Advanced Scheduler for Wonderware MES Chris Mollison Scheduling Solutions

Introduction Project Solution Agenda Benefits Considerations Summary

Background to the Project This presentation shows how the Preactor scheduling functionality has been integrated with Wonderware Operations 3.4 It discusses the benefits of using finite scheduling functionality. It reviews the results obtained at Aquacolor where Wonderware Operations and Preactor are integrated

Background to the Project Receive Preparation Batching Make Unit Packaging Ship Manufacturing Order Management Enterprise Integration Finite Scheduling Dispatching Material Management/ Formula Manufacturing Performance Management Manufacturing Reporting/ Analysis/ Dashboard In Line Product Quality Compliance Equipment Condition Monitoring Production Capacity Management (OEE, TEEP) Deviation/ Yield Management/ Scrap Rework Material Management Material Receivables Pre-Weighing/ Dispensing Food and beverage solution map Inventory Material Management Material Quality Inspection Manufacturing Operations Execution WIP Status Management Production Practices Enforcement (multi Unit) Product Traceability Brand Integrity/ Quality Sample Plan Management Container Management (Tote bin management) Regulative Compliance (HACCP) Batch/ Process Execution Batch/ Unit Execution Final Inventory Process Automation Control Bar Code Printing Secondary Production Execution RFID Coding Production Order Execution Shipping Execution Discrete Automation Control

Project Goals To create a certified integration between Wonderware Operations 3.4 and Preactor.

Introduction Project Solution Agenda Benefits Considerations Summary

Wonderware Food and beverage solution map Receive Preparation Batching Make Unit Packaging Ship Manufacturing Order Management Enterprise Integration Finite Scheduling Dispatching Material Management/ Formula Manufacturing Performance Management Manufacturing Reporting/ Analysis/ Dashboard In Line Product Quality Compliance Equipment Condition Monitoring Production Capacity Management (OEE, TEEP) Deviation/ Yield Management/ Scrap Rework Material Management Material Receivables Pre-Weighing/ Dispensing Inventory Material Management Material Quality Inspection Manufacturing Operations Execution WIP Status Management Production Practices Enforcement (multi Unit) Product Traceability Brand Integrity/ Quality Sample Plan Management Container Management (Tote bin management) Regulative Compliance (HACCP) Batch/ Process Execution Batch/ Unit Execution Final Inventory Process Automation Control Bar Code Printing Secondary Production Execution RFID Coding Production Order Execution Shipping Execution Discrete Automation Control

Where does APS fit? ERP APS MES System Control Automation Jurgen Kletti, 2008

Fills the MESA function group for detailed planning: APS Role in MES 20-Apr-17 Fills the MESA function group for detailed planning: Sequence and time optimization of the orders finely tuned to the performance of the machines, including their finite capacity and relationship to other resources (c) 2002 Invensys Systems, Inc.

Why is scheduling different from planning? 20-Apr-17 Why is scheduling different from planning? Planning systems are bucketed (monthly, weekly, daily) and cannot preserve operation sequences within the time bucket True scheduling systems are bucketless, preserving sequencing, and capable of generating work-to or dispatch lists. Assignment of operation to resource is a key function to achieve operational efficiency and optimizing performance (c) 2002 Invensys Systems, Inc.

SAP APO APO is a global Supply Chain solution 20-Apr-17 APO is a global Supply Chain solution APO is made up of several modules : Collaborative Planning (CP) Supply Chain Cockpit (SCP) Demand Planning (DP) Supply Network Planning (SNP) Production Planning & Detailed Scheduling (PP/DS) Global Available-to-Promise Preactor does not compete with APO, but only with the “Production Planning & Detailed Scheduling” (PP/DS) module of APO (c) 2002 Invensys Systems, Inc.

Limitations PP/DS for MES 20-Apr-17 PP uses an MRP calculation with infinite capacity and large planning and scheduling ‘bucket’ sizes (typically a week) and mid/long term vision Hence a planning system with all the limitations DS does not link dependent WOs (pegging), it uses launch date data, No synchronization of materials between dependent WOs or WOs to WOs APO uses heuristics technology Very difficult to parameterize Solver cycle long and not repeatable Very difficult for users to understand Limited, rigid rule set (c) 2002 Invensys Systems, Inc.

