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Themes - iFIX_ Historian_ Portal_ MES_ VIX Automation

VIEWS: 6 PAGES: 27

  • pg 1
									Proficy Functional
Overview

Sheila Kester
September 24, 2009
Proficy in a Production Plant            Open
                                                  Flexible
                                                  Building
                                                   Blocks



                                          and
                                        Layered


                                                      Operational
                                                        Model




                                                     2/
                                GE Title or job number /
                                              1/25/2012
                                           iFIX/Cimplicity


                                                                             HMI
                                            Change Mgt

                                          Batch Execution

                                          Plant Applications
                                                                             MES

                                              Datamart

                                           Maint. Gateway




                            Modules
                                             Scheduler
                                                                                                  Excellence Platform




                                              Tracker

                                              Historian
                                                               Proficy SOA




                                               Portal

                                           Troubleshooter
                                              Workflow
                                                                             Historian Workflow




                                          Open Enterprise
                                                                                                  Introducing the Proficy Operational




                                            Data/Equip.
                                                                                  3rd




                                             Models
                                                                                 Party




                                              Events
                                                                              Applications




              1/25/2012
                           Services 3 /
GE Title or job number /
What is Proficy?
Real insight, real-time. Automates and
integrates the information activities of
performance management. It enhances the
ability to optimize and balance operating
priorities in manufacturing. Connects and
scales across the supply chain.




                                                          4/
                                     GE Title or job number /
                                                   1/25/2012
With Proficy,
you can!
Collect – Analyze – Control - Share real time
production data across your enterprise!
• Full-featured HMI/SCADA on the Web
• Plug-and-Play thin client, zero config
• Operator Container for all Proficy
   products
• One time iFIX/Historian DB Configuration
• Standards Supported, Extensive
   Connectivity, Failover & Synchronization
• Open & Layered, Scalable, Flexible, &
   Proven
Value
• Discovery & Auto Configure (DAC) Tool
       • Deployment Speed
• Available on Embedded Platforms
       • Control and Data analysis

        • Maintenance/Expansion Costs
        • TCO                                     iFIX             6/
                                              GE Title or job number /
                                                            1/25/2012
  Deploy Faster…
  from the Machine to the Enterprise
 • Out-of-the-box screen templates &
    configurable objects for faster
    development
 • OMAC Standards compliance
 • Includes machine performance, manual
    fault entry and fault analysis templates.
 • Trend screens for instant
    troubleshooting and further data
    extrapolation at the machine.
Value
           • Development & stds alignment
           • Application Consistency

           • Customization and integration
           • Costs & time to solution             iFIX OEM
                                                                       7/
                                                      GE Title Pack
                                                Solutions or job1/25/2012/
                                                                 number
Store & Retrieve Process & Plant Data –
FAST!! production/process data into a common repository
 •Consolidate

  •Built-in Data Collection, Faster Speeds, Higher Data Compression

  •Robust Redundancy for High Availability

  •Quicker Time to Value/Easy to Use

  •Enhanced Data Security, Data Governance


  Value

          System Response Time                                  Historian
          Access to Information

          Systems Downtime
          Performance Delays
                                                                                     8/
                                                                GE Title or job number /
                                                                              1/25/2012
Find “Hidden” Correlations, ID Root Causes
– FAST!
  • Advanced analytical capabilities in modeling and simulation allowing better
  understanding of causes of process variations and problems, impact on
  assets

  • Build business cases with knowledge extracted and benefit estimations
  done before attempting real-time solutions.

  • Prevents unnecessary conventional “alarm bursts”
  • Capture expert knowledge for real-time expert system use as well as
  making modelling and expert system technology available to “normal” users.
  Value
          Root Cause Identification
          Flexibility for “What If” Analysis
          Supplier Performance
                                                               Troubleshooter
          Quality Problems
          Performance Delays                                                          9/
                                                                 GE Title or job number /
                                                                               1/25/2012
Make Every Operator Your Best Operator
•Electronically guide operators through step-by-step instructions
•Ensure production complies with defined processes - with validated entry
•Capture both automated and manual data entry
•Digitize and enforce compliance with policy manuals and Standard
Operating Procedures (SOPs)
•Troubleshooting trees to rapidly determine root cause and best solution
•Train new personnel using best practices
•Support LEAN Initiatives

Value
        Quality (first time thru) by reducing errors
        Throughput / Yield by reducing errors
        Compliance by enforcing SOPs
                                                                     iFIX
        Costs by reducing errors and waste
                                                                Workflow
        Training time through electronic instruction
        Risk by enforcing SOP compliance                                            10 /
                                                                GE Title or job number /
                                                                              1/25/2012
Manage Product Specifications & Recipes
•Connect Product/Engineering specs with production work processes
•Automate the process of spec changes and route changes for approval
•Ensure cross-functional team knows about critical changes
•Speed changes to production work processes to quickly reflect new specs
•Manage site recipe --> master recipe --> control recipe

