FactoryTalk Metrics Introduction Lab

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Copyright 2014 Rockwell Automation, Inc. All Rights Reserved.

Objectives
This is an Introductory Lab, so no prior exposure to FactoryTalk Metrics is
assumed.
If you have prior exposure to FactoryTalk Metrics, you may have seen this
material before.
There is an Advanced Pick & Choose Lab offered
Understand how a user can use the data that FactoryTalk Metrics collects
to help improve operations.
Become familiar with the Report Expert reporting environment.

Copyright 2014 Rockwell Automation, Inc. All Rights Reserved.

Do You Ever Hear This?

Plant Management

How can we
reduce costs?
What is my first
pass quality?

Where are
Scheduling
bottlenecks?

Do we
have enough
capacity?

Knowledge Worker

What are
downtime
causes?

Machine Builder

What is my
equipment
Quality
utilization?

Information Technology

Control Engineering

Operator

Planning and Logistics

Maintenance
Copyright 2014 Rockwell Automation, Inc. All Rights Reserved.

What Are Your Challenges?

You may want to:
Track downtime
Reduce cycle time variation
Increase production without buying new
equipment
Reduce unit costs
Reduce overtime

You may call it:

Bigger question: who doesnt need to:

Make better use of existing assets
Be more productive in manufacturing
Increase profitability

Performance Management
Machine Monitoring
Downtime Tracking
Process Improvement
Overall Equipment Efficiency
(OEE )
LEAN
All of the aboveor none of the
above

Copyright 2014 Rockwell Automation, Inc. All Rights Reserved.

Lets Make This Simpler.

Would You Like to be More Profitable?
Goal: Increase Revenue and Profitability
You suspect this can be done by Increasing the Production of
manufacturing assets and Reducing production Costs.
You are almost certainly right.
This area is often called Performance Management, and OEE is the most
common methodology

Performance Management is the most strategically important IT

investment (23%) (AMR survey)
Copyright 2014 Rockwell Automation, Inc. All Rights Reserved.

Overall Equipment Efficiency (OEE)

Key Performance Indicator
(KPI)

Time

Loss Causes

Available Time
Total * Ideal Cycle

Performance% =

Running Time
Total Scrap

Quality% =

Total

Overall Equipment
Effectiveness (OEE) =
Uptime x Performance x Quality

Down
time

Running Time
Uptime% =

Available Time

Running Time

Production @ Rated Speed

Good Production

OEE %

Speed
Loss

Shift time
Unavailable Time

Scrap

Available Time =

Sched
Unavail

One Shift

Scheduled Unavailable Time

Breaks, meetings, maintenance, etc.

Downtime
Breakdowns, setups, changeovers
Speed/Cycle Time Loss
Reduced speed, cycle time variation
Quality Loss
Rejects, scrap

Lost
Capacity%

Copyright 2014 Rockwell Automation, Inc. All Rights Reserved.

Does an OEE System Make Sense?

There are three general ways to reduce costs in an automated process:
1.
2.
3.

Reduce unproductive machine time

Reduce cycle times
Reduce waste/scrap

OEE measures the three things that reduce costs:

1.
2.
3.

Productive time = Uptime. Are the machines running when expected?

Cycle times = Performance. Are they running as fast as expected?
Good vs. scrap = Quality. Are they wasting cycles and material producing scrap?

OEE % = Availability % x Performance % x Quality %

Higher OEE = Lower costs

Copyright 2014 Rockwell Automation, Inc. All Rights Reserved.

Why is OEE so prevalent?

It is a simple performance indicator that everyone can relate to it is
the ratio of actual good parts produced vs. what could have been
produced under ideal conditions: no downtime, no cycle time
erosion, and no scrap.

OEE = Actual / Ideal

It can be applied to any machine, in any industry, anywhere in the

world.
Because it shows a machines actual performance compared to its
theoretical maximum, OEE can be used to accurately compare the
performance of any machine, line, etc. to any other.
Increasing OEE leads to decreasing costs.

Copyright 2014 Rockwell Automation, Inc. All Rights Reserved.

Is OEE Enough?
OEE is effective at measuring:

Overall Efficiency

Efficiency in 3 broad categories

Progress over time

Comparative performance of machines/lines

OEE data alone is not sufficient to impact performance

Your objective is not just to measure, but to improve

You need to know the WHYs behind the numbers

Need detailed, machine-specific data that uncovers the causes of inefficiency

Without this, you have a stick and no carrot continuing profits for years.

You need OEE and More!

Copyright 2014 Rockwell Automation, Inc. All Rights Reserved.

