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siemens.com/simatic-it

SIMATIC IT Historian

Siemens AG 2013 All rights reserved. siemens.com/answers


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ro uc on pera on ar ua y pera on ar

Production Production

Siemens AG 2013 All rights reserved.

Page 3 Author / Department


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ompe ve pressure s orc ng manu ac urers o n a e us ness per ormance

improvement strategies

Each role in the enterprise must be empowered with accessible, meaningful and

consistent information which improves the decision making process

Improvements strategies cannot be effective without putting data into a business

The goal is to transform data into information, and information into insight.

Carly Fiorina (1954)




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SIMATIC IT Historian:

rov es a e oo s o an e an ana yze s op oor a a

KPI calculation and validation

Long Term Archive concept

Data analysis tools

Reporting

Web based data distribution, analysis and reporting

Integrated with SIMATIC IT Production Suite

KPI management




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Integrated with SIMATIC BATCH:

rov es a e oo s o an e an ana yze s op oor a a

Batch Archive

Electronic Batch Reporting

Integrated with SIMATIC WinCC/PCS7:

Scalable Plant Intelligence Solution

Product Options

OEE-DTM (Overall Equipment Effectiveness and Downtime Management)



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Real-time dataSIMATIC IT RTDS

transforms them into valuable information

OPC Server WinCC Data Manager

( Data compression

with optional Plant Data

Archive module )

SIMATIC IT PlantPerformance Analyzer

OPC Server WinCC Archive Relational Database

s or ca a a sources

RDB

Alarms events

Long-term archive

Batch data

n rc ve r ar y app ca ons



SIMATIC BATCHCustom data


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Applicable on data from historical data

sources

Pre-defined aggregations available(Average, Min, Max, Sum, )

Validation functions

Set the ualit code GOOD or BAD INPUT PARAMETERS

of the samples Can be applied on raw data or on

calculated data

Custom algorithms with PPA scripting

environment




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Trend Viewer Bargraph Viewer

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Production Viewer X-Y chart




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Message analyser

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Message Viewer




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PPA automatically stores Batch information from SIMATIC

BATCH:

Batch stepping sequence

Batch-related messages

Batch-related measures (trends)

Analyze Batch events and related data (trends, alarms, KPIs)

A Query Tool is available in order to

select batches

Search criteria can be applied to any

Batch characteristic

Batch reporting



Pre-defined batch reports


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A Formula Editor inte rated in HDD controls allows on-the-fl anal sis based

on archived data

It is possible to save and reuse formula templates




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epor ng ramewor ex en s e unc ona y o

Production Suite by providing:

, ,

exposed according to the ISA 95 standard

ea y- o-use n us ry spec c repor

templates and report parts integrated inMicrosoft Report Builder

Access to reports through SIMATIC IT

Portal, controlled by SIMATIC IT User




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abstraction model that better works for him

Business Model

Business information

Consolidated data

SIMATIC IT terminology

Business reports

Data Model Production data

Real time data

O erational re orts

Physical Model




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understand the complexity of database logic or to be familiar with the tool where

the physical data is stored.

The following MES relevant information are

available for reporting purposes

S95 entit iese.g. Equipment model, Orders, Materials, PPRs, Shift

, , .

Historical tags

OEE SPC and EBR data

Compliance Services and Logbook info




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The Business Model is built around the standard business terminolo of ISA 95

and provides the end-user the ability to autonomously query and retrieve

information using common business terms.




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to the right users through a web-based client interface at Zero Administration Cost

Embed pre-defined viewers in CAB screens

Display data by means of dedicated interfaces

Graphically build queries using Smart Query Builder(SQB)




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Assign KPI to Equipment Classes (site, area, cell, unit) in the Plant Model

Schedule KPI calculation directly from Production Modeler rules

PPA automatically contextualizes KPIs against manufacturing events or elements

(production runs, batches, production orders, equipments, )

Activate KPI 1Activate KPI 1 Calculate KPI 2Calculate KPI 2 Calculate KPI 3Calculate KPI 3 Deactivate KPI 1Deactivate KPI 1

Trace Trace

Production Operation Production Step Production Step

Production Viewer allows analyzing KPIs relevant to a specific production event



Comparison of KPIs can be done using Bargraph Viewer or Trend Viewer


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and Compliance Services

Audit Trail and/or Electronic Signature can be applied to any modification of archived data

u cus om za on o ec ron c gna ure scenar os s suppor e




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User specific, up-to-date and comprehensive information offers crucial

business advantages

each corporate level

Faster and better understanding and solving problems

Reduce downtimes and idle-times

Optimization of production processes

Quality performance improvements

Reduction of paper based activities

Reduction of production costs

Support compliance to regulations and normative practices




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Product Options:

OEE-DTM

(Overall Equipment Effectivenness and Downtime Management)

SPC-SQC

(Statistical Process Control and Statistical Quality Control)




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Hi h Performance, hi h Qualit , hi h Availabilit

the everyday targets in the plant

need to improve maintenance and operational performances

Which is the actual performance against my performance targets?