Value
        Quality - more complete spec implementation
        Productivity - faster spec implementation
        Compliance with new specs
        Agility to respond to changes
                                                                 Batch
        Costs through less waste and training
        Time to implement new specs/recipes                Plant Applications
        Risk with improved production agility                  Workflow
                                                                                  11 /
                                                              GE Title or job number /
                                                                            1/25/2012
Automate QA Plans, Sampling, & Actions
•Automate and manage the Quality Assurance plan and sampling
•Automatically trigger QA sampling based on production events or elapsed
time
•Automatically trigger non-conformance workflows to manage assignments,
inventories, rework, quarantines and recalls
•Guide operators through supplemental work
•Bracket product batches/lots suspected of sharing a quality problem
•Close the loop on non conformance, investigation and corrective action - and
record data for analysis and ISO, GMP and other compliance
Value
        Quality through improved product consistency,
        /closing the loop on non-conformance
        Efficiency - improved QA and faster response

        Costs - reducing waste & scarp                       Plant Applications
        Time - to modify specs and work processes due to         Workflow
        quality issues
        Risk through improved QA and enforcing                                      12 /
                                                                GE Title or job number /
                                                                              1/25/2012
        non conformance SOPs
Manage Alarms and Take Corrective
Action and dynamically respond to production problems and events,
•Automatically
monitoring alarms from multiple systems
•Send tasks to people or other systems to correct for alarms in real time - and
escalate as needed
•Store execution data for visibility, analysis and continuous improvement
•Minimize nuisance alarms and ensure proper action on critical alarms
•Digitize “Proof of Effectiveness” loop in ISO-900x
Value
        Uptime/throughput/yield faster response
        Quality through automatic corrective action
        Compliance with correction action plans
                                                               Plant Applications
        Costs by reducing waste and labor
        Downtime through faster response                               iFIX
        Risk through automatic remediation or escalation           Workflow
                                                                                      13 /
                                                                  GE Title or job number /
                                                                                1/25/2012
Reduce Changeover Time
•Walk operators through the steps to set up a machine or recipe
•Provide links to all reference documentation needed for completing the tasks
•Record the time it takes operators to complete each step
•Require input from the operator at various steps - or from multiple operators
•Verify proper machine or recipe set up prior to raw materials usage
Value

        Efficiency through faster production set up
        Quality by ensuring proper set up
        Agility for changing production
        Sustainability of production processes

        Costs of machine changeover & errors
        Downtime associated with equipment set up
        Inventory through less waste                              Workflow
                                                                                      14 /
                                                                  GE Title or job number /
                                                                                1/25/2012
 Manage Batch Orders….
 • ISA-88 based object-oriented batch
    management and execution
 • Active Binding™ for dynamic unit
    allocation
 • Accommodates for complex operator
    workflow
                                        More …
 • Open API for customization
                                        • Campaign Management
 • Comprehensive and secure batch       • Batch Transition Breakpoints
    archives with active journaling     • Recipe parameters in
 • Designed for 21 CFR Part 11
Value                                      Formulations

         • Consistency and product
           quality
         • Flexible manufacturing
         • Time to solution
           Equipment utilization
         • Validation costs                       Batch Execution
                                                                             15 /
         • Installation Costs                            GE Title or job number /
                                                                       1/25/2012
Track & Manage Production Efficiencies
   Track downtime, waste, production counts, etc…
   Track and monitor overall equipment effectiveness (OEE)
   Associate real-time events with a specific cause/reason
   Aggregate information for line and plant root cause analysis


Value

        Equipment Effectiveness
        Material Throughput

        Production Response Time
        Material Costs
        Equipment Usage Costs
                                                              Plant Applications
                                                                                       16 /
                                                                   GE Title or job number /
                                                                                 1/25/2012
Manage & Improve Product Quality
•   Apply product specs and recipes to production
•   Alarm out-of spec, SPC and SQC conditions
•   Centerline processes and run-to-target
•   Capture, summarize and analyze manufacturing and quality data in the
    context of production events such as batch, lot, item, serial number, time
    period and more
•   Increase product and process quality to lower production waste, scrap
    and product recall cost


Value
        Equipment Effectiveness
        Material Through Put
        Production Response Time

        Material Costs
        Equipment Usage Costs                                 Plant Applications
                                                                                     17 /
                                                                 GE Title or job number /
                                                                               1/25/2012
Execute Production Orders, Track
Genealogy quality, consumption plans, and then scheduled
• Use a “scoreboard” to track production orders against
  completion time,                                      adjust routing,
    material delivery and schedules based on actual production events
•   Track and analyze batch information
•   Trace a product throughout every step of the process, develop auditable
    reports
•   Improve operational efficiency, cycle time and inventory management,
    and ensure regulatory compliance by gaining insight and control over
    real-time production operations
Value
        Response Time to Actual Prod. Rqts.
        Efficiency
        Sustainability of production processes

        Material and Energy Consumption
        Waste                                               Plant Applications

                                                                                   18 /
                                                               GE Title or job number /
                                                                             1/25/2012
Manage routing, tracking and sequencing
•For discrete assembly environments producing products that are high
valued, with high variability, and/or produced in high volume.