From OEE to
If you want to:

You must:

Increase
OEE

Reduce:

Which means
Increasing
Availability,
Performance,
Quality

Downtime
Unproductive
time
Cycle times
Scrap

This is where the

improvement
happens.

And that will result in:

Reduced:

Unit costs
Material costs
Labor costs
Capital costs
for more
capacity

Increased:
Production
Revenue
Profitability

And the $$ will

follow!
Copyright 2014 Rockwell Automation, Inc. All Rights Reserved.

10

Whats the Strategy for Reaching Your

Goal?
Goal: Increase Revenue and Profitability by Increasing Production and
Reducing Costs
Strategy: Reduce Downtime, Unproductive Time, Cycle Times, and Scrap

This is where you must take action Directly

Changes here impact Production, Costs, Revenue and Profitability Indirectly
Everyone can participate in this strategy

Copyright 2014 Rockwell Automation, Inc. All Rights Reserved.

11

So How Do You Improve Efficiency?

Strategy: Reduce Downtime, Unproductive Time, Cycle Times, Scrap
You need to measure

Production counts, Scrap rates

Machine cycle times
Downtime durations and causes
Unproductive time (all forms)

You need to analyze

To uncover the real problems that are impacting production

To quantify and prioritize the problems

You need to take corrective action

To make changes that will result in the greatest improvement

To make decisions based on accurate data

Then repeat

You need a system to Measure and Analyze

Copyright 2014 Rockwell Automation, Inc. All Rights Reserved.

12

You Measure and Analyze Now

Typically, information is gathered manually or from various plant
systems. Reports are generated in Excel spreadsheets and
distributed in paper form.
Some issues:
Gathering data is tedious and time
consuming (and expensive)
Manual data collection is inaccurate
Data is stale at time of reporting
Data and reports are not available
for analysis
Data is not detailed enough to be
actionable
No time - you still have to attain
todays production goals!

Is that working for you?

Copyright 2014 Rockwell Automation, Inc. All Rights Reserved.

13

What Will You Do to Get to Your Goal?

Goal: Increase Revenue and Profitability by Increasing Production and
Reducing Costs
Strategy: Reduce Downtime, Unproductive Time, Cycle Times, and Scrap
Methodology:
Measure need a (better) system
Analyze need a (better) system
Take Corrective Action with confidence
Repeat

Copyright 2014 Rockwell Automation, Inc. All Rights Reserved.

14

Something Like This Would be Better

Reliable, accurate,
timely, automatic
data collection
One place for all
data
Flexible reporting
that gives each user
what they need

Copyright 2014 Rockwell Automation, Inc. All Rights Reserved.

15

FactoryTalk Metrics
A complete system for collection and analysis of:

OEE data
Detailed event data required for process improvement
(You need both)

To Measure

Automatic, 24/7 data collection from the control system

Configurable to use existing PLC/HMI programs
Timely and accurate data

To Analyze
Real-time data for plant floor personnel
KPIs and summarized data for management
Detailed downtime and root cause data for driving
corrective action
Context data for multi-dimensional analysis

Copyright 2014 Rockwell Automation, Inc. All Rights Reserved.

16

How Does FactoryTalk Metrics Measure?

Strategy: Reduce Downtime, Unproductive Time, Cycle Times, Scrap
Collects and stores machine performance data

Not on a clipboard; not in an Excel spreadsheet

From the control system, using existing PLC/HMI programs
24/7 in real time timely and accurate
In an open SQL Server database

What kinds of data?

Production counts, Scrap counts

Downtime events and reasons
Events that represent unproductive time (in all its forms)
Context data Part Id, Operator, Work Order, etc.
Minimum needed from control system 1 data point (Good Part Count)
No maximum number of tags the more tags, the more detailed the potential analysis

Takes raw control system data and:

Computes timers and counters, calculates KPIs, cycle times
Computes States using a built-in state engine
Adds context data for analysis

Copyright 2014 Rockwell Automation, Inc. All Rights Reserved.

17

How does FactoryTalk Metrics Analyze?

Strategy: Reduce Downtime, Unproductive Time, Cycle Times, Scrap
Provides 69 out-of the box reports

Dashboards real-time machine information for operators

Performance and production information

Including KPIs, Scrap/Quality, Actual Cycle Times

Event data

Including Downtime and causes, Unproductive Time

Reporting interface that supports/encourages ad-hoc analysis

Dynamic filtering/grouping on all reports

Drill-down and drill-through functionality

Connector to FactoryTalk VantagePoint for Enterprise Manufacturing

Intelligence analysis

Copyright 2014 Rockwell Automation, Inc. All Rights Reserved.

