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SIMATIC IT Historian

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The Four Operations of ISA 95 Level 3The Four Operations of ISA-95 Level 3

SIMATIC IT Historian addresses Production and Quality Operations of ISA- 95

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SIMATIC IT Historian addresses Production and Quality Operations of ISA- 95

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© Siemens AG 2013 All rights reserved.

Author / Department

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ISA 95 Standard Operation Pillar in detailsISA-95 Standard Operation Pillar in details

P d ti O ti Pill Q lit O ti PillProduction Operation Pillar Quality Operation Pillar

Production Production


Author / Department

Market challengesMarket challenges

C titi i f i f t t i iti t b i fCompetitive pressure is forcing manufacturers to initiate business performance improvement strategies

Each role in the enterprise must be empowered with accessible, meaningful and

consistent information which improves the decision making process

Improvements strategies cannot be effective without putting data into a business

context and distilling them into Key Performance Indicators (KPI)context and distilling them into Key Performance Indicators (KPI)

“The goal is to transform data into information, and information into insight.”Carly Fiorina (1954)


Author / Department

SIMATIC IT HistorianSIMATIC IT Historian

P id ll th t l t h dl d l h fl d t

SIMATIC IT Historian:

Shop Floor data collection and aggregation

Provides all the tools to handle and analyze shop floor data

Shop Floor data collection and aggregation

KPI calculation and validation

Long Term Archive concept

Data analysis tools

Reporting

Web based data distribution, analysis and reporting

Integrated with SIMATIC IT Production Suite

KPI management


Author / Department


P id ll th t l t h dl d l h fl d t


Integrated with SIMATIC BATCH:

Batch Analysis

Provides all the tools to handle and analyze shop floor data

Batch Analysis

Batch Archive

Electronic Batch Reporting

Integrated with SIMATIC WinCC/PCS7:

Scalable Plant Intelligence Solution

Product Options

OEE-DTM (Overall Equipment Effectiveness and Downtime Management)

SPC-SQC (Statistical Process Control and Statistical Quality Control)


Author / Department

SPC-SQC (Statistical Process Control and Statistical Quality Control)

Data collection and aggregationData collection and aggregation

SIMATIC IT Historian collects and aggregates data from different sources and

Real-time dataSIMATIC IT RTDS

SIMATIC IT Historian collects and aggregates data from different sources and transforms them into valuable information

OPC Server WinCC Data Manager

SIMATIC IT RTDS

( Data compressionwith optional Plant Data

Archive module )

Hi t i l d tSIMATIC IT Plant

Performance AnalyzerOPC Server WinCC Archive Relational Database

Historical data sources

RDB

Alarms events

Wi CC A hi 3 d P t li tiLong-term archive

Batch data

WinCC Archive 3rd Party applications


Author / Department

SIMATIC BATCHCustom data

Data calculation & Data validationData calculation & Data validation

Data aggregation functionsData aggregation functions• Applicable on data from historical data

sources• Pre-defined aggregations available

(Average, Min, Max, Sum, …)

Validation functions• Set the quality code (GOOD or BAD) INPUT PARAMETERSSe e qua y code (GOO o )

of the samples• Can be applied on raw data or on

calculated data

Custom algorithms with PPA scripting environment


Author / Department

Data/KPI AnalysisData/KPI Analysis

Pre defined viewers are available for data analysis

Trend Viewer Bargraph Viewer

Pre-defined viewers are available for data analysis

Production Viewer X-Y chart


Author / Department

Alarm AnalysisAlarm Analysis

Pre defined viewers are available for alarm analysis

Message analyser

Pre-defined viewers are available for alarm analysis

Message Viewer


Author / Department

Batch analysisBatch analysis

PPA automatically stores Batch information from SIMATIC BATCH:

• Batch stepping sequence

• Batch-related messages

• Batch-related measures (trends)

Analyze Batch events and related data (trends, alarms, KPIs)

