An Overview Of Wonderware MES Products Jan Rasmussen Sales Director EMEA - MES
Wonderware Manufacturing Operations Software Solution Offerings
Wonderware OPERATIONS 3.5 - PREMIUM Wonderware QI Analyst
Enterprise Integration
Wonderware InBatch
Wonderware MES & EMI Software Solutions
Batch Operations
Asset Monitoring Quality
Local Scheduling Performance
Food & Beverage
System Platform
Clients
Industry Wonderware Applications PERFORMANCE & Industry Packs
3.5
Microsoft Technology & Industry Standards
Wonderware OPERATIONS 3.5 - STANDARD
Mtelligence for Wonderware Partner Solution
Wonderware EMI Offerings
Common Industrial IT Services for Increased Sustainability
Wonderware System Platform
Platform
Enterprise Integration
Native integration of plant model with MES production model for low TCO Superior reusability via object templates and deployment with sharing of best practices Intuitive user interfaces for appropriate operator involvement
Wonderware MES & EMI Software Solutions
Batch Operations
Asset Monitoring Quality
Local Scheduling
Performance
Food & Beverage
System Platform
Clients
Industry Applications & Industry Packs
Microsoft Technology & Industry Standards
Unparalleled data connectivity incl. leading historian for process data, and advanced security model
Accurate Management of Batch Processes
Wonderware Operations Software
Batch
Enterprise Integration
Simple batch management with recipe definitions using site specific processes Accurate equipment setup with automatic download of set points
Wonderware MES & EMI Software Solutions
Batch Operations
Asset Monitoring Quality
Local Scheduling
Performance
Food & Beverage
System Platform
Clients
Industry Applications & Industry Packs
Microsoft Technology & Industry Standards
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
Improved Execution of Operational Activities
Wonderware Operations Software
Operations
Enterprise Integration
Food & Beverage
Dispatching and management of electronic work orders, with multilevel BOM Improved process and production consistency and repeatability Accurate inventory mgt and operational enforcement through procedural steps
Wonderware MES & EMI Software Solutions
Batch Operations
Asset Monitoring Quality
Local Scheduling
Performance
System Platform
Clients
Industry Applications & Industry Packs
Microsoft Technology & Industry Standards
Equipment Operations Modules
Non-model based approach for recording of production events and as-built records as simple extension of supervisory system
Wonderware Operations Software
Provides a scalable & configurable Manufacturing Execution System solution for a wide range of industries
Background:
Core MES software capability (formerly Factelligence) obtained from 2007 acquisition of leading MES software provider, CIMNET
Product History
November 2008
February 2008
October 2007
EPM 2.0 = Factelligence 3.1 + QuickStart
July 2007
Wonderware Factelligence 3.1
2002
Wonderware Operations Software
Comprehensive MES Functionality Bill of Material, Work Orders, Events, Data Collection,
Specifications, Set Point Download, Inventory, Certifications, Steps/Procedures, Labor Management, User Management, Genealogy, Traceability, Web Reporting
Fully Scalable Functionality Standard & Premium Edition, Enterprise
Integration, MES Clients plus .net controls to embed in InTouch Physical Scalability equipment, lines, plants Taking advantage of ArchestrA services
Highly Configurable Application
Highly Configurable User Interface
Wonderware MES Features
Deliver planned vs. actual production
using
Electronic Work Order Management Recording of Production Events
Improve process and production consistency
using
Centralized Manufacturing Model Production Rules Certifications Real time inventory management Detailed definition of materials, substitutes and byproducts Bill of Materials Dynamic prioritization and sequencing Labor management Connection to HMI/SCADA Downtime Utilization OEE
Improve inventory velocity
using
Reduce order lead time
using
Monitor and analyze production performance
using
General Overview Wonderware Operations & Performance
Solutions Powered By MES Modules
System Platform benefits on MES
Track & Trace Error Proofing Electronic Batch
Receiving Lower Cost of IT in Industrial Applications for data collection Order Management and automated transactions WIP Management Connect andManagementthe Inventory Collect : out of box connectivity to any Quality Data Collection information source Weigh & Dispense Reduce effort and cost on designing, building and Batch Processing maintaining system Recipe/Spec. Mgt. Complete Data Mgt.upscaling in Master scalability, size and functionality without impact to existing system
Records (EBR) Electronic Work Instructions Procedural Execution Performance Mgt. (OEE) Asset Utilization Labor Mgt.
