FactoryTalk Metrics Customer Presentation PPT (v10.0)

FactoryTalk Metrics
Copyright © 2012 Rockwell Automation, Inc. All rights reserved.

Agenda
1. Manufacturing Challenges
2. Performance Management – OEE and More
3. FactoryTalk Metrics Solution
4. Summary and Q&A
Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 2

Do You Ever Hear This?
Plant Management
How can we
reduce costs?
What is my first
Where are pass quality?
bottlenecks?
Scheduling
Knowledge Worker
Do we
have enough What are Machine Builder
capacity? downtime
causes?
What is my
equipment
Information Technology
utilization?
Quality
Operator Control Engineering
Planning and Logistics

Maintenance
What Are Your Challenges?
 You may want to:  You may call it:

 Track downtime  Performance Management
 Reduce cycle time variation  Machine Monitoring
 Increase production without buying new  Downtime Tracking
equipment  Process Improvement
 Reduce unit costs  Overall Equipment
 Reduce overtime Efficiency (OEE )
 LEAN
 Bigger question: who doesn’t need to:
 All of the above…or none of
 Make better use of existing assets
the above…
 Be more productive in manufacturing
 Increase profitability
Copyright © 2011 Rockwell Automation, Inc. All rights reserved. Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 4
Let’s 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)
Performance Management
Success Stories
 Food Producer
 Focused on capacity
 Determined that a new budgeted piece of equipment was not needed – saved
millions of dollars in the first week!
 Tier 1 Automotive Supplier

 Focused on quality – identifying and tracking defects
 Reduced defects by 90% - saved thousands of dollars per defect
 Packaging supplier
 Continuing focus on fixing the current #1 efficiency problem
 Increased production to twice the rate of an identical plant
 Invested $100K, increased profits $1.2M per year
ROI in weeks, continuing profits for years.

Agenda
4. Summary and Q&A

Overall Equipment Efficiency (OEE)
Key Performance Indicator Time Loss Causes
(KPI)
One Shift
Unavail
Scheduled Unavailable Time
Sched
Available Time = Shift time –
Unavailable Time Available Time
Breaks, meetings, maintenance, etc.
Down
Running Time Downtime
time
Availability% = Running Time
Available Time Breakdowns, setups, changeovers
Total * Ideal Cycle Speed/Cycle Time Loss
Speed
Loss
Performance% = Production @ Rated Speed
Running Time Reduced speed, cycle time variation
Total – Scrap Quality Loss
Scrap
Quality% = Good Production
Total Rejects, scrap
Overall Equipment Lost

Effectiveness (OEE) = OEE % Capacity%
Availability x Performance x Quality

Does an OEE System Make Sense?
 There are three general ways to reduce costs in an automated process:
1. Reduce unproductive machine time
2. Reduce cycle times
3. Reduce waste/scrap
 OEE measures the three things that reduce costs:
1. Productive time = “Availability”. Are the machines running when expected?
2. Cycle times = “Performance”. Are they running as fast as expected?
3. Good vs. scrap = “Quality”. Are they wasting cycles and material producing scrap?
 OEE % = Availability % x Performance % x Quality %
 Higher OEE = Lower costs

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 machine’s 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.

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
 The improvement, and the money that it generates, requires more data
 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!

From OEE to
If you want to: You must: And that will result in:
Increase Reduce: Reduced:

OEE… • Downtime • Unit costs
• Unproductive • Material costs Increased:
Which means • Production
Increasing • Labor costs
• Revenue
• Availability, time • Capital costs
• Profitability
• Performance, • Cycle times for more
• Quality • Scrap capacity
This is where the And the $$ will

improvement follow!
happens.
What’s 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

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 the changes that will result in greatest improvement
 To make decisions based on accurate data
 Then “repeat”…
You need a system to Measure and Analyze

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

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
today’s production goals!
How is that working for you?
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

What About Lean or Six Sigma?
 Six Sigma
 DMAIC (Define/Measure/Analyze/Improve/Control) is a
standard breakdown for existing processes
 “Measure” and “Analyze” are things at which FactoryTalk
Metrics excels
 Lean
 An effort to reduce waste in nearly any form, including
scrap and production inefficiency
 MEASURING is crucial - you can’t fix what you can’t
measure
 “Overall equipment effectiveness (OEE) is a set of
performance metrics that fit well in a Lean environment.” –
Wikipedia

Agenda
4. Summary and Q&A

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
 KPI’s and summarized data for management
 Detailed downtime and root cause data for driving
corrective action
 Context data for multi-dimensional analysis
How Does FactoryTalk Metrics Measure?
 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

How does FactoryTalk Metrics Analyze?