Compare data on different batchesCompare data on different batches• A Query Tool is available in order to

select batches• Search criteria can be applied to any pp y

Batch characteristic

Batch reporting


Author / Department

• Pre-defined batch reports

On the fly analysisOn-the-fly analysis

A Formula Editor integrated in HDD controls allows on-the-fly analysis based o u a d o eg a ed co o s a o s o e y a a ys s basedon archived data

• It is possible to save and reuse formula templates

• All main mathematical operators and brackets are supported• All main mathematical operators and brackets are supported


Author / Department

SIMATIC IT Reporting Framework

SIMATIC IT R ti F k t d th f ti lit f SIMATIC IT


SIMATIC IT Reporting Framework extends the functionality of SIMATIC IT Production Suite by providing:

A data management infrastructure where production data are stored andA data management infrastructure, where production data are stored, and exposed according to the ISA 95 standard

R d t i d t ifi tReady-to-use industry specific report templates and report parts integrated in Microsoft Report Builder

Access to reports through SIMATIC IT Portal, controlled by SIMATIC IT User ManagementManagement


Author / Department


Hide the complexity of the physical model and let the user choose the


Hide the complexity of the physical model and let the user choose the abstraction model that better works for him

ISA 95 terminology

Business Model

ISA 95 terminology

Business information

Consolidated data

SIMATIC IT terminology

Business reports

Data ModelProduction data

Real time data

Operational reports

Physical Model

p p


Author / Department


The Data Model enables the end-user to interact with data without having to


The Data Model enables the end-user to interact with data without having to understand the complexity of database logic or to be familiar with the tool where the physical data is stored.

The following MES relevant information are available for reporting purposes

S95 entitiese.g. Equipment model, Orders, Materials, PPRs, Shift Calendars Personnel etcCalendars, Personnel, etc.

Historical tagsOEE, SPC and EBR data,Compliance Services and Logbook info


Author / Department


The Business Model is built around the standard business terminology of ISA 95


gyand provides the end-user the ability to autonomously query and retrieve information using common business terms.


Author / Department

Web based analysis & ReportingWeb-based analysis & Reporting

Client Application Builder (CAB) allows providing the right information at the right momentClient Application Builder (CAB) allows providing the right information at the right moment to the right users through a web-based client interface at “Zero Administration Cost”

Embed pre-defined viewers in CAB screens

Display data by means of dedicated interfaces

Graphically build queries using Smart Query Builder (SQB)


Author / Department

KPI ManagementKPI Management

KPIs managed through to the integration with Production Modeler:KPIs managed through to the integration with Production Modeler:

• Assign KPI to Equipment Classes (site, area, cell, unit) in the Plant Model

• Schedule KPI calculation directly from Production Modeler rules

• PPA automatically contextualizes KPIs against manufacturing events or elements (production runs, batches, production orders, equipments, …)

Activate KPI 1Activate KPI 1 Calculate KPI 2Calculate KPI 2 Calculate KPI 3Calculate KPI 3 Deactivate KPI 1Deactivate KPI 1

Trace Trace TraceTraceProduction Operation

TraceProduction Step

TraceProduction Step

• Production Viewer allows analyzing KPIs relevant to a specific production event


Author / Department

• Comparison of KPIs can be done using Bargraph Viewer or Trend Viewer

FDA 21 CFR Part 11 SupportFDA 21 CFR Part 11 Support

FDA 21 CFR Part 11 regulation is supported through the integration between HistorianFDA 21 CFR Part 11 regulation is supported through the integration between Historian and Compliance Services

• Audit Trail and/or Electronic Signature can be applied to any modification of archived data

F ll t i ti f El t i Si t i i t d• Full customization of Electronic Signature scenarios is supported


Author / Department

SIMATIC IT Historian key benefitsSIMATIC IT Historian key benefits

User specific, up-to-date and comprehensive information offers crucial business advantages

