Wonderware Performance Software
Dawid Sadie
Wonderware SA
Agenda
Introduction
Building the Foundation
Wonderware Solution
Considerations
Summary
Introduction
The machine is producing at maximum –
there is nothing more I can do … except
if I could find a reliable replacement for
Part-X …
When will order X be
Complete?
Is the capex for the new line
approved yet? We struggle to
get orders out the door.
Why should I be interested
In performance management?
My machines run just fine …
Why does Line A always produce less
scrap than Line B? The operator ensured
me the setup is identical …
Agenda
Introduction
Building the Foundation
Wonderware Solution
Considerations
Summary
Building the Foundation for
Repeatable Process Improvement
1. Determining operational goals and
requirements
2. Specifying business metrics and key
performance indicators
3. Measuring, visualising, analysing and
acting upon information
Determining Operational Goals and
Requirements
► First step in improving ANY production process is
to understand the Business Drivers
► Improving Productivity and Asset Utilisation
▪ Reduce capital expenditures
▪ Get the most from your existing equipment
▪ Get more from less  lower budgets, fewer personnel
► Increase Efficiency to preserve (and even
increase) bottom-line
▪ Can’t make more  Capacity limited
▪ Can’t increase prices  Price limited
► So … Make it right the first time !!!
Specifying Business Metrics and
Key Performance Indicators (KPI’s)
► Several KPI’s can provide substantial
insight into improving operational results ► Overall Equipment Effectiveness (OEE)
▪ Includes Availability, Performance and Quality
► Equipment Uptime
▪ Time running compared to scheduled time
► Others, including TEEP, TAKT, MBTF
► Key is having a consistent way to
measure, visualise, analyse and act upon
these metrics
Overall Equipment Effectiveness
(Key Efficiency Metric)
OEE = Availability * Performance * Quality
Example: (.77)*(.65)*(.98)*100% = 49% OEE
Availability =
Running Time
* 100%
Net Operating Time
Performance =
Actual Output
Target Output
* 100
Quality =
Good Output
Actual Output
* 100
OEE Analysis is a Key Tool for
Improving the Bottom Line
► OEE – The percentage of time that equipment is
actually producing quality goods
► Improving OEE will directly lead in increased
production, and can significantly impact the
bottom line, especially in these cases ▪ High speed - (CPG, bulk products, electronic parts)
▪ High value - (automotive, aerospace, electronics
▪
finished goods)
High capacity - (oil and gas, water and wastewater,
mining & metals)
► Most companies have far lower baseline OEE
than accepted industry-standard
► Improving OEE by even a small incremental
amount can result in Big Bottom Line Impact
Impact on Financials
OEE Impact on Financial Results
Scheduled Hours (SH)
Scheduled Hours (SH)
Units Produced (UP)
Units Produced (UP)
Unit Price
Unit Price
Average Asset Value (AV)
Average Asset Value (AV)
Net Sales
Net Sales
7680 hours
7680 hours
1.1 Million
1 Million
100 Rands
100 Rands
90 Million
90 Million
Detail
Detail
Debit
Debit
Credit
Credit
110.00 Million
100.00 Million
OEE
OEE
Availability
Availability
Speed
Speed
Quality
Quality
0.66
0.60
0.72
0.65
0.97
0.97
0.95
0.95
Theoretical Runtime (TR)
Theoretical Runtime (TR)
OEE
OEE
0.66 x
0.60 x
► Improving OEE by even a small incremental
Direct Costs
Direct Costs
Direct Materials
Direct Materials
Direct Labour
Direct Labour
27.50
25.00
26.40
24.00
amount can result in Big Bottom Line Impact
► 10% increase in OEE results in 38% increase in
Operating Income
Factory Overhead
Factory Overhead
Depreciation
Depreciation
Utilities
Utilities
Insurance
Insurance
Property Tax
Property Tax
Indirect Labour
Indirect Labour
Factory Supplied
Factory Supplied
Other
Other
Total
Total
2.50
2.50
3.40
3.40
1.50
1.50
2.80
2.80
3.90
3.90
2.10
2.10
1.80
1.80
Operating Expenses
Operating Expenses
Selling Expenses
Selling Expenses
Administration Expenses
Administration Expenses
Ideal Speed Rate
Ideal Speed Rate
Actual Rate
Actual Rate
18.00
18.00
ROA
ROA
17.60
16.00
8.00
8.00
Operating Income (EBIT)
Operating Income (EBIT)
SH
SH
7680
7680
5060 hours
4600 hours
UP
UP
1100000
1000000
SH
SH
7680 x
7680 x
OEE
OEE
0.66
0.60
UP
UP
1100000
1000000
/
/
/
/
SH
SH
7680 143.2 units/hour
7680 130.2 units/hour
EBIT
EBIT
/
/
12.50
9.00
/
/
12.50 Million
9.00 Million
ROA directly effects the ROE (Return on Equity) which inturn effects the share price.