Building the Production Model
Highly configurable & customizable to ensure a complete & accurate model of your production processes
Reduce Variances with Specification and SPC
Wonderware Qi Analyst
Quality
Enterprise Integration
Realtime 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 better understanding of actual process capabilities
Wonderware MES & EMI Software Solutions
Batch Operations
Asset Monitoring Quality
Local Scheduling
Performance
Food & Beverage
System Platform
Clients
Industry Applications & Industry Packs
Microsoft Technology & Industry Standards
Wonderware Operations Software
Central administration of process and product specifications with versions and min/max limits per BOM entity
Using Standard Deviation
Cream Cheese Online Controlling Water percentage Operators only allowed to adjust paramaters based on rule violations from QIAnalyst Water is cheaper than milk
Mozarella Planning production based on the orders solid material requirements in the cheese
Cream Cheese On line Weight control in filling line Butter On line controlling fat and water
Using standard deviation
Rapid and Accurate Decision Making via Realtime Visibility
Wonderware Performance Software
Performance
Enterprise Integration
Improve asset utilization by automated data collection and selective involvement of operators Consistently monitor and compare equipment performance and OEE.
Wonderware MES & EMI Software Solutions
Batch Operations
Asset Monitoring Quality
Local Scheduling
Performance
Food & Beverage
System Platform
Clients
Industry Applications & Industry Packs
Microsoft Technology & Industry Standards
Wonderware System Platform
Powerful reporting infrastructure through Information Server
Improve Asset Utilization and OEE
Operations / Mgt Engineering IT & Infrastructure
Productivity gains drop straight to bottom line
Engineering Efficiency
Operations / Mngt Engineering IT & Infrastructure
IT Environment Consistency
Operations / Mngt Engineering IT & Infrastructure
Increase Capacity
Reduce unplanned equipment downtime By tracking and analyzing equipment downtime Improve the output of existing equipment Track and analyze equipment output (performance) Reduce quality related losses (scrap) Track and analyze first pass yield
All require detailed equipment performance information
Empower Operators
Leverage existing automation system Provide more accurate, reliable and granular downtime data than manual systems Flexible capture of downtime events with
unlimited downtime reasons per equipment Enhanced operator involvement with highly configurable .NET based Operator interface
Real-time Graphics
OEE KPI Control Displays OEE value and/or the OEE components (Availability, Performance, Quality) Count/Duration KPI Control Displays the number and duration of events for the current entity Production Progress Control Displays the current progress of production for the current shift compared to a provided target
Drill Down to Root Cause
Tight Alignment with Business Processes
Enterprise Integration
Enterprise Integration
Enterprise Integration
Out-of-the-box integration using predefined mappings. Simple, yet powerful integration capabilities in a standardized formats
Wonderware MES & EMI Software Solutions
Batch Operations
Asset Monitoring Quality
Local Scheduling
Performance
Food & Beverage
System Platform
Clients
Industry Applications & Industry Packs
Master/Static Data (30+ templates):
Attributes BOM Item / Oper. Links BOM Item / Oper. Step Links BOM Item Substitutes BOM Items Data Log 16 and 48 Folders & Files Operation Routes Operation Step Entity Excl. Operation Steps Operations Operations Step Groups Operation / BOM Spec Links Operation / Entity Links Operation / Entity Spec Links Operation Attributes Process / Item Links Process Attributes Processes Rework Process Usage Specifications Item Attributes Item Classes Item Folders Item Reasons Item Substitutes Items Standard Operations Standard Operations Entity Links Standard Operations Attributes Utilization Reasons
Microsoft Technology & Industry Standards
Dynamic Data (20+ templates):
Customer Inventory Items Job Attributes Job BOM Job Step Links Job BOM Substitutes Job Routes Job Specifications Job Step Groups Job Steps Jobs Lot Attributes Sales Order Sales Order Items Work Order Attributes Work Order Folders Work Orders (with Process) Work Orders (without Process)
Enterprise Integration
Basic Features
Provides standard mechanism to import and export data
from WW Ops & Perf Database Provides a set of data import and export templates Integrate with ERP, SCM, LIMS and other business level or plant level systems Used to synchronize BOM, orders, WIP, items, specs, certifications, attributes, etc. Configurable data formats including XML, flat file, and Database table transfers Configurable triggers including period, weekly, data changes, table data exists, file exists Delivers standard production reports, exception reports and email alerts