Improve performance visibility for proactive and timely decision making atImprove performance visibility for proactive and timely decision making at each corporate level

Faster and better understanding and solving problems

Reduce downtimes and idle-times

Optimization of production processes

Quality performance improvements

Reduction of paper based activities

Reduction of production costs

Support compliance to regulations and normative practices


Author / Department

SIMATIC IT Historian Product Options:SIMATIC IT Historian Product Options:

Product Options:

OEE-DTM (Overall Equipment Effectivenness and Downtime Management)

SPC-SQC (Statistical Process Control and Statistical Quality Control)( y )


Author / Department

The Four Operations of ISA 95The Four Operations of ISA-95

SIMATIC IT OEE-DTM addresses Production and Quality Management of ISA-95Q y g

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ISA 95 Standard Operation Pillars in detailISA-95 Standard Operation Pillars in detail




Author / Department

Key questions for manufacturersKey questions for manufacturers

High Performance, high Quality, high Availability…

…the everyday targets in the plant……need to improve maintenance and operational performances…

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Which is the actual performance against my performance targets?How effectively is the organization using its assets?Why my capacity is idle or non-productive?Why my capacity is idle or non productive?Are resources being used efficiently for the products currently produced? What is the economic impact of the inefficiency?How much revenue has been lost due to the operationalHow much revenue has been lost due to the operational inefficiencies?Why two teams, that appear to be equal, produce products that are so different?Is your factory fully utilized?Is your factory fully utilized?Does your process create waste when stopped?


Author / Department

All necessary data must be available to make informed decisions

The “Six Big Losses”The “Six Big Losses”

In manufacturing plants the most common causes of efficiency loss have beenIn manufacturing plants the most common causes of efficiency loss have been identified and

classified as the “Six Big Losses”

Six Big Losses Category Comment

Breakdowns

Setup / Adjustments

Downtime Loss

Downtime Loss

Difference between Breakdown and Small Stop

Includes tool changeovers

Small Stops / Idling

Reduced Speed

Speed Loss

Speed Loss

Only stops under (5) minutes and no maintenance

Process not running at its theoretical speed

Startup Rejects

Production Rejects

Quality Loss

Quality Loss

Scraps in warm-up, startup or other early production

Scraps during steady-state production


Author / Department

OEE CalculationOEE-Calculation

OEE is a total measure of performance that relates the availability of process to

OEE controls and reduces the “Six Big Losses”

OEE is a total measure of performance that relates the availability of process to productivity and quality

OEE-Category OEE-CalculationStandby

D ti L

Not part of OEE calculation

A il bilit i th ti f ti ti t l d d ti tiDowntime Loss Availability: is the ratio of operating time to planned production time.

100% availability means the process has been running with no recorded stops

Speed Loss Performance: is the ratio of ideal cycle time to actual cycle time, or alternatively the ratio of actual run rate to ideal run rate.

100% performance means the process has been consistently running at its theoretical maximum speed

Quality Loss

theoretical maximum speed

Quality: is the ratio of good parts to total parts.

100% quality means there have been no reject or failure in parts


Author / Department

OEE = Availability * Performance * Quality

World Class OEEWorld Class OEE

A erage of OEE rate in man fact ring plants is 60%

World Class OEE is considered to be 85% or more

Average of OEE rate in manufacturing plants is 60%

OEE FACTOR World Class

Six Sigma is not enough!

99 % in Quality

Availability 90,0 %

Performance 95,0 %99 % in Quality

doesn’t mean

OEE >= 85% !