 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

Dashboards for Plant-Floor Personnel to
Enable Increased Efficiency
 Real-time information
on machine
performance
 See what’s happening
while there’s still time
to react
 Operators receive
information, instead of
recording information
Drill-through links
for more detailed data.

OEE and Production Data
 Data collected for all monitored machines
 OEE and 3 components
 Production counts – Total, Good, Scrap
 Available time, Downtime, Running time
 Slice and dice in up to 9 dimensions for reporting
 Date/time, Plant Model, Shift, Part, 5 user-defined
OEE and all data by

Line/Workcell/Date/Shift/Part!

Event Data to Assist with
Process Improvements
 FactoryTalk Metrics excels as
an Event Tracking System
 Downtime and reasons
 Unproductive Time – Blocked,
Starved, Setup, etc.
 Event Data can tell you Why
and How
 Why a machine is inefficient
 How it is spending its time
 This Event report is showing
Faults and Estops –
frequency and duration
This Fault causes more
 Configurable, based on downtime
 Machine being monitored than any other in the plant!
 Control system programming

Agenda
2. Role-based Reporting Solutions to Meet Challenges
4. Summary and Q&A

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
FactoryTalk Metrics is key to reaching your goal!

What Results Can You Expect?
 Increased capacity
 More product, revenue and profit in the same amount of time
 Decreased manufacturing costs
 Less overtime, reduced labor costs
 Deferred capital expenditures
 Make your current equipment produce more
 Decreased cost of quality
 Improved quality
 Lower material costs
 Decreased overhead costs
 Save time in collecting data and preparing reports
Efficiency improvements of 10-40% are typical!

You May Be a Potential FactoryTalk
Metrics User if You…
 Have a directive or desire to measure Overall Equipment Efficiency or
other Key Performance Indicators
 Have a system that tracks downtime that is inadequate (electronic or paper)
 Have utilization/downtime problems, but can’t seem to improve
 Are at capacity and considering adding more equipment or shifts
 Have excessive overtime
 Have an active Six Sigma quality program
 Have sufficient automation in place to provide data

Questions?

For more information:
http://discover.rockwellautomation.com/OEE
Todd Smith
Product Manager, FactoryTalk Metrics
[email protected]

Thank You
For more information, visit us at discover.rockwellautomation.com/OEE
Follow ROKAutomation on Facebook & Twitter.

Connect with us on LinkedIn.
www.rockwellautomation.com

Reference Slides

Discussion Topics
 Do you have a requirement to provide OEE or other performance data to management? If so, how
do you do it now? Is the data accurate and timely? Is it widely used within the plant? How much
does it cost over the course of a year to generate?
 Do you have efficiency, process improvement or cost reduction goals? Do you know how you will
reach them? Can you measure them? Are other plants in your organization operating more
efficiently?
 Does your staff spend any time disagreeing about the amount of downtime or its causes? Would it
be valuable if that information was readily available and they were working on the highest-value
improvements instead?
 Do you need to schedule overtime to make production goals? Is the plant’s ability to produce
consistent or inconsistent?
 Is your plant at capacity and you are considering adding more shifts or purchasing more equipment?
Are you confident your existing equipment is not capable of producing more? Do you have to prove
that to make a capital expenditure?
 What impact would a 1% increase in overall equipment efficiency have on the bottom line for this
plant? Does the possibility of realizing that number, perhaps many times over, make this worth
pursuing?
Different Users, Different Needs
Plant Mgmt.
 Plant Management cares about
 Costs, production output, overall efficiency
 Financial indicators, capacity
Production  Production mgmt care about