How effectively is the organization using its assets?

Wh m ca acit is idle or non- roductive?

Are resources being used efficiently for the products currently

produced?

What is the economic impact of the inefficiency?

inefficiencies?

Why two teams, that appear to be equal, produce products that are

so different?

Does your process create waste when stopped?



All necessary data must be available to make informed decisions


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identified and

classified as the Six Big Losses

Six Big Losses Category Comment

Breakdowns

Setup / Adjustments

Downtime Loss

Downtime Loss

Difference between Breakdown and Small Stop

Includes tool changeovers

Small Stops / Idling

Reduced Speed

Speed Loss

Speed Loss

Only stops under (5) minutes and no maintenance

Process not running at its theoretical speed

Startup Rejects

Production Rejects

Quality Loss

Quality Loss

Scraps in warm-up, startup or other early product ion

Scraps during steady-state production




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OEE is a total measure of erformance that relates the availabilit of rocess to

OEE controls and reduces the Six Big Losses

productivity and quality

OEE-Category OEE-Calculation

Standby Not part of OEE calculation

own me oss va a y: s e ra o o opera ng me o p anne pro uc on me.

100% availability means the process has been running with no recorded

stops

Speed Loss Performance: is the ratio of ideal cycle time to actual cyc le time, or

alternatively the ratio of actual run rate to ideal run rate.

100% performance means the process has been consistently running at its

Quality Loss

Quality: is the ratio of good parts to total parts.

100% quality means there have been no reject or failure in parts



OEE = Availability * Performance * Quality


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World Class OEE is considered to be 85% or more

verage o ra e n manu ac ur ng p an s s

OEE FACTOR World Class

Six Sigma is not enough!Availability 90,0 %

Performance 95,0 %

doesnt mean

OEE >= 85% !

Quality 99,0 %

OVERALL OEE 84,6 %

Big Room for Improvements




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ep oyment o equ pment e c enc es an ownt me management so ut on

Time model Define general time categories as a basis for Key Performance

definition

Modeler

configuration Indicators (KPI) calculation

Reason tree Define all the possible equipment status conditions (failures,

, , ,

Data collection

configuration Configure data collection in SIMATIC IT Historian

KPI configuration Customize and personalize KPI algorithms




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SIMATIC IT OEE-DTM is a product option of SIMATIC IT Historian, and it is wholly

and seamlessly integrated within the entire MES solution

SIMATIC IT for OEE, through integration with the entire SIMATIC IT environment,

allows:

the calculation of all standard and custom KPIs to fully support the Downtime Management

to perform active and corrective actions to react to efficiency decreases

to improve economic Return on Investments (ROI)

to maximize the plant performance




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Pre-defined standard KPIs algorithms:

Availability rate, Performance rate, Quality rate, OEE,

MTTA, MTBF, MTTR, MTBA, and more

Possibility to create new custom KPIs algorithms,

combining the existing ones or implementing brandnew ones

ese n ca ors, manage y - , are ava a e e er :

for executives (who, having an extended vision of the overall plant, manage indicators and charts)

for operators (who mainly monitor run-time views, customizing downtime parameters, and have a restricted view of a



spec c un


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Downtime Management:

detailed information about equipment states

, ,by equipment, status, product, or any other

context data

Downtime Analysis:

enables exploring the causes that have

enerated a roduction breakdown




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or prov es a num er o pre e ne grap cs screens spec ca y u n

order to provide out-of-the-box analysis OEE-related KPIs and equipment downtimes

re- e ne grap c o ec s are ava a e o u a ona grap cs

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the user interface, since the user interface is built on top of standard technology (namely .Net

from Microsoft) a wide range of third-party graphic objects can be embedded in any GUI

interface for OEE anal sis




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Time Model:

through its graphical representation, it provides an easy way to create

the complex model

Reason Tree:it defines in details the hierarchy of all the possible machine states within

the defined time categories for individual or for groups of equipments

Shift Calendar (SHC) Management:

strong integration between equipments and calendars are defined in the

SHC component




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Produced units, scraps, reworked units and any other

production counter can be displayed and summarized,

according to the different grouping criteria

Current production can be compared with theoretical

SIMATIC IT for OEE makes use of SIMATIC IT Report Manager in

order to provide flexible and effective performance reporting(customized according to the user needs)

Reports can be launched directly from the web




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.