AV
AV
217 units/hour
217 units/hour
90 13.89 %
90 10.00 %
Producing more product
Production Cost (direct)
Increase availability
► Improving OEE by even a small incremental
amount can result in Big Bottom Line Impact
► 10% increase in OEE results in 38% increase in
Operating Income
Measuring, Visualising, Analysing
and Acting upon Information
► KPI’s and Business Metrics can be useful for
improving a process, but only if they can be –
► Measured and Recorded
▪ Needs to be consistent and repeatable
▪ Must take advantage of automatic data capturing
rather than manual entry
► Delivered in easy-to-understand visual format
to all relevant personnel
▪ Plant dashboards targeted to specific groups of users
▪ Easily configurable and customisable
► Analysed in real-time
▪ Before bad products are made or production goals are
missed
► Made actionable
▪ Allow users to drill down for more detail and to
determine root cause
Agenda
Introduction
Building the Foundation
Wonderware Solution
Considerations
Summary
Wonderware MES & EMI Software
Solutions Built on Strong Platform
Real-Time Manufacturing Operations Management
ERP
(SAP, Oracle,
Microsoft..)
Database
Applications
Wonderware MES & EMI
Software Solutions
Enterprise
Integration
Food &
Beverage
Asset
Monitoring
Asset
Management
Batch
LIM Systems
Devices
Operations
System
Platform
Quality
Performance
Clients
Industry
Applications
&
Industry
Packs
Microsoft Technology & Industry Standards
Information /
Visibility
Empowering All Roles in the Plant
Devices, Applications, Enterprise Integration
System
Interoperability
Adopting a Flexible Approach to
Improving Your Manufacturing Operations
Enable an incremental,
low-risk deployment of
increased application
functionality, one step
at a time.
Get to the Bottom of your
Unplanned Downtime Issues
Wonderware Performance Software v3.5
► Leverages existing automation system
▪ Provide more accurate, reliable & granular
downtime data than manual systems
► Highly flexible capture of downtime events
with Unlimited downtime reasons per
piece of equipment
► Enhanced operator involvement with
highly configurable .NET based Operator
interface
► Information delivery via standardised and
pre-configured reports and KPI-displays
Reduce Costs with Equipment
Efficiency Tracking
Wonderware Performance Software v3.5
► Real-time Overall Equipment
Effectiveness (OEE) Monitoring
▪ Monitor equipment, line or plant OEE
▪ Compare machine to machine, line to line,
plant to plant
▪ Leverages existing automation system for
accurate and timely OEE data
► Unlimited number of OEE calculations
► Include real-time OEE on Operator HMI
screens and web-based plant
information portals
Wonderware Performance
Software
Monitors, analyses and reports on
asset efficiency & equipment
downtime - resulting in improved
productivity and asset utilisation.
Capabilities
Equipment Utilisation
•
What is
Equipment Performance?
Equipment Utilisation
Equipment Efficiency
Reporting
Real-time Tracking/Display/Analysis of
Unplanned Equipment Downtime
Drive Better Equipment Utilisation…
through Operator Awareness
Customisable Operator Interface
► User definable utilisation states
► Define an unlimited number of reason
codes to establish the utilisation state
► Reason code triggered automatically
from I/O or manually input by operator
► Define a target Utilisation & OEE for
each asset
► Configure if utilization reasons affect
OEE values
Reason
State
Powerful Utilisation Control
Real-time Visualisation & Input
Capabilities
Equipment Utilisation
•
Real-time Tracking/Display/Analysis of
Unplanned Equipment Downtime
What is
Equipment Performance?