Quality 99,0 %

OVERALL OEE 84,6 %

Big Room for Improvements


Author / Department

Engineering an OEE DTM SolutionEngineering an OEE-DTM Solution

D l f i ffi i i d d i l i

Plant model Equipment hierarchy is shared with SIMATIC IT Production

Deployment of equipment efficiencies and downtime management solution

Time model Define general time categories as a basis for Key Performance

Plant model definition

Equipment hierarchy is shared with SIMATIC IT Production Modeler

configuration Indicators (KPI) calculation

Reason tree configuration

Define all the possible equipment status conditions (failures, stops states reasons )configuration stops, states, reasons, …)

Data collection configuration Configure data collection in SIMATIC IT Historian

KPI configuration Customize and personalize KPI algorithms

g


Author / Department

SIMATIC IT for OEESIMATIC IT for OEE

SIMATIC IT OEE-DTM is a product option of SIMATIC IT Historian, and it is wholly and seamlessly integrated within the entire MES solution

SIMATIC IT for OEE, through integration with the entire SIMATIC IT environment, allows:

• the calculation of all “standard” and “custom” KPIs

• to fully support the Downtime Management

• to perform active and corrective actions to react to efficiency decreases

• to improve economic Return on Investments (ROI)

• to maximize the plant performance


Author / Department

KPI EvaluationsKPI Evaluations

SIMATIC IT OEE-DTM manages efficiency-related and downtime-related KPIsSIMATIC IT OEE DTM manages efficiency related and downtime related KPIs

Pre-defined standard KPIs algorithms:Availability rate, Performance rate, Quality rate, OEE, MTTA, MTBF, MTTR, MTBA, and more…

Possibility to create new custom KPIs algorithms,combining the existing ones or implementing brand new ones

All th i di t d b SIMATIC IT OEE DTM il bl ithAll these indicators, managed by SIMATIC IT OEE-DTM, are available either :

for executives (who, having an extended vision of the overall plant, manage indicators and charts)

for operators (who mainly monitor run-time views, customizing downtime parameters, and have a restricted view of a specific nit)


Author / Department

specific unit)

Downtime Management and AnalysisDowntime Management and Analysis

Downtime Management:detailed information about equipment states can be displayed updated and filteredcan be displayed, updated, and filtered by equipment, status, product, or any other context data

Downtime Analysis:enables exploring the causes that have generated a production breakdown


Author / Department

generated a production breakdown

Runtime AnalysisRuntime Analysis

SIMATIC IT f OEE id b f d fi d hi ifi ll b ilt iSIMATIC IT for OEE provides a number of predefined graphics screens specifically built in

order to provide out-of-the-box analysis OEE-related KPIs and equipment downtimes

P d fi d hi bj t il bl t b ild dditi l hiPre-defined graphic objects are available to build additional graphics

SIMATIC IT Client Application Builder provides the engineering and run-time platform forSIMATIC IT Client Application Builder provides the engineering and run-time platform for the user interface, since the user interface is built on top of standard technology (namely .Netfrom Microsoft) a wide range of third-party graphic objects can be embedded in any GUI interface for OEE analysis


Author / Department

interface for OEE analysis

Easy and flexible engineering phasesEasy and flexible engineering phases

Time Model:through its graphical representation, it provides an easy way to create the complex model

Reason Tree:it defines in details the hierarchy of all the possible machine states within the defined time categories for individual or for groups of equipments

Shift Calendar (SHC) Management:strong integration between equipments and calendars are defined in the SHC component


Author / Department

Comprehensive and detailed analysis phasesComprehensive and detailed analysis phases

Production Counter Analysis:Production Counter Analysis:

Produced units, scraps, reworked units and any other production counter can be displayed and summarized, according to the different grouping criteria

Current production can be compared with theoretical productionproduction

Reporting:Reporting:

SIMATIC IT for OEE makes use of SIMATIC IT Report Manager in order to provide flexible and effective performance reporting (customized according to the user needs)

Reports can be launched directly from the web


Author / Department

Focus on what’s new in SIMATIC IT OEE v1 2 SP2Focus on what’s new in SIMATIC IT OEE v1.2 SP2

Planned / Induced Downtime Management

MES Context Support

On Value Change Design Speed Acquisition

Web Client integrated in SIMATIC IT CAB PortalWeb Client integrated in SIMATIC IT CAB Portal

