology services company involved in business consulting and systems implementation. We partner exclusively with a market-leading technology company that design and supply advanced technologies to optimize the operational performance and profitability of industrial and commercial customers. We combine consulting, technology and business process expertise to help our customers co-define their operation and performance optimization strategies, ultimately reducing downtime and increasing production with turnkey solutions.
We provide and integrate solutions such as Manufacturing Execution Systems (MES), SCADA, Enterprise Asset Management (EAM) and Motor Conditioning Monitoring (MCM). As a part of a leading system integrator in Process Control Instrumentation, SCADA and Telemetry System, we aim to leverage on the vast experience in industrial automation to move organization to the next level using the operational performance optimization tools to achieve best-in-class performance and operation excellence.
MANUFACTURING OPERATIONS MANAGEMENT (MOM)YNY provides solutions and expertise in the Manufacturing Operations Management (MOM) level to help achieve an
organization achieve its major goals, which are to: Replicate improvement across plants and integrate intelligence
from the shop floor to the top floor, maximizing efficiency and quality across production operations. This in turn leads
to increase in profitability and cost reduction.
Together with our partners, we bring organizations a world-class MOM that enables them to standardize and optimize
manufacturing processes, minimize lead-times, optimize asset utilization, reduce global Time-to-Market improves
response time and increase production visibility.
ERP, APO, APS, CRM
PLM, PLANT/ PROCESS
DESIGN EH&S, BRM
BI, DW, SCM, EQMS
Business Application
LEVEL 2, 1, 0 Industrial Automation
PLC/PAC Safety
Motion DCSAutomation Applications
LEVEL 3 Manufacturing Operation Management
MES (Manufacturing Excution Systems)
• Operation: Track & Trace
• Performance: OEE & Downtime
• Quality Management
• Performance with Energy Management (OEE+E)
Asset Performance Management
• Maintenance/ Inventory/ Procurement
• Workforce Optimization/ Scheduling
• Mobility Solution
• Web Inventory and Barcoding
Motor Conditioning Monitoring
(Perdictive Maintenance)
Energy Management & Power Quality
MOM Applications
LEVEL 4 Enterprise / Business Operations
An enterprise level solution that accommodates multiple businesses or sites in a single solutionEnsures labor, material, tools, drawings, subcontractor requirements and safety information can be
Preventive maintenance function helps users proactively manage and plan maintenanceHelps minimize inventory costs, ensure spare part availability and provides extensive analysis capabilitiesAutomates requisitions, purchase orders and quotations with contract and invoice matching
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Avantis® Enterprise Asset Management
Performance Management (APM) solution set. APM will help you deliver outstanding return from all your assets —people, processes and equipment, thereby enabling true Asset Excellence.
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Proactively monitor your assets –
Avantis.PRO to take account of current operating conditions, and respond to warnings and alarms raised by monitoring systems in the production environment.
Longer Equipment Life - No more unplanned repair costs. Avantis builds a detailed history of equipment information based on day to day maintenance activities.
Less Downtime - Be alerted before parts are needed for machine breakdown. No more waiting for spare parts and labor
Integration with ERP - Integration with the inventory and procurement functions of your ERP or Avantis.PRO ensures material availability, improved productivity of maintenance
complete costing of all activities.
Discover Web and Mobility - A web-enabled and mobile CMMS provides on-demand information right
inventory stock level, PO statuses right from your web browser, mobile or desktop.
Increased Productivity -
Know what, when and where it is needed. A holistic view of all maintenance jobs to ensure timely completion.