Equipment Utilisation
Equipment Efficiency
•
Equipment Efficiency
Reporting
Real-time Tracking/Display/Analysis of
Equipment Efficiency
Higher Equipment Efficiencies
with Operator Involvement
Capabilities
Equipment Utilisation
•
Real-time Tracking/Display/Analysis of
Unplanned Equipment Downtime
What is
Equipment Performance?
Equipment Utilisation
Equipment Efficiency
Reporting
Equipment Efficiency
•
Real-time Tracking/Display/Analysis of
Equipment Efficiency
Reporting
•
Real-time Web Reports or Paper Reports
“Zero Footprint” Web-Based
Reporting
►Flexible Report Templates
▪ OEE & Downtime
▪ Production Event Summary
►Extensible
▪ Easily create report
instances for specific users
►Wired for Analysis
▪ Drill through by passing
parameters
▪ Determine root cause of
production problems
Web-Based Reporting
Drill Down to Root Cause
What’s
in Performance 3.5?
► Simplified Configuration
▪ New Utilization Capability Object
▪ New Performance Configuration Client
► Improved Visualisation
▪ New ArchestrA Graphic Templates
• OEE, Downtime & Production Progress
▪ Improved Operator Interface
• New Utilisation Grid .NET Control
► Enhanced Reporting
▪ New Web based ArchestrA reports
► New Migration Utility
▪ Easier upgrades
Object Based Configuration
► New Utilization Capability Object
▪ Configure downtime events & OEE
calculations
▪ Define production attributes for production
progress tracking
▪ Associate with ArchestrA Graphic templates
▪ Extend with custom scripts
► Benefits
▪ Facilitates corporate standards
▪ Template approach promotes engineering
reuse
▪ Faster configuration & reduced maintenance
New Performance Configuration
Client
► Helps configure:
▪ Users & Groups
▪ Utilisation States,
Reason Groups &
Reasons
▪ Shifts & Shift Schedules
▪ General System
Parameters
► Helps simplify system
configuration
New Performance Graphics
Templates
► OEE KPI Control
▪ Displays OEE value and/or the OEE components (Availability,
Performance, Quality
► Count/Duration KPI Control
▪ Displays the number & 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
OEE KPI Control
► Shows OEE or OEE components
▪ Dial or Bar chart
► Configure
▪ All standard graphic properties are available
for setup.
Counts and Duration Control
► The control will display either counts or duration for
Utilisation States, Reason Groups, or Reasons on the graph
► Filtered for the time period specified by the Filter properties
for the current entity
Production Progress Control
► Used to display progress towards a production
target for the current shift
▪ The projected production is based on the current rate
of production for the current job running on the current
machine
New .NET Control – Utilisation
Grid
► Allows enhanced operator displays
► Employs advanced filtering capabilities
► Time based
•
Last N events, this/last shift,
last N hours
► State based
•
•
Unacknowledged
Minimum Duration
► Status based
•
Utilization state
► Any combination of filters
Reporting
► New ArchestrA Utilisation Reports
Information at your fingertips
Web based or Paper Reports, You choose
Efficiency Information for
Decision Makers
Agenda
Introduction
Building the Foundation
Wonderware Solution
Considerations
Summary
Considerations
► Wonderware Performance Software is the
key to achieving consistency in equipment
performance
▪ Consistently measure and record
▪ Single or multiple “lines”
► Modular solution for adding functionality
▪ Grow towards Operational Excellence (start
with Performance)
► Start small, get benefit, and grow bigger
▪ Eliminates the “big-bang” approach
► Can integrate with your existing investment
… co-exist
Agenda
Introduction
Building the Foundation
Wonderware Solution
Considerations
Summary
Summary
► Business Benefit –
▪ Reduce operational costs
▪ Delay the need for investing in new equipment
► Business metrics and KPI’s
▪ Required to track and measure performance
▪ Measure (consistently) to improve
► Wonderware builds the foundation
▪ Modular functionality
▪ Re-usable, repeatable, consistency
► Making the “1st time right” approach not just
a vision but a reality!
Wonderware Ease of Use
► Single development environment
▪ Wonderware Integrated Development
Environment (IDE)
► Single configuration object
▪ Utilization Capability Object
► Pre-built visualization graphics
▪ Downtime, OEE, Production Progress
▪ ArchestrA graphic template
technology
► Pre-configured Web Reports
▪ Out of the box value
Powering intelligent plant
decisions in real time.