Comprehensive Application for Packaging Lines
Vertically oriented Packaging Solution
Industry App for Packaging
Leverage System Platform, InTouch, Performance Module and Information Server Provides a window for Planners (job sequencing and dispatching), Operators and Supervisors (line and machine state, status, yield, Performance, Events and alarms) Generates and distributes reports via Wonderware Information Server State Model Compliant with OMAC and PackML Food& Beverage, Tobacco, Consumer Packaged Goods (CPG) Easy setup via Excel Utility Alternative to traditional MES/Performance project
Enterprise Integration
Wonderware MES & EMI Software Solutions
Batch Operations
Asset Monitoring Quality
Local Scheduling
Performance
Food & Beverage
System Platform
Clients
Industry Applications & Industry Packs
Microsoft Technology & Industry Standards
Improved Maintenance Strategy with Condition Based Monitoring
Asset Monitoring
Enterprise Integration
Condition Based Monitoring Mtelligence
Endorsed Partner Solution Equipment run-time hours fed to maintenance system with automatic generation of work orders Detect health degradation and prevent equipment failures
Wonderware MES & EMI Software Solutions
Batch Operations
Asset Monitoring Quality
Local Scheduling
Performance
Food & Beverage
System Platform
Clients
Industry Applications & Industry Packs
Microsoft Technology & Industry Standards
Open Standards eliminate Upgrade and Migration Risk (MIMOSA, ISA-95)
Improved Maintenance Strategy with Condition Based Monitoring
Preactor Finite Scheduling
Local Scheduling
Enterprise Integration
Wonderware offers you a world class MES solution Preactor offers the best available finite scheduling tool available on the market today The two have been integrated to offer both scheduling and manufacturing shop floor control With a record that shows a ROI which is unsurpassed Largest installed base of any independent planning & scheduling software company for the manufacturing sector >2,300 companies in almost every manufacturing sector Discrete/process/hybrid >10,000 licenses Users in 64 countries Translated into 30 languages
Wonderware MES & EMI Software Solutions
Batch Operations
Asset Monitoring Quality
Local Scheduling
Performance
Food & Beverage
System Platform
Clients
Industry Applications & Industry Packs
Microsoft Technology & Industry Standards
Adopting a Flexible Approach to Improve Your Manufacturing Operations
Enable an incremental, low-risk deployment of increased application functionality, one step at a time.
Milkshake Manufacturer Scenario #1
Three Lines Produce Milkshakes Two Manufacturing Sites Currently, no MES
Goal: Monitor/Improve equipment
performance Answer the question, How are we doing?
Overall Equipment Effectiveness (OEE) Downtime Asset Utilization
Manufacturing Pains
Fillers not running at designated capacity Output & profits lower than forecast Not meeting daily schedule Pasteurization process blocked Production storage is full No information about filler stops Operators often wait around Dont knowing how to resolve issues
Scenario #1: Performance
Initial Deployment of Performance
Line 1 Clients
Install InTouch, Install InTouch WW Ops & Perf license
Install InTouch, Install InTouch WW Ops & Perf license
Line 2 Clients
Install InTouch, Install InTouch WW & Perf license Ops
Line 3 Clients
Production Server
System Platform
Install System Install System Platform license Platform
Install Historian, Install Historian, WW Ops & Perf, WW Ops & Perf, WISServer Info licenses
MES database Historian Info Server
Manufacturing Scenario #1
Solution Diagram
Reports
Machine Utilization
MES Configuration
Scenario 1: Machine Utilization
Reports
Scenario #1 Asset Utilization Downtime OEE Utilization
Milkshake Mfgr Scenario #2
Mfgr now has visibility to performance OEE & Downtime Asset Utilization Goals (one or more): Increase consistency using electronic work orders for line management Track & Trace Consistent data model
Manufacturing Pains
Possible pains
Cant correlate process conditions with WOs or batches when issue detected Small issues become big problems because impacts cant be easily assessed. Mistakes are made repeatedly Major concerns about recalls Operators waste time figuring out what to produce next Differences in time to complete jobs between lines, shifts, operators Different definitions of product formulas / recipes Introducing new product variants causes issues Too much time spent compiling manual reports
Potential Self-Diagnosis
Increased requests for additional / special reports Firefighting since information not shared across
