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MES Solutions

11 March 2014 Invensys proprietary & confidential Slide 1

Why MES? Questions to consider Are you a manufacturer in a regulated industry?

– Food & Beverage

– Tobacco

– Automotive

– Cement

– Pharmaceutical/Chemicals

– Consumer product,…

Do you have “challenges” in your business? – Compliancy issues (21 CFR Part 11, HACCP, BioTerrorism, TREAD)

– Cost of Quality/Product out of balance?

– Supply chain issues?

– Meeting supply/volume targets?

– Managing plant assets/resources?

Do you have legacy/custom software applications to track, trace or document the product manufacturing?

Do you have initiatives like: – LEAN, Six Sigma

– Cost reduction, OEE, DTM

Do you have improvement projects being driven by Operations, Finance, or Quality? Are they X-Departmental?

–

If so, then they may be a good MES candidate

What is MES…

“I need to reduce

downtime”

“I need to have traceability”

“I need to manage recipes”

“I need to improve quality”

“I need to improve yield” “I need to

reduce inventories”

“I need to reduce

cycle times”

“I need to reduce costs”

Integration &

Collaboration

Platform

Enterprise

Integration

Workflow

Open Device

Integration

Web

Portal

Application

Toolkit

Historian

Th

ird

-Part

y O

fferi

ng

s

So

ftware

Ap

plic

atio

ns

Execution

Manufacturing Execution

Systems Batch

Enterprise Asset

Management Mobile Workforce

Management

Performance

Enterprise Manufacturing

Intelligence Performance Measurement

and Reporting Visualization Quality

Asset

Performance

Optimization

Operator Training Design Advanced Process

Control Simulation /

Optimization

Control

DCS PAC SCADA HMI

Safety

Safety Instrumented Systems General Purpose Safety Turbomachinery Control

Measurement &

Instrumentation

Instrumentation Controllers Recorders

Au

tom

atio

n

So

ftware

Ap

plic

atio

ns

Where The Offerings We Will Discuss Fit Within The InFusion Enterprise Control System

11 Functions of MES Fully Covered by Invensys

ISA Model

Level 2

MES

Dispatching

Production

Units

Operations/

Detailed

Scheduling

Resource

Allocation &

Status

Document

Control

Product

Tracking &

Genealogy

Performance

Analysis

Labor

Management

Maintenance

Management

Process

Management

Quality

Management

Data

Collection

Acquisition

Sales &

Service

Management

Enterprise

Resource

Planning

Supply Chain

Management Control

WW

Operations

Software

WW

Performance

Software

WW

Enterprise

Integrator

Avantis

WW QI

Analyst

System

Platform

ArchestrA

Workflow

ISA Model

Level 3

Wonderware MES MESA 11 Point Coverage Operations & Execution Portfolio Solutions “Powered By” MES…

► Track & Trace

► Error Proofing

► “Paper-on-Glass”

► Electronic Batch

Records (EBR)

► Electronic Work

Instructions

► Procedural Execution

► Labor Mgt.

► Receiving & Inspection

► Order Management

► WIP Management

► Inventory Management

► Shipping

► Quality Data Collection

► Weigh & Dispense

► Batch Processing

► Recipe/Spec. Mgt.

► Master Data Mgt.

► HACCP

► …

Em

po

werin

g S

uc

ce

ss

of P

rod

uc

tion

Wo

rkers

D

evic

es

, A

pp

licati

on

s,

En

terp

rise In

teg

rati

on

Database Applications

Asset Management

LIMS Systems

Devices

ERP (SAP, Oracle, Microsoft..)

Manufacturing Operations Management:

Operations Mgt Solution Offerings

Information / Visibility

System Interoperability

Manufacturing Operations Management

Microsoft Technology & Industry Standards

System Platform

Clients

Enterprise Integration

Industry Applications

& Industry Packs

Wonderware HMI, MES & EMI Software Solutions

Operations Performance Quality Batch

Food & Beverage

Intelligence (EMI)

ArchestrA Workflow

Operations & Execution Portfolio MES – Operations Value Proposition

17

Improves Manufacturing Agility by providing real-time production execution information and alerts to the right people, at the right time

Drives Consistent Production Execution through strict enforcement of electronic manufacturing procedures (process, operator, equipment & materials) associated with semi-finished and finished goods – enforces “best practices”

Captures Comprehensive Manufacturing Genealogy by collecting a complete production routing history (including assets), labor history and material usage history – improves compliance and governance

Improves Decision Support & Planning within the Supply Chain by providing real-time order, material (raw material & WIP), equipment and labor status

Operations & Execution Portfolio MES – Operations Features

Product Definition

Ability to Define Raw, Semi-Finished or Finished Goods Attach Multiple BOM Definitions (versions) to a Product Attach Multiple Specifications (versions) to a Product Synchronize Products Definitions with External Systems

Bill of Material Definition

Multi-level BOM (n-tier) Define Multiple Substitutes per BOM Item Define Co-Products / By-Products Configure Specific Material Processing and Tracking

Business Rules per BOM Item (e.g. backflush, maintain inventory, must consume from previous step, etc.)