Planned / Induced Downtime Management

MES Context Support

On Value Change Design Speed Acquisition

GUI Enhancements

Predefined Reports

Documentation enhancements

Note: SIMATIC IT OEE V1.2 SP2 is compatible with SIMATIC IT Production Suite V6.3 SP2




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,

Web Client page, or programmatically through COM or GSI methods:

anne own mes

which cause OEE to disregard the status information retrieved from the field

for the specified time span, are used when an equipment have predefined

planned time where it is off-line.

Induced Downtimes

used to model a bottleneck situation, where the machine state of a piece of

e ui ment de ends on the state of another iece of e ui ment. The areused to put in Downtime status an equipment on real-time.




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anne own me s a per o o own me con gure o occur n e u ure.

e o ow ng parame ers e ne a p anne own me:

A start-time and an end-time

o n e u ure

A machine state

The piece(s) of equipment involved




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n n uce own me s a per o o own me w c was cause y ano er

downtime occurring on a different piece of equipment.

A start time set when the record is opened

A machine state

The piece(s) of equipment involved




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,

counter and design speed records:

GroupName

UserName

LotID

r er

BatchID

Shift

manually (by a programmatic interface)

automatically (by either a screen or a Production Modeler rule)



On Value Change Design Speed


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g g p

n . . ere s e poss y o acqu re es gn spee va ues on a a

change:

the user must define two RTDS points (one to trigger the design speed reading

and one to retrieve the design speed value)

Now, the user can easily define all

the parameters of design speed

acquisition, beyond product id

and context ac uisition




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The followin redefined a es are rovided full -inte rated in SIMATIC IT CAB

Portal:

Counters Graphic

Counters Grouped

KPI Viewer

Counters Viewer

Design Speed Viewer

DTM Viewer

Gantt Viewer

Runtime Operator Panel

Equipment Comparison

Context Management



anne own me


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e o ow ng repor s are prov e :

Actual &Target

Downtime

DTM Detail

Availability details

Counter values

DTM values




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This version includes the following new documents:

OEE Developer Guide:

a comprehensive guide on how to use OEE programmatic interfaces to develop custom applications

OEE Installation Manual:a dedicated installation manual for SIMATIC IT OEE

OEE Web Client Documentation:new contextual documentation accessible directly from OEE Web Client pages

Additionally, the following existing documents have been substantially updated:

OEE Functional Overview




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Through integration with

SIMATIC IT Product ion Modeler:

SIMATIC IT OEE-DTM

key benefits:

Increase acquisition performances using high speed

acquisition rules

Customization of the application through the user-

-information

Preventing unscheduled downtimes

exits capabilities, inside the Production Modeler (PM)

rules

S eedin -u ac uisition erformances b bufferin

Improving of data synchronization and safety with data

recovery system

Maximization of production equipment utilization

mechanisms

Improvement of the acquired data contextualization

Reducing maintenance costs by optimizing planning

activities

Improving assessment and business process

Definition of high-level contexts Easy Import / Export configuration data from Excel

worksheets



p m z ng pro uc qua y gra ng process


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a piece of equipment in a trend graph

Additionally, it is also possible

to display the equipment units

design speed in the trend,

if it was configured during the

.




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user-defined filters on contexts

Such filters can be set if

counter values where acquired with

phase.




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KPI Viewerdisplays KPIs associated to a particular piece of equipment using

one of the following graphs:

Bargraph

Trend

Stacked bargraph Pareto chart




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oun ers ewer sp ays coun er recor s n a u ar orm




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,

gives the user the possibility to edit them and export them to a CSV file




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equipment in a Gantt chart

The user can perform the following actions:

Filter data by

e ui ment

context

time interval

Zoom in and out the chart

Export and print data




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piece of equipment

Two types of trend charts can be displayed:

to view the values of all the counters

associated to the piece of equipment

OEE Chart

to view all OEE indicators associated

to the piece of equipment.




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qu pmen ompar son g ves e user e oppor un y o compare wo

or more pieces of equipment

For each piece of equipment, the following

KPIs are displayed (if available):

OEE

Availability

Performance

Quality

Current counter values



Note: This page provides only real-time data and can be configured to refresh itself automatically or manually.


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Context Management can be used to set the current values for one or more

contexts which were defined during the engineering phase

By doing so, it is possible to modify

contextualization of:

design speed, counter




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anne own me a ows e user o se a anne own me or one

or more equipment




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SPC project opportunities are still under evaluation on behalf of

SIMATIC IT Product Management

For further information lease contact:

[email protected]




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For further information please contact:

[email protected]

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