ENTERPRISE ASSET MANAGEMENT (EAM)
AVANTIS – YOUR PATH TO ASSET PERFORMANCE AND RELIABILITYThe path to asset performance and reliability excellence can be viewed as a journey through multiple platforms of maturity and growth. The diagram on the left describes the four distinct levels:
CONTINUOUS IMPROVEMENT
COLLABORATIVE
PROACTIVE
FUNDAMENTAL
Condition Monitoring
Alignment of Business Processes with best Practice
Avantis Implementation
Organization Leadership & Skills Management
Preventive Predictive
Measures & Benchmarks
Analysis & Tactical Planning
Reliability Centered
Maintenance
Total Productive Maintenance
Avantis Path to Asset Performance and Reliability
Fundamental Levelestablishes the foundation on which successive levels are built on
Proactive Level
necessary to take control
Collaborative Levelfocuses on and unleashes the creativity of the organization to open new doors
Continuous Improvement Levelnourished by leadership and support
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Rules Engine
Optimize
Avantis Condition Manager
ConfigurationEngine
CONDITION MONITORING
Avantis® Condition Manager is an intelligent real-time condition management solution that collects and analyzes real-time diagnostics (vibrations, temperatures, density etc.)
from all plant production assets. By using this information intelligently, customers will be able to drive appropriate action that will lead to early
failure detection to increase asset availability, reduce costs and avoid unnecessary maintenance and downtime.
It also provides operations, engineering, and maintenance with easy access to current asset information for better decision making to help
optimize asset contribution over its full lifecycle. Avantis® CM can be integrated along with any SCADA system with Historian to many CMMS or
ERP systems that are commercially available.
ENTERPRISE ASSET MANAGEMENT (EAM)
Inventory ManagementMobile Inventory
Web Inventory
Inventory Catalog
Storeroom Management
Cycle Count
Issues and Returns
Receiving
JIT Replenishment
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Condition Management (CM)
Plant Floor Information
ERP or Financial
Systems Maintenance Management
Asset Information, Entity Hierarchy
Physical Equipment, Logical,
Land & Facilities, Infrastructure
Preventive and Condition
Based Maintenance
Work Management
Maintenance Scheduling
and Assignment
Time Entry
Mobile Solutions -
Work Management, RTM,
Operator Rounds
Contractor Management
KPI Reporting
Workflow
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ProcurementPurchase Catalog
Vendor Records
Requests
Purchase Requisitions
Purchase Orders
Contract Management
RFQs
Invoice
B2B Solutions
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Avantis. PRO Enterprise Asset Management
Collect ActAnalyze
Industrial Rapid Implementation Methodology (InRIM): Avantis EAM is implemented via a structured, multi-component methodology that uses
field proven best practices. This ensures a low-risk initial implementation of the Avantis
solution without compromising the ongoing evolution and continued growth of the
applications in use
InRIM provides the client organization with additional business process and organizational
features that make business benefits a reality. While the core of the InRIM approach that
includes the preformatted database remains consistent, the activities are broadened
based on client-specific applications of Best Practice principles.Achieving these criteria everytime
ON B
ud
get
Time Exp
ec
tatio
n
Mobile MaintenanceMobility for asset management applies to maintenance and field service workers whose daily
workflow involves going to the equipment’s location to perform their assignments. Mobility
solutions provide bidirectional data exchange, including information display, data entry,
automated data collection, and access to documentation for work orders while the technician
is located at the asset. This assures automated error checking and improves both data integrity
and compliance. There are 2 mobile maintenance applications in the Asset Performance
Management portfolio:
Avantis Mobile MaintenanceComplete maintenance activities from Avantis.PRO core modules anywhere, anytime. No more manual
forms and data entry. Key highlights:
Completed activities and readings are wirelessly synchronized to Avantis.
Record time cards and capture RCM related details.
Parts requests from the PDA
GIS features to pin point the location of work and view activities on a map.
Record ad hoc statistics readings directly into the handheld
Planners can add material and labor requirements, link work requests to work tasks, add activity lists
to tasks, create new tasks while in the plant looking at the equipment with the problem
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Wonderware IntelaTracThe industry-leading mobile workforce and decision support system. IntelaTrac includes configurable
software and ruggedized mobile hardware solutions that enable workflow, data collection, and general
task management for plant operations, maintenance management, production tracking, and compliance
applications. IntelaTrac is platform-independent, enabling it to work with a variety of EAM, inspection, and
process control systems.
Avantis Mobile Maintenance Home screen
WonderwareIntelatrac
AVANTIS CMMS MOBILITY SUITE
Links your Factory Floor Historian (SCADA) to Avantis.PRO CMMS.