GUI Enhancements

Predefined Reports

Documentation enhancements

Note: SIMATIC IT OEE V1.2 SP2 is compatible with SIMATIC IT Production Suite V6.3 SP2


Author / Department

Planned / Induced DowntimePlanned / Induced Downtime

Two special types of downtime records defined either through a dedicated OEETwo special types of downtime records, defined either through a dedicated OEE Web Client page, or programmatically through COM or GSI methods:

Pl d D tiPlanned Downtimes• which cause OEE to disregard the status information retrieved from the field

for the specified time span, are used when an equipment have predefined planned time where it is off-line.

Induced Downtimes• used to model a ”bottleneck“ situation, where the machine state of a piece of

equipment depends on the state of another piece of equipment. They are q p p p q p yused to put in Downtime status an equipment on real-time.


Author / Department

Planned DowntimePlanned Downtime

A Pl d D ti i i d f d ti fi d t i th f tA Planned Downtime is a period of downtime configured to occur in the future.

Th f ll i t d fi l d d tiThe following parameters define a planned downtime:

• A start-time and an end-time (b th i th f t )(both in the future)

• A machine state

• The piece(s) of equipment involved


Author / Department

Induced DowntimeInduced Downtime

An Ind ced Do ntime is a period of do ntime hich as ca sed b anotherAn Induced Downtime is a period of downtime which was caused by another downtime occurring on a different piece of equipment.

A start time set when the record is opened

An end time set when the record is closedAn end time set when the record is closed

A machine state

The piece(s) of equipment involved


Author / Department

MES Context SupportMES Context Support

The following predefined MES Contexts are managed for downtimeThe following predefined MES Contexts are managed for downtime, counter and design speed records:

GroupNameUserNameLotIDO d IDOrderIDBatchIDShiftUserCommentUserComment

The user can set the context values either:The user can set the context values either:manually (by a programmatic interface)

automatically (by either a screen or a Production Modeler rule)


Author / Department

On Value Change Design Speed AcquisitionAcquisition

I OEE V1 2 SP1 th i th ibilit t i d i d l d tIn OEE V1.2.SP1 there is the possibility to acquire design speed values on data change: the user must define two RTDS points (one to trigger the design speed reading and one to retrieve the design speed value)

Now, the user can easily define all the parameters of design speed acquisition, beyond product id and context acquisitionq


Author / Department

Web Client integrated in SIMATIC IT CAB Portal

The following predefined pages are provided fully-integrated in SIMATIC IT CAB

Web Client integrated in SIMATIC IT CAB Portal

g p p g p y gPortal:

• Counters Graphic

• Counters Grouped

• KPI Viewer

C Vi• Counters Viewer

• Design Speed Viewer

• DTM Viewere e

• Gantt Viewer

• Runtime Operator Panel

• Equipment Comparison

• Context Management

Pl d D ti


Author / Department

• Planned Downtime

Predefined ReportsPredefined Reports

Th f ll i t id dThe following reports are provided:

Actual &Target

Downtime

DTM Detail

Availability details

Counter values

DTM values


Page 43 Author / Department

Documentation enhancementsDocumentation enhancements

This version includes the following new documents:

OEE Developer Guide: a comprehensive guide on how to use OEE programmatic interfaces to develop custom applicationsp g p g p pp

OEE Installation Manual: a dedicated installation manual for SIMATIC IT OEE

OEE Web Client Documentation: new contextual documentation accessible directly from OEE Web Client pages

Additionally, the following existing documents have been substantially updated:OEE Concept GuideOEE Concept Guide

OEE Functional Overview



SIMATIC IT OEE DTM benefitsSIMATIC IT OEE-DTM benefits

Through integration with SIMATIC IT Production Modeler:

SIMATIC IT OEE-DTMkey benefits:

Reducing efforts to collect real time production Increase acquisition performances using high speed acquisition rules