 Production output, achieving targets
 Efficiency of production
Ops/Quality  Ops/quality cares about

 Systemic problems
 Ways to improve production and yield
Maintenance  Maintenance cares about

 Reducing downtime
 Maintaining equipment without impacting
production
Operator
 Operators care about
 Monitoring process to keep production running
 Identifying problems in real time

Operator

Operator
Challenge Resource Benefits
Current Status of machines; VP workcell dashboard Integrated current and shift-

current shift performance to-date information
Identifying problems in real Standard dashboard See what’s happening while

time there is still time to react.
Remembering all the details Automatic data collection This responsibility is

for a post-shift report eliminated! Now operators
are information consumers,
not scribes.

Supervisor

Shift Supervisor
Current status of machines Dashboards, State History See what’s happening while
and lines; Current Shift report there is still time to react.
performance
Understanding performance Historical analysis of Understand progress over

over time; Differences performance data time
between shifts
Identify recurring problems Event reports, Pareto charts Know if today’s problem is
part of a pattern.

Operations Manager

Operations Manager
Recurring/systemic Event Reports, Pareto Seeing the plant-wide impact

problems; Understanding Charts, Line summary data of problems
largest losses
Differences between Use Context data to make Understand and eliminate
lines/products/shifts comparisons variations.
Identifying areas were more State engine – how much System can scale up as new
data is required time is in “undefined” states? requirements for data
collection are identified.
Improve quality Scrap counts, KPIs, Scrap Reducing scrap increases
reasons capacity and reduces
material costs

Plant Manager
Plant production Production and Performance Understand performance at all

information at all levels of the levels. Compare to other plants
plant. in the company.
Understanding of plant Ideal Capacity KPI, TEEP KPI Can confidently answer what-
capacity ifs: Can we take on new
products? Do we need to add
more capacity?
Reduce costs Focus on Availability, Lower fixed costs; lower unit
Performance, Quality - the things costs
that drive costs in the plant.
Increase profitability Increasing OEE leads to Higher revenue + lower costs =
increased production increased profitability

Maintenance
How often are machines MTBF, MTTR, Faults reports Everyone has the same
breaking down? accurate data.
Which faults are causing the Event reports and pareto Spend time on most
most downtime? charts important failures.
Is our maintenance program Scheduled Maintenance time Adjust program based on

working? vs. Emergency Repair time actual results.
vs. Downtime

FactoryTalk Metrics Data Model
OEE and its 3 components Production Data
• For any time period • Data to calculate OEE
• For any part of the plant model • Production counts, Scrap
• Available time / Running Time / Downtime
• Cycle Times
Custom Events/States
• What are the machines
doing?
• Downtime, Unproductive time
• State engine
OEE • Time tracking
• Uncover root causes
Context Data
• Used to filter and slice/dice other
data
• By Date/Time/Shift
• By Plant Model
• By User-defined:
Part/Operator/Batch/Work Order, etc.
Context Data
 All FactoryTalk Metrics data contains 9 levels of context

 Time and time parts - hour, day, week, month, etc.
 Shift, Shift instance
 Plant model – Enterprise, site, area, line, work cell
 Product (or Part Id)
 Up to 5 user-defined context fields (Flex Fields)
 Operator
 Work Order
 Batch
 Etc.
 All reports can use context data for:

 Filtering
 Grouping and summarizing

Data Available for Analysis
Production Data KPI’s Event Data State Data Context Data
•Good Part Count • OEE% • Event Category • State Name • Plant Model
•Scrap Part Count • TEEP • Event Name • State Duration (Enterprise/Site/
•Total Part Count • Availability% • Event Reason • State Area/Line/Workcell)
• Scheduled • Performance% • Event Starting Occurrence • Date/Time
Available Time • Quality% Value Count (Hour/Date/Day/
Week/Month/Year)
•Available Time • Running% • Event Ending
• Shift
•Running Time • Good Parts% Value
• Shift Instance
•Downtime • Scrap% • Event Reporting
• Part Id
•Faults • Downtime% Value
• Five User-
•Faulted Time • Available% • Event Severity
Defined Fields
• Fault% • Event Duration
• Ideal Capacity • Event
• Failure Rate Occurrence
• Failure Count
Frequency
• MTBF
• MTTR