CSG.PRO links to the Historian using a standard or historian specific OLEDB
Specify tags or readings of equipment
Information about what readings to collect can be input to Avantis
electronically using DataPilot.
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Avantis.CSG (Control Systems Gateway)
Adding attachments on the go
Record Activity lists and Task
Enter Time cards
Parts requests from handheld
GIS features to pin point the location of work (outside)
Safety procedures at your finger tips
Record ad hoc statistics readings on the go
Planners can add material and labor requirements to maintenance engineers
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Avantis Mobility App (iOS & Android)
Easy access to maintenance activities through Touch Screen interface
Involve the plant operators in the maintenance process
Operators can see the status of their requests
Operators can create emergency work orders and request parts, record time
and close work
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Avantis OIT (Operator Interface Terminal)
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MANUFACTURING EXECUTION SYSTEMS (MES)Manufacturing Execution Systems (MES) are a software-based approach that gives manufacturers complete plant visibility and control to effectively manage manufacturing and quality operations and ensure product safety compliance.
The MES software system gathers in-process data, such as yields, throughput, equipment efficiencies, material consumption and product quality. It also provides functionality, such as inventory management, work order/ Bill of Material management, real-time reporting, and analysis, for a full view into operational efficiencies.
Wonderware MES Software provides a configurable, and highly scalable, Manufacturing Execution System in three functional modules:
OperationsPerformanceQuality
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MES Components of functionalities
Group Name
Unplanned Downtime
Production
Unknown Stoppage
Reason Name
Break Timw Exceeded
Change Foil Time Exceeded
Meal Time Exceeded
Shift Waiting Time Exceeded
Emergency Stop
Material Shortage
Process Warm Up
Top 10 Downtime Durations by Reason Group
0.7
0 20 40 60
Unplanned Downtime
% Downtime (0 to 100)
Rea
son
Gro
up
s
Production 3.3
Unknown Stoppage
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4
1
1
1
1
2
2
5
3
2
Occurences
9.9
5.9
1.5
0.3
3.6
0.5
3.3
3.3
0.7
0.4
0.3
Durantion(mins)
59.1
14.6
2.9
36.5
5.1
33.5
33.5
7.4
4.4
3.0
% Total Duration
5.9
Operations Performance Quality Common
Certifications
Labor Management
Procedure Steps
Data Collection
Inventory
Product Specifications/Parameters
Bill of Materials
Product Events Tracking
Work Order Execution
Quality Specifications
Sample Plan Definition
Sample Plan Execution
Statiscal Process Control (SPC)
Equipment Utilization & Downtime
Overall Equipment Effectiveness (OEE)
HOW EFFICIENT DO YOU THINK YOUR PLANT IS?
What is OEE?Overall Equipment
Effectiveness
“A measure of how healthy your production process is relative to your
planned production schedule”
WonderwareMES
MES Performance – OEE & Downtime
Planned Down�me
AVAILABILITY1
2
3
4
5
6
Breakdowns
Setup / adjustment
Idling / minor stoppages
Speed
Defects in process and rework
Start up losses
EQUIPMENT SIX BIG LOSSES
Total Available time
Available time
Available operating time
Actual operating time
Effective operating time
OEE & 6-BIG LOSSES
OEE FACTOR
PERFORMANCE
QUALITY
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OPERATIONS & PERFORMANCE OPTIMIZATION
StruxureWare Power Monitoring is an operations-level supervisory software that provides a complete power management solution for
industry, large commercial and institutional buildings, data centers, healhcare facilities, and utilities. StruxureWare Power Monitoring Expert
enables you to maximize operational efficiency, optimize your power distribution system, and improve your bottom-line performance.
Real-time monitoring, alarming, and power quality analysis helps you avoid critical conditions that can cause equipment failures and
downtime. Track consumption and the cost of power, gas, and other resources, and allocate costs by building, department, or process.
The software helps you uncover energy waste, unused system capacity, and shows new ways to extend equipment perfomance and life
span. Plus, cuttingedge flexibility let you extend your power management system at your own pace, and allows for an open system with
the integration of third-party devices and systems. Save thousands of engineering hours with ready-to-use device drivers, preconfigured
tables, views, and reports dedicated to power and energy management.
