1. Wonderware Operations Software “Improving Manufacturing Operations”
Terence Tan
General Manager
Title Slide: Operations Software 3.4
This short presentation highlights the value propositions, the benefits and some of the capabilities of Wonderware Operations Software version 3.4.
Operations Software version 3.4 uses “Factelligence” software technology obtained from the 2007 Cimnet acquisition.
Operations Software version 3.4 has been designed to better integrate with the Wonderware System Platform 3.0 and the exciting InTouch 10.0 HMI application.
(c) 2002 Invensys Systems, Inc.
19-Apr-17

2. MES MES What is MES? anufacturing xecution ystem
Definition according to MESA International:
Manufacturing Execution Systems (MES) deliver information that enables the optimization of production activities from order launch to finished goods.
MES
anufacturing
Definition according to ISA:
The MES layer focus in a group of activities (operations, inventory, quality and maintenance activities) corresponding to Level 3 in the Functional Hierarchy model.
xecution
ystem

3. ISA Model Level 4 Business Planning & Logistics Level 3 Manufacturing
Plant Production Scheduling,
Operational Management, etc
Level 3
Manufacturing
Operations & Control
Dispatching Production, Detailed Production
Scheduling, Reliability Assurance, ...
Levels
2,1,0
Batch
Control
Continuous
Control
Discrete
Control

4. Purdue CIM Model Level 4: Enterprise Resource Planning System
Level 3: Manufacturing Execution System
Level 2: Process Supervisory System(s)
Level 1: Real time Controllers
Level 0: Instruments and Actuators

5. The MESA model MES Sales & Service Management
Enterprise Resource Planning
MES
Operations/
Detailed Scheduling
Resource Allocation & Status
Document Control
Dispatching Production Units
Product Tracking & Genealogy
Performance Analysis
Labor Management
Maintenance Management
Process Management
Quality Management
Data Collection Acquisition
Supply Chain Management
Control

6. What is Wonderware MES?
Wonderware MES
Wonderware MES is an out-of-the box, configurable, modular Manufacturing Execution System (MES) software focused on production execution, shop floor data collection and analysis.
(c) 2002 Invensys Systems, Inc.
19-Apr-17

7. Product History March 2009 February 2008 October 2007 July 2007 2002
Wonderware Operations and Performance 3.5
March 2009
Wonderware Operations and Performance 3.4
February 2008
EPM 2.0 = Factelligence QuickStart
October 2007
Wonderware Factelligence 3.1
July 2007
First version of Factelligence by CIMNET
2002

8. Wonderware MES Features
Wonderware MES will enable you to…
Deliver planned vs. actual production
Electronic Work Order Management
Recording of Production Events
using
Improve process and production consistency
Centralized Manufacturing Model
Production Rules
Certifications
using
Improve inventory velocity
Real time inventory management
Detailed definition of materials, substitutes and byproducts
Bill of Materials
using
Reduce order lead time
Dynamic prioritization and sequencing
Labor management
Connection to HMI/SCADA
using
Monitor and analyze production performance
Downtime
Utilization
OEE
using
(c) 2002 Invensys Systems, Inc.
19-Apr-17

9. Licensing Wonderware MES Performance Operations Standard Operations
Utilization and Downtime
OEE
Performance
Work Order Execution
Bill of Materials
Production Events Tracking
Parameters Download
Operations
Standard
Operations
Premium
Data Collection
Inventory
Certifications
Labor Management
Steps
(c) 2002 Invensys Systems, Inc.
19-Apr-17

10. Wonderware MES Architecture
Clients
Manager
Configurator
Supervisor
Operator
Custom
.NET App
IIS
Middleware
Wonderware MES
Service
COM+ Package
Factory Connector
Database Server
Production DB
(c) 2002 Invensys Systems, Inc.
19-Apr-17