FactoryTalk Metrics Architecture
System
Data Collection Configuration
 System Configuration
 Define work cell properties and data
collection with Configuration Console
 Data Collection - Measure Configuration

 Collects all data automatically via Metrics Server Console
Manager
FactoryTalk Live Data Server and Report Client
FactoryTalk Transaction Manager
 Aggregates and stores performance and FactoryTalk SQL Server
Reporting
Transaction Manager
event data via Metrics Server Manager in a Services
SQL Server database
 Reporting - Analyze
 Report Expert – web client using SQL Server Live Data Server Report Expert
Reporting Services
 FactoryTalk VantagePoint Portal – web client
VantagePoint
 Report Expert reports Portal
Excel/Trend
 FactoryTalk VantagePoint reports VantagePoint
Dashboards
 FactoryTalk VantagePoint dashboards
Automation Devices
Configuring FactoryTalk Metrics
 It is a Configured application, does not require custom code
 Compatible with any control system hardware/software using OPC
 Configuration of each workcell that will be monitored can be done:
 Manually, using a wizard
 Using XML files
 Using a FactoryTalk Metrics UDT (requires ControlLogix)
 Configuration can evolve/expand over time

 There are ControlLogix-based UDTs for accelerated configuration
 Can be done by Rockwell or a qualified partner
 A small-scale Express Proof of Concept (xPOC) can be done in one day

Configuring Metrics Data Collection
Simplified Even More with User
Defined Type (UDT) in Logix &
Header Information
Workcell Configuration Tool to speed
Actual & Ideal Cycle Time
development
by Part ID
Fixed? PLC? List?
Summarization
None?
Part PLC? Default Value?
Count
None? Availability
Workcell PLC? Formula?
Plant
CustomSchedule
Events or Workcell Driven
, Downtime
Tracking & Reason Codes
Copyright © 2011 Rockwell Automation, Inc. All rights reserved. Copyright © 2012 Rockwell Automation, Inc. All rights reserved.

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FactoryTalk Metrics

Copyright © 2012 Rockwell Automation, Inc. All rights reserved.

2. Performance Management – OEE and More

3. FactoryTalk Metrics Solution

4. Summary and Q&A

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 2

Operator Control Engineering

Planning and Logistics

 You may want to:  You may call it:

Performance Management is the most strategically important

 Tier 1 Automotive Supplier

ROI in weeks, continuing profits for years.

2. Performance Management – OEE and More

3. FactoryTalk Metrics Solution

4. Summary and Q&A

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 7

Total * Ideal Cycle Speed/Cycle Time Loss

Total – Scrap Quality Loss

Overall Equipment Lost

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 8

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 9

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

 Because it shows a machine’s actual performance compared to its

 Increasing OEE leads to decreasing costs.

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 10

 OEE is effective at measuring:

 OEE data alone is not sufficient to impact performance

You need OEE … and More!

Increase Reduce: Reduced:

This is where the And the $$ will

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 13

 You need to “analyze”…

You need a system to Measure and Analyze

 Goal: Increase Revenue and Profitability by Increasing Production and

 Strategy: Reduce Downtime, Unproductive Time, Cycle Times, and Scrap

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 15

Typically, information is gathered manually or from various plant

 One place for all

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 17

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 18

2. Performance Management – OEE and More

3. FactoryTalk Metrics Solution

4. Summary and Q&A

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 19

 What kinds of data?

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 21

Strategy: Reduce Downtime, Unproductive Time, Cycle Times, Scrap

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 22

Copyright © 2012 Rockwell Automation, Inc. All rights reserved.

OEE and all data by

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 24

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 25

2. Role-based Reporting Solutions to Meet Challenges

3. FactoryTalk Metrics Solution

4. Summary and Q&A

Copyright © 2012 Rockwell Automation, Inc. All rights reserved. 26

 Goal: Increase Revenue and Profitability by Increasing Production and