OEE is a well understood metric that can assist in the optimization of production processes (availability, performance and quality).
However, this tested formula lacks an energy efficiency component. By considering energy, in addition to OEE, the effectiveness
of your assets can be maximized.
Enabling Energy Management in the Production Environment
Rubber Gloves Industry Automotive Industry
Overall Equipment Effectiveness and Energy (OEE+E) is an option of Ampla
Gauges OEE and displays it as a KPI for monitoring and improvement. When combined with the
additional energy-related knowledge, asset optimization is achievable
Connects to multiple plant and business systems, collects required data and presents it as easy-to understand,
real-time intelligence for productivity analysis, data mining, querying and reporting
Tracks OEE with energy over consumption events in the same context
Is a simplified, out-of-the-box application that can easily integrate with existing automation architectures
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Ampla: OEE+E
OPTIMIZE YOUR POWER NETWORK WITH DATA-DRIVEN DECISIONSStruxureWare Power Monitoring Expert software delivers the integratedinformation for maximizing network reliability and performance
BUSINESS PROCESS MANAGEMENT (BPM)
The Manufacturing world involves three major components:
People, Assets and Raw Materials. An organization’s efficient
use of these resources provides them with a competitive
advantage – an advantage that allows them to thrive beyond
competition, to get maximum yield in an economical way,
passing on the cost or performance benefits to the end users.
A solution connecting people, assets and raw materials is the
basic building block of any organization. A solution which
helps encompass the various manufacturing processes,
people and assets not only helps the organization to avoid a
loss of efficiency, but enables it to be productive and efficient.
The solution towards operations optimization is the Business
Process Management.
Wonderware Skelta BPM is a solution that provides direct integration to industrial processes, systems and automated assets, this sophisticated
Business Process Management (BPM) application enables organizations to model, execute, analyze and improve processes inside and outside
their organization.
Wonderware Skelta BPM acts as a platform for capturing best practices in electronic workflows for work processes including operations and
production, quality, warehouse and logistics, maintenance and inspections related activities.
Digitize Standard Operating Procedures (SOPs), Good Manufacturing Practices (GMPs), work instructions and processes that include people,
equipment, and/or systems
Automate and ensure consaistent execution of standardized work processes
Document and measure processes for continuous improvement opportunities Integrate and synchronize plant or enterprise systems
Extended integration with Schneider Electric software applications such as Wonderware System Platform, MES, Avantis
Asset Management etc.
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Key Capabilities:
Increase efficiency, accountability and consistency of operational activities
Reduce cost of regulatory compliance
Improve cross-functional collaboration
Preserve process and best practices knowledge
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Business Value:
Enable Collaboration Across and Beyond the Enterprise
Model-Execute-Analyze-Improve
Gain real-time visibilityand control over processes
Extend the value ofexisting applications
Ensure dataquality & integrity
Respond tochange faster
Discover
Deside
BPM
Analyze
RightInformation
Right Context
ProcessInstitution-alization
Right Time
RightPeople
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WonderwareSkelta BPM
CentralizedAdministration
User and GroupCollaboration
EnterpriseIntergration
Business RulesManagement
Model-DrivenDevelopment
Business ActivityMonitoring
Optimization
AdvancedWorkflow Engine
Do you want to safeguard your assets?
Can you predict failures in your plant?
KEY INFOGRAPHICS: INDUSTRIAL BENCHMARK
MAINTENANCE EXECUTION MATURITY CURVE
Ca
pa
bili
tie
s
*AT Kearney and Schneider Electric (formerly Invensys) Project experience
> 0%increase in effectiveequipment lift
> 10%-20%reduced downtime
> 15%-30%increasesd dequipment
> 20% - 30%more operator effcenny
> up to 30%reduced maintenance cost
> 1-35%inventory reducton
> 50%reduced breakdowns
> 10%-20%Aof productctivitty enhancements
A
B
C
D
E
F
G
H
TOP BENEFITS ACHIEVED WITH AVANTIS
What benefits did you get from using Avantis software
Note: this is a multiple-choice question - response percentages may not add up to 100
Source: Survey of 151 users of Invensys Avantiswww.techvalidate.com/product-research/invensys-avantis TVID: 46c-8B3-C25
Reduced reactive maintenance
Improved asset utilization
Improved labor efficiency
Improved inventory productivityand cost avoidance
Reduced unexpencted downtime
Extended asset life
Improved safety & compliance
Reduced overtime
Other
64%
58%
51%
53%
40%
43%
34%
19%
15%
Time
Condition-based algorithms
Predictive Maintenance
Sustainable reliabilitybig data, predictive analytics
Proactive Maintenance
Preventive Maintenance
Time-and Statistical-based
Reactive Maintenance
Corrective Maintenance
LEVEL 4 Enterprise / Business Operations
How efficient do you think your plant is?