18

FactoryTalk Metrics Architecture

System Configuration

Data Collection

Server

System
Configuration

Define work cell properties and data

collection with Configuration Console

Data Collection
Collects all data automatically via
FactoryTalk Live Data Server and
FactoryTalk Transaction Manager
Aggregates and stores performance
and event data via Metrics Server
Manager
Data editing through Report Expert

Report Client
Report Expert web client using SQL
Server Reporting Services
FactoryTalk VantagePoint Portal
web client

Report Expert reports

FactoryTalk VantagePoint reports
FactoryTalk VantagePoint dashboards

Metrics Server
Manager

SQL Server
Reporting
Services

Configuration
Console

Report Client
FactoryTalk
Transaction Manager

Live Data Server

Report Expert

VantagePoint
Portal
Excel/Trend
VantagePoint

Dashboards

Automation Devices
Copyright 2014 Rockwell Automation, Inc. All Rights Reserved.

19

Whats New in FactoryTalk Metrics

11.50?
Support for Windows Server 2012
Support for SQL Server 2012 SP1
SQL Server 2012 SP1 Standard Edition Included
Existing SQL licenses must be upgraded

Support for Windows 2003 and SQL 2005 dropped

Performance improvements
Reports
Editing

&Metrics

Some new reporting capabilities

New Gantt chart report
Reporting on Event Comments

Includes FactoryTalk VantagePoint 6.0

July 2014
Copyright 2014 Rockwell Automation, Inc. All Rights Reserved.

20

FactoryTalk Metrics Lab Architecture

One VMWare image

Data Collection

Server

System
Configuration

Contents:
FactoryTalk Metrics
Report Expert
FactoryTalk VantagePoint
SQL Server 2008 R2

Metrics Server
Manager

SQL Server
Reporting
Services

Configuration
Console

Report Client
FactoryTalk
Transaction Manager

Control System/simulation
SoftLogix
FactoryTalk View SE

Live Data Server

Report Expert

VantagePoint
Portal
Excel/Trend

SoftLogix

VantagePoint

Dashboards

Copyright 2014 Rockwell Automation, Inc. All Rights Reserved.

21

Introductory Lab Overview

You will use FactoryTalk Metrics 11.0 and Report Expert 3.1
FactoryTalk View Site Edition HMI and SoftLogix provides simulated data.
You will use Report Expert to answer some common questions:

How is my operation performing?

History / Now

By various measures

By Line/Machine/Shift/Part/Operator

How can we start reducing downtime?

Where is the most downtime occurring?

What is causing the most downtime?

Can we increase machine speeds?

Can quality be improved?

How can we get the right information to the right users?

You will use FactoryTalk VantagePoint to view FactoryTalk Metrics data.

Does not cover product configuration. (Thats an Advanced Lab)
Copyright 2014 Rockwell Automation, Inc. All Rights Reserved.

22

Other FactoryTalk Metrics Sessions

MI17 - FactoryTalk Metrics: Pick and Choose Lab

Lab 1 - Report Expert Overview

Lab 2 Configuring FactoryTalk Metrics

Lab 3 FactoryTalk Metrics Connector for FatoryTalk VantagePoint

Lab 4 Manual Workcells and Manual Data Entry

MI15 - FactoryTalk Metrics: Showing Value in 50 Minutes

Customer Case Studies:

AP01 - American Colloid Company: Using FactoryTalk Metrics to Provide Reliable Data to
Improve Plant Operations

AP06 - Barry Callebaut: Reducing Raw Materials Losses With FactoryTalk Metrics

Copyright 2014 Rockwell Automation, Inc. All Rights Reserved.

23

Questions?

PUBLIC INFORMATION
Copyright 2014 Rockwell Automation, Inc. All Rights Reserved.

We care what you think!

Please take a couple minutes to complete a quick
session survey to tell us how were doing.
On the mobile app:
1. Locate session using
Schedule or Agenda Builder
2. Click on the thumbs up icon on
the lower right corner of the
session detail
3. Complete survey
4. Click the Submit Form button

Thank you!!

4
Copyright 2014 Rockwell Automation, Inc. All Rights Reserved.

25

Thank you for participating!

Please remember to tidy up your work area for the next session.
We want your feedback! Please complete the session survey!

Minimize the VMWare image

Click on the Survey link on the Desktop of the Host computer

Session Id =
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Copyright 2014 Rockwell Automation, Inc. All Rights Reserved.