MES 4.0 Operations

Mobility

Product Definition

Operations & Execution Portfolio MES – Operations Features (cont.)

Production Management & WIP Execution

Full Production/Process Order Management Define and Execute Product Specific Production Routings Record and Track Production, Consumption and Labor WIP Status and Characteristics

Inventory Management

Configure Business Rules for Tracking Inventory on the Plant Floor (e.g. maintain composite lots, etc.)

Can track bulk, lot or serialized inventory items Ability to Transfer, Split, Combine, Receive, Ship and

Reclassify Inventory Items

MES 4.0 Operations

Mobility

Production Execution

Storage Management

Ability to Define Fixed or Mobile Inventory Locations Ability to Monitor the State of Inventory Locations Track the Movements and Location of Mobile Storage

Devices

Operations & Execution Portfolio MES – Operations Features (cont.)

Equipment / Machine Setup

Common Equipment Setup Templates Enable Consistency in Equipment setup Ability to Capture a “Golden” Setup Ability to Enforce Steps and/or Procedures

Procedure Step Manager

Guide an Operator Through a Manual or Semi-Automatic Procedure at a Particular Manufacturing Operation

Configure Required “Step Actions” (e.g. consume material, acknowledge message, view document, etc.)

MES 4.0 Operations

Mobility

Equipment Operations

Production Event Tracking

Ability to Capture Production Events Including Counts, Weights, Scrap and Reason codes

Ability to Report and Drill Through History, Enabling Genealogy, Traceability

Operations & Execution Portfolio MES – Operations Features (cont.)

Enable Plant Document & Work Instruction Definition

Define Electronic Folders with Associated Documents and Work Instructions (multiple versions)

Configure Document Viewers to Use for Specific Document Types

Manage Links to Other Documents

x x Work Instructions & Document Management

View Many Different Document Types (e.g. PDF, MS Documents, Web Page, etc.)

Link Work Instructions and Documents to Products, Production Orders, Operations, Work Centers or Procedural Steps

MES 4.0 Operations

Mobility

Work Instructions

Operations & Execution Portfolio MES – Performance Value Proposition

22

Reduce Capital Expenditures by identifying the most productive assets for continued operation

Improve Asset Utilization by identifying production bottlenecks more quickly and increasing supplier accountability

Increase the Capacity of your existing assets by pinpointing the causes of unplanned downtime and improving operational efficiency

Leverage Best Practices by comparing line-to-line and plant-to-plant performance, including real-time OEE measures

Empower Operators by providing visibility to real-time asset performance KPIs that enable them to “take action”

Operations & Execution Portfolio MES – Performance Features

Equipment Utilization

Ability to Detect and Capture Utilization Events Ability View Equipment Events Ability to Monitor and Record Equipment State Ability Automatically or Manually Assign Reason Codes

Equipment Performance

Ability to Calculate OEE for Equipment / Line Ability to Trigger Events and Display Ability to Analyze Event Frequency and Duration Ability to Assign What States Affect OEE Calculation

Production Progress

Provide a Clear Indication of Job or Production Order Progress to the Operator in Real Time

Ability to Calculate OEE Other Key Parameters Ability to Estimate Expected Completion Date and Time

Mobility

MES 4.0 Performance

Batch

Wonderware Operations Software

Simple batch management with recipe

definitions using site specific processes

Accurate equipment setup with automatic

download of set points

Wonderware InBatch

Powerful batch execution engine with

dynamic allocation of shared equipment for

even the most complex batch processes

Graphical recipe definitions according to

S88 with unit procedures, operations and

phases for equipment independent master

recipes

Accurate Management of Batch Processes

Quality

Wonderware QI Analyst

Real-time and historical SPC with

comprehensive charts and custom run

rules with alarm generation upon violations

Minimize costly scrap and rework through

detection of process variations and better

understanding of actual process

capabilities

Wonderware Operations Software

Central administration of process and

product specifications with versions and

min/max limits per BOM entity

Reduce Variances with Specification and SPC Management

Avantis.PRO

•Enterprise Asset Management

•Maintenance

•MRO Inventory

•Procurement

•Integration Toolkit

Avantis.DSS

•Maintenance & Reliability Decision Support

•KPI Portal

Avantis Approvals

•Document Approvals workflow

Avantis Asset Intelligence

•Asset Health Aggregation and Visualization

Avantis Condition Management

•CbM Extensions

•Multi-variable Rules

Avantis Continuous Monitoring

•Voltage & Current Analysis

•Stress Wave Analysis

Asset Mgt with

Slide 26

Avantis Asset Performance

Avantis EAM Suite

Wonderware EMI Strategy Enterprise Manufacturing Intelligence

Production/Process Information Platform

Self-service access

to information

& content authoring

Share content

& Collaborate

User-friendly

Configuration &

Administration

Wonderware &

Non-Wonderware

Data sources

Incremental approach

Wonderware Intelligence (EMI)