11. Wonderware MES Middleware

12. Wonderware MES Client

13. System Requirement - Software

14. System Requirements - Hardware

15. Operations Software… Functional Overview
Quick Changeovers Between Products and Lines
Electronic work orders, BOM, specs
Delivering Planned vs. Actual Production
Work orders, data collection, symbols
Process and Production Consistency
Templates, BOM, specs, security
Quick Changeovers Between Products and Lines
Electronic work orders, BOM, specs
Delivering Planned vs. Actual Production
Work orders, data collection, symbols
Process and Production Consistency
Templates, BOM, specs, security
Operations
Premium
Operations
Standard
Work Order Execution
Improve Inventory Turns and Reduce Inventory Cost
Accurate recordkeeping, visibility
Reduce Order Lead Time
Dynamic allocation of production assets
Enforcement of production rules / steps
Reduced Time-to-volume for New Products
Map entity model, product / process context
Improved Compliance & Governance
Electronic system records, history
Specifications
Bill of Materials
Parameters Download
Data Collection
Inventory
Operations Software… Functional Overview
Key Talking Points:
Wonderware offers two editions of the Operations Software Standard and Premium.
Operations Standard Edition includes basic MES functionality including:
Work Order Execution
Specifications
Bill of Materials
Parameter Download
Data Collection
Using the Standard Edition, a manufacturer can shorten up product changeover times, better understand “Actual” versus “Planned” production, and improve production consistency.
Let’s look at each of these areas of improvement in more detail.
Certifications
Labor Management
Steps
Operations Software – Standard Edition
(c) 2002 Invensys Systems, Inc. 15
19-Apr-17

16. Improve Productivity via faster product or line ‘Changeovers’
Central administration of process and product parameters
Maintain Bills of Material (w/ version mgt)
Product & material specs w/ min/max limits per BOM entity
General recipe definitions using site specific processes
Accurate equipment setup
Site specific product specifications
Automatic download of set points
User-based parameter management
Operator visibility of set point values (.NET Controls)
Associate drawing, multimedia file or documents to specifications
Build Operator dashboards tailored to specific operation (InTouch, .NET controls)
Improve Productivity via Faster Product or Line Changeovers
Key Talking Points:
One aspect of improving Product or Line Changeovers is better control of process or product parameters. Central administration of this key information enables a single version of the truth.
Operations Standard provides electronic Bills of Material and specifications with version control. Each product can have multiple Bills of Materials and specifications. Specifications for products and materials allow min/max limits defined on a per entity basis on a Bill of Material item. Recipes can be defined with site specific processes to ensure product consistency.
Another key way of improving Changeover times is through accurate equipment setups and that starts with site specific product specifications. Specifications are a standard feature of Operations Standard. Automatic download of machine set points to PLCs can be performed with Operations Standard minimizing errors caused by the manual setup of production equipment.
Using Operations Standard, operators can be provided visibility into set point values for material consumptions via a .NET control (that can include this information in HMI screens).
Provide operators more information by associating a file or files for each specification that provides instructions, comments, drawing or even multimedia files demonstrating a specific task or procedure.
Leverage stunning InTouch graphics to build powerful production operations dashboards tailored to individual operator information needs.
(c) 2002 Invensys Systems, Inc.
19-Apr-17

17. Faster Changeovers – One Version of the Truth
Electronic Bills of Material & Specifications
Centralized administration with version control
Faster Changeovers – One Version of the Truth
Key Talking Points:
An important aspect to improving your changeover times is to have electronic bills of materials and product and material specifications that are centrally managed.
This helps everyone one in the plant read from a single script – eliminating wasted time on finding the information they need to get a new product running on a production line.
(c) 2002 Invensys Systems, Inc.
19-Apr-17

18. Faster Changeovers – Accurate Equipment Setup
Site Specific Product Specs
Auto Download of Set Points
Faster Changeovers – Accurate Equipment Setups
Key Talking Points:
Another way you can speedup changeovers is through Operations Software’s site specific product specifications and the automatic download of machine set points.
If you are producing a specific product across multiple manufacturing sites you undoubtedly have variation in the type of production equipment and systems being used at each site. Operations Software allows you to create site specific product specifications to reduce product quality variation across sites. Also, because each site has its own specifications there is no need to tweak machine settings so changeovers go faster.
Also, Operations Software allows machine set points stored in the product specifications to be automatically downloaded to production equipment when a production run is initiated. This speeds up the set up of machines and gets products rolling off the production line faster.
(c) 2002 Invensys Systems, Inc.
19-Apr-17

19. Faster Changeovers… Better Operator Visibility
Powerful Set of .NET Controls for Building Operator Displays
Flexible Display Options
InTouch
Operator
Third Party HMI
Web
Faster Changeovers… Better Operator Visibility