shifts and departments Reduction in customer service due to delays in response time Rework has increased Production costs have increased Changeovers take too long
Scenario #2: Ops Standard
Deployment of Operations (Standard)
Line 1 Clients
Line 2 Clients
Line 3 Clients
Production Server System Platform
Install Ops Standard license
MES database Historian
Info Server
Manufacturing Scenario #2
Solution Diagram Solution Diagram
Reports
Reports
Machine Utilization Machine Utilization Work Order Execution
MES Configuration
MES Configuration
Scenario 1: Machine Utilization
Scenario 2: Work Order Execution
Reports
Scenario #2 Track
and Trace, Execution Consumption and
Scenario #1 Asset Utilization Additional domains By item, work order
Waste Production and Rejects Genealogy Traceability Yield
Milkshake Mfgr Scenario #3
Mfgr now has Visibility to equipment performance Increased consistency w/electronic work orders Track & Trace
Goal #3: Add more MES capabilities Inventory tracking capability Reduce WIP inventory Manage expiration of WIP Improve inventory turns Reduce inventory costs Reduce order lead time
Manufacturing Pains
Excessive Scrap Too Much Inventory Inventory Costs Too High No Traceability To Quality Check
Accurate Labor Costs Unknown
No enforcement of business rules for
intermediate WIP Starved processes
Scenario #3: Full MES
Deployment of Operations (Premium)
Line 1 Clients
Line 2 Clients
Line 3 Clients
Production Server System Platform
Install Ops Premium license
MES database Historian
Info Server
Manufacturing Scenario #3
Solution Diagram Solution Diagram Solution Diagram
Reports
Reports
Reports
Machine Utilization Machine Utilization Machine Utilization Work Order Execution Work Order Execution
WIP Inventory Tracking
MES Configuration
MES Configuration
MES Configuration
Scenario 1: Machine Utilization
Scenario 2: Work Order Execution
Scenario 3: WIP Inventory Tracking
Reports
Scenario #3 Inventory Tracking
Additional reports available
available reports
Scenario #2 Track and Trace, Execution
Additional information provided to previously
More Manufacturing Scenarios
Example 1: Scalability from a Small System to Large System
Procedure to scale:
Scale from a pilot to a larger system with ease Start with a pilot system Add clients and servers without re-engineering the applications Reuse library of templates for multisite rollouts
Scalability
Line 1 Clients Line 2 Clients Line 3 Clients Line 4 Clients Line 5 Clients
Production Server System Platform MES database Historian Info Server
More Manufacturing Scenarios
Example 2: Incremental Growth from One Application to Multiple Applications Scale to address additional functional requirements Procedure to grow incrementally
Start with Performance Add Operations Standard Add Operations Premium all by simply changing the license file!!!
Incremental Growth
Line 1 Clients Line 2 Clients Line 3 Clients
Production Server System Platform MES database Historian
Info Server
Differentiators
Standard application content out of the box Single comprehensive database for all
MES capabilities not disparate solutions Modular operator interface concept Support for mixed manufacturing modes Data master flexibility True integrated SCADA through MES capability Modern Microsoft-based architecture
Additional Benefits of Wonderware MES
Integrated use of System Platform + MES Templates for MES User Interfaces
The Value of a consistent data model Templates Deployment
In Conclusion
Wonderware Operations and Performance
Software offers: Rich MES functionality that can be deployed
incrementally Maximizing effectiveness While reducing risk and time to value
Wonderware Workshops Operations Management - Monday
Time
10.00-10.50 11.00-11.50
Topic
An Overview of Wonderware MES Products NEW! - Wonderware Performance Software - Real-time equipment downtime and performance tracking Manage and maintain your assets utilising Wonderware's condition based monitoring (CBM)
Zunkles Room
Jan Rasmussen Dawid Sadie
14.00-14.50
Tim Sowell
15.20-16.10
NEW! - Wonderware Industry Application Andrea Sartori for Packaging
Wonderware Workshops Operations Management - Tuesday
Time
10.00-10.50
Topic
Manage and maintain your assets utilising Wonderware's condition based monitoring (CBM) NEW! - Wonderware Operations Software - improve production consistency, visibility and agility
Zunkles Room
Tim Sowell
11.00-11.50
Andrea Sartori
14.00-14.50
15.20-16.10
NEW! - InBatch 9.0 - Flexible management for batch processes
Advanced Scheduler for Wonderware MES
Jos Peters
Chris Mollison Preactor
Time
11.00-11.50
Topic
NEW! - Wonderware Performance Software - Real-time equipment downtime and performance tracking
Injasuti Room
Dawid Sadie
14.00-14.50
NEW! - Wonderware Industry Application Andrea Sartori for Packaging
Questions
Thank You
[email protected]