Where does APO fit? APS MES ERP/PPS SNP DP SCP GATP CP 20-Apr-17 (c) 2002 Invensys Systems, Inc.

Why Preactor? 20-Apr-17 Founded in 1993 – 15 years of experience in developing and implementing scheduling solutions Microsoft Gold Partner International coverage across 5 continents Over 10 000 licenses sold (c) 2002 Invensys Systems, Inc.

Preactor’s Install Base 20-Apr-17 Why Preactor? Preactor’s Install Base Since its first release in 1993 more than 10,000 Preactor scheduling systems have been installed in the broadest range of verticals….. (c) 2002 Invensys Systems, Inc.

Data Flow Production Order item qty ERP SYSTEM date Operations management production process recipe management inspection tracking Wonderware Operations 3.4 Sequencing sequencing logic dates & times resources to use APS

Integration with Wonderware Operations Work Order Wonderware Ops (MES) Data Sent per Op Scheduled Start Time Target Scheduled Resource Data Sent per Op Initial Scheduled Resource Required Finish Time Priority Route constraints Actual Start Time Preactor APS

Integration structure Links with Operations 3.4 Demand passed from Operations 3.4 to Preactor APS Schedule is released from Preactor APS to Operations 3.4 Context sensitive windows in Preactor shows data from WIS Resource calendar exceptions sent from Operations 3.4 Shop floor data updates Preactor APS Static data synchronized from Entities Preactor Gantt charts available though WIS Wonderware's Operation Modules (Factelligence) Supply Chain Connector Clients

Integration Example

20-Apr-17 Flash Demo of Preactor (c) 2002 Invensys Systems, Inc.

Aquacolor Aquacolor is also heavily involved in the development of applied nanotechnology for textiles finishing and works with leading fashion brands including Levi Strauss, Burberry, Hugo Boss and Trussardi The ability to respond to this and consistently deliver high levels of customer service depends on a solid yet flexible manufacturing approach Different orders may require different levels of dyeing, washing and finishing yet challenges exist for some orders may require repeat operations – typically washing - with some processes – typically dying – involving correction and adjustments during the actual process Every order may be different

Aquacolor Aquacolor are a Wonderware user and they wanted improved management over shop floor operations. They selected Wonderware Operations (originally Factivity) to provide the required functionality. Factivity does not have inbuilt scheduling functionality so Aquacolor selected Preactor to provide this capability.

Introduction Project Solution Agenda Benefits Considerations Summary

Wonderware Operations - benefits Benefits achieved from Wonderware Operations implementations Improved control of operations Improved recipe management Improved traceability

Preactor - benefits Benefits achieved from Preactor implementations VISIBILITY Decision support Improved customer service Improved delivery date promising Improved delivery performance Improved productivity Better machine utilization Reduced inventories

Aquacolor Benefits Operational improvement at recipe management, operations information and traceability levels, with a direct impact on costs. 50% reduction in the time spent to build a new work order Saves 70% time required to give a delivery date Scheduling overhead reduced 35%

Benefits / Goals Achieved Were the initial goals achieved? Yes – an integration has been developed Is the customer happy with the project? Wonderware and Preactor are happy with the integration. The interface has been certified. What benefits (business, technical & other) were gained A certified solution is now available to Wonderware Operations users to role out scheduling functionality with minimal effort.

Introduction Project Solution Agenda Benefits Considerations Summary

Lessons Learned This is possible to integrate Wonderware Operations 3.4 and the Preactor scheduling functionality. Wonderware has certified the interface. Linking Wonderware Operations and Preactor delivers measurable benefits.

Introduction Project Solution Agenda Benefits Considerations Summary

Conclusions The certified interface shows that it is possible to easily transfer data between Wonderware Operations and Preactor. Wonderware Operations users can feel secure in knowing that world class scheduling functionality is available to them when required. Wonderware Operations users can benefit from implementing the scheduling functionality now available to them.

Going to Market With Wonderware Local Wonderware distributors will sell Preactor with the support of Preactor Network Partner responsible for region Wonderware distributors will place their orders with Network Partner Preactor servcies, training, and annual support provided by Network Partner

….any questions?