How can you automate your standard process & procedures?
EXPECTATIONS OF BENEFITS OF MES ARE INCREASINGWhich three of the following Manufacturing Execution System
success criteria does your organization use most?
Gartner 2013, N=104
Arrows show main trendsfrom 2012 study
1st Choice
2nd Choice
3rd Choice
Information from MES is basis for continuous Improvement
Increased product quality
Operational cost reductions (including COPQ)
Required support and maintainability of the MES
Achievement of performance standards
Responsiveness to demand
Employee Productivity
Increase net operating profit
Factory flexibility gains
Decreased time implement engineering/ process change
Adherence to program budget
Increased market share
Cultural adoption
% of respondents 0% 20% 40% 60% 80%
61%
54%
38%
23%
22%
21%
20%
17%
15%
9%
7%
4%
3%
5%
13%
7%
6%
13%
The Top 3 rated strongest benefits of a Skelta BPM workflow system:1. Automation of standard Processes and Procedures2. Ability to model and optimize processes3. Ability to adopt change with low effort and low risk
WHICH OF THE FOLLOWING WOULD YOU RATE AS THE SINGLE GREATEST BENEFIT OF ANY BPM SOFTWARE YOU ARE USING?
Ability to visualize, simulate, and troubleshoot business processes
Analytical reporting and business procedures and processes
Automation or standard procedures and Processes
Change business rules and processes without impacting underlying applications
Enforce best practices and required procedures
Ensure accurate and consistent data entry of document creation
Manage and monitoring the performance of operations and personel
Standardize interchange of process models
19%
7%
28%
17%
10%
4%
11%
3%
TOTAL
Wonderware
MESPerformanceOperations Quality
WonderwareSkelta BPM
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LEVEL 2, 1, 0 Industrial Automation
LEVEL 3ManufacturingOperation Management
ARTESIS MOTOR CONDITION MONITORING (MCM)
Stop
Perform Maintenance
Watch Load
Watch Line
OK
Model Voltages
Model Currents
Measured Currents
Measured Voltages
Motor Model
Output Currents
Monitoring phase
Artesis AMT Toolkit Services uses MCM technology onto a
portable platform that will provide an instant condition
assessment report indicating existing electrical and
mechanical faults of the measured equipment. Besides, it
also provides energy efficiency information and possible
remedies to the existing electrical/mechanical faults.
AMT Toolkit uses three phase voltage and current signals
which these signals are obtained from MCC (Motor Control
Cabinet) through current sensors and voltage cables.
Artesis AMT-Toolkit Services
Artesis AMT Toolkit
Artesis MCM monitors the condition of equipment driven by an electric
motor, effectively using the motor itself as a sophisticated transducer. It
requires only connection into the motor’s electrical supply, avoiding the
need for specialised sensors. Because Artesis MCM is permanently
installed, it provides continuous fault monitoring and doesn’t depend on
expensive manual data collection.
In general, Artesis MCM uses advanced processing algorithms to monitor
the condition of the connected equipment and simplifies predictive
maintenance to answer the following questions:
Artesis MCM can be applied to any three phase motor driven equipment
such as conveyer, water pump, air blower, cooling tower fan, air compressor,
chiller, and even generator.
What’s wrong with my equipment?
What do I have to do?
How soon do I have to do it?
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Artesis MCM is a patented solution to condition monitoring, providing all the benefits without the high complication and cost of traditional systems.
ECH
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NOLOGY
From This… To This...