Customization of the application through the user-

Reducing efforts to collect real-time production information

Preventing unscheduled downtimes

exits capabilities, inside the Production Modeler (PM) rules

Speeding-up acquisition performances by buffering

Improving of data synchronization and safety with data recovery system

Maximization of production equipment utilizationp g p q p y g

mechanisms

Improvement of the acquired data contextualization

Reducing maintenance costs by optimizing planning activities

Improving assessment and business process performance

Definition of high-level contexts

performance

Easy Import / Export configuration data from Excel worksheets

O ti i i d t lit di



Optimizing product quality grading process

Counters GraphicCounters Graphic

Counters Graphic displays the value of one or more counters (sum) associated toCounters Graphic displays the value of one or more counters (sum) associated to a piece of equipment in a trend graph

Additionally, it is also possible

to display the equipment unit’s

design speed in the trend,

if it was configured during the

engineering phaseengineering phase.



Counters GroupedCounters Grouped

Counters Grouped displays counter values in tabular form grouped according toCounters Grouped displays counter values in tabular form grouped according touser-defined filters on contexts

Such filters can be set ifcounter values where acquired withcontexts during the engineeringcontexts during the engineeringphase.



KPI ViewerKPI Viewer

KPI Viewer displays KPIs associated to a particular piece of equipment using one of the following graphs:

• Bargraph

• Trend

• Stacked bargraph

• Pareto chart



Counters ViewerCounters Viewer

C t Vi di l t d i t b l fCounters Viewer displays counter records in tabular form



Design Speed ViewerDesign Speed Viewer

Design Speed Viewer displays design speed records in tabular form and it alsoDesign Speed Viewer displays design speed records in tabular form, and it also gives the user the possibility to edit them and export them to a CSV file



DTM ViewerDTM Viewer

DTM Viewer let the user to visualize and manage the DownTime recordsDTM Viewer let the user to visualize and manage the DownTime records



Gantt ViewerGantt Viewer

Gantt Viewer displays downtime records related to one or more pieces ofGantt Viewer displays downtime records related to one or more pieces of equipment in a Gantt chart

The user can perform the following actions:Filter data by

equipmentequipmentcontexttime interval

Zoom in and out the chart

Export and print data



Runtime Operator PanelRuntime Operator Panel

Runtime Operator Panel gives a general overview on the efficiency of aRuntime Operator Panel gives a general overview on the efficiency of a piece of equipment

Two types of trend charts can be displayed:

Production ChartProduction Chartto view the values of all the counters associated to the piece of equipment

OEE Chartto view all OEE indicators associated to the piece of equipment.



Equipment ComparisonEquipment Comparison

E i t C i i th th t it t tEquipment Comparison gives the user the opportunity to compare two or more pieces of equipment

For each piece of equipment, the following KPIs are displayed (if available):

OEEAvailabilityPerformancePerformance QualityCurrent counter values



Note: This page provides only real-time data and can be configured to refresh itself automatically or manually.

Context ManagementContext Management

Context Management can be used to set the current values for one or more contexts which were defined during the engineering phase

By doing so, it is possible to modify contextualization of:

design speed, counter downtime recordsdowntime records



Planned DowntimePlanned Downtime

Pl d D ti ll th t t Pl d D Ti fPlanned Downtime allows the user to set a Planned DownTime for one or more equipment



The Four Operations of ISA 95The Four Operations of ISA-95

Production and Quality Management in ISA 95: Process & Product AnalysisProduction and Quality Management in ISA-95: Process & Product Analysis

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ISA 95 Standard Operation Pillar in detailISA-95 Standard Operation Pillar in detail





SIMATIC IT SPCSIMATIC IT SPC

SPC project opportunities are still under evaluation on behalf of

SIMATIC IT Product Managementg

For further information please contact:p

[email protected]



ContactsContacts

For further information please contact:

[email protected]

siemens.com/answers



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