• Multiple databases and/or multi-site deployment

• Easy configuration of Information Model contextualizing multiple data sources

• Self-Service browsing of information model, analytics and dashboard creation

• Integrate content previously created

Site

Multi-site Information Browser Dashboards Analytics

Wonderware Intelligence: Problems Solved

Disparate

Data Sources

Diverse

Data Sources

Naming scheme

inconsistency

Data overload

Inconsistent

Metrics

Broad Data

Connectivity

Domain specific tools,

Applications and Templates

Master data referencing

and data cleansing

Self-service dashboards,

reports and analytics

Data contextualization Data caching

and storage

Data Aggregation

and Alerts Pre-Aggregated Data

Central and Customizable

Metric Definition

Business-friendly Model

Access Layer

Intelligence

Slow Data

Access

Production

Systems Impact

Dependence on

IT Department

Complex

Data Access

Long solution

Development

User Problems User Problems

What is ArchestrA Workflow Software?

30

Manufacturing Business Process Mgt. (BPM) Framework for the Invensys Operations

Management Portfolio

Visualize/collaborate/improve operations

ArchestrA Workflow for Quality-Example

Assigned back

to Greg

(ALERT)

System Updates

the Company

SharePoint KB

No

Action/Notification/Event

Alert

Successful Completion

Legend

Jay (Supervisor in charge)

Greg (Quality Manager)

John (Quality Inspector,

part of Greg’s team)

Start

Jay

Jay Receives a

Complaint Call Jay Runs the Batch

Genealogy Report

Material with Issue

is Identified

John is notified to

continue investigation John

John fills out “Hold Lot Investigation

form” and submits for approval

Jay submits Hold

Lots Form

Inventory system notified

To put specific Lots on Hold!

Workflow is

triggered

Yes

Workflow Ends

Has Greg

Approved the

Audit Report?

System Notifies Greg

for Approval

Notification

sent to Greg Greg

Greg reviews

Batch Report

ArchestrA Workflow Software How Do We Package It?

ArchestrA Workflow – Standard or Enterprise Edition

ArchestrA Workflow – “Add-On’s”

User Directory

System Platform EMI MES Mobile Batch ROMeo

Platform & Application Integration Connectors

Microsoft Integration Other Integration

Microsoft Integration Forms Designer

DB Integration

Enterprise Integration

Plant Manager

Global Distributed Manufacturing

Is The New „Norm‟

MANUFACTURING

PLANT MANUFACTURING

PLANT

MANUFACTURING

PLANT

NEW CUSTOMER

CUSTOMER

SPOT MARKET

CUSTOMER

Field Sales

Customer Service

Plant Manager Product Variability -

Inconsistent quality: by

plant, by product, by shift

Difficulty meeting tighter

customer specifications – Can’t match quality to

orders

No visibility – Can’t see

plant wide production status

due to 10 - 200 disparate

shop floor info systems

Varying process

conditions lead to Higher

energy use

Lack of predictability

Can’t see business performance

to plan, and recommend new

plans to affect results

Capacity erosion –

high off-grade produced

and wide quality swings

Plant Manager

Production Processes

Shared Information

Orders Shipped

Missed orders

Orders

returned

Orders

changed

VP Sales

VP Manuf.

VP BU

Planners

CIO

Inflexible production

process contributes to Missed Opportunity

Hidden capacity

obscured by inefficient

grade transitions &

conservative operation

Enterprise

Integration

Wonderware Enterprise Integrator

Transactional integration with ArchestrA

real-time data model

Reduced Cost of Ownership using industry

standards ISA-95 and B2MML

Wonderware Supply Chain Connector

Out-of-the-box integration using pre-

defined mappings.

Simple, yet powerful integration capabilities

in a standardized formats

Tight Alignment with Business Processes

Ecosystem

35

• More than 3,000 partners

• Complementary hardware, software

• Systems Integration & Consulting

• Suppliers, distributors, OEMs

• Complete solutions providers

• Global/regional coverage

► Raised OEE by 3% in first year

► $200,000 ROI on an initial investment of $80,000

► Payback in 5 months

Direct bottom line results…

A Customer Success Story

Major Beverage Container Manufacturer • Leading producer of plastic beverage containers • Products in such demand they can sell more than they can produce

Success Story 2

► Within 3 months, identified problem areas in bottleneck machines

► Due to increased efficiency, able to cancel large capital expenditure (> $1.5 Million)

Direct bottom line results…

Major Paper Producer • One of world’s largest producers of paper products • $22 billion annual revenue • Legacy system relied on manual entry of downtime fault reasons • Planned large capital expenditure to eliminate production bottleneck • Implemented Wonderware software as interim measure

11

Mar

ch

201

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Invensys proprietary &

confidential