• Automatic tracking of Serialized   Parts, Assemblies, Carriers

• Automatic routing and scheduling based oncurrent process conditions in
real time, including Broadcast management to suppliers

•Automatic data distribution for: Equipment set up, User interface displays
  • Label/document printing, JIT delivery triggers

Value
        Resource Utilization
        Asset Utilization
        Right First Time

        Scrap and Rework
                                                                     Tracker
                                                                                       19 /
                                                                   GE Title or job number /
                                                                                 1/25/2012
Manage & Optimize Production Schedules
in Real Time
•Manage production orders, load and capacity based on plant floor activity

•Simulate alternative plans before execution

•Automated rule-based scheduling

•Upload adjusted plans into other applications (ERP, etc))
Value
        Response Time Plant Floor Level Occurrences
        Flexibility to respond to customer change requests

        Lag time between ERP and Plant Floor Systems
        Time to Make Production Changes
        Mistakes based on rules based automation tool

                                                                Scheduler
                                                                                    20 /
                                                                GE Title or job number /
                                                                              1/25/2012
Report at the Enterprise & Aggregate Level
 •   Slice and dice, roll-up stats of any context and across sites, drill-down to
     details
 •   OLAP cubes for efficiency , quality and production data
 •   Increase velocity of deployment of custom reporting for Plant
     Applications
 •   Improve performance of complex reports
 •   Reduce the TCO of reports by removing the need to understand the
     database schema

 Value
         Access to Critical Performance Info
         Access to Information
         Report Response Time
                                                                    Datamart
         Report Creation Time & Expense
                                                                                        21 /
                                                                    GE Title or job number /
                                                                                  1/25/2012
Improve Asset Performance
•   Create, Approve, Execute and Close Maintenance Work Orders (MWO)
    automatically using Proficy data:
•   Log maintenance events in plant floor systems including root causes
•   Determine which activities/events impact asset productivity most


Value
        Response Time to Necessary Equipment Maint.
        Efficiency Through Reduced MTBF
        Sustainability of production processes

        Costs of unplanned machine downtime
        Costs of unplanned maintenance labor


                                                             Maintenance
                                                              Gateway 22 /
                                                              GE Title or job number /
                                                                            1/25/2012
Manage Data Assets …
Enable the Undo Button!
• Version Management/Difference
   Reports
• 21 CFR Part 11 Compliant
• Easily Schedule Backups & Perform
   Compares
• Detect unauthorized changes & use
• The perfect Tool for Disaster Recovery
• Support a wide range of products
Value integrated with your HMI/SCADA
• Fully
        • Plant Up-Time
        • Safety
        • Enforce GMP
        • Recovery time
        • User Errors                      Change Management
                                                                      23 /
        • Engineering / Maintenance $             GE Title or job number /
                                                                1/25/2012
Connect to ERP Systems
•Connects Proficy to ERP and other business level systems

•Download production orders, inventory requests, etc, Upload production
results

•User configurable

•Standards Based (B2MML, S95, Workflow)

Value
          Visibility Across the Enterprise
          Flexibility to respond to customer change requests


          Lag time between ERP and Plant Floor Systems
          Inaccurate Costs and Schedules Based
                                                               Open Enterprise
                                                                                     24 /
                                                                 GE Title or job number /
                                                                               1/25/2012
Provide a Summary View…
•   Connect to all the real-time, historical, and relational data within the
    plant and across the Enterprise

•   Role specific views

•   Drill down to determine root causes of identified problems or successes


Value
        Ease of Use
        Accessibility
        Response
        Consistent KPI Usage

        Disparate Data

                                                                      Portal
                                                                                       25 /
                                                                   GE Title or job number /
                                                                                 1/25/2012
                                           iFIX/Cimplicity


                                                                             HMI
                                            Change Mgt

                                          Batch Execution

                                          Plant Applications
                                                                             MES

                                              Datamart

                                           Maint. Gateway




                             Modules
                                             Scheduler
                                                                                                  Excellence Platform




                                              Tracker

                                              Historian
                                                               Proficy SOA




                                               Portal

                                           Troubleshooter
                                              Workflow
                                                                             Historian Workflow




                                          Open Enterprise
                                                                                                  Introducing the Proficy Operational




                                            Data/Equip.
                                                                                  3rd




                                             Models
                                                                                 Party




                                              Events
                                                                              Applications




              1/25/2012
                           Services26 /
GE Title or job number /
Questions?




                                 27 /
             GE Title or job number /
                           1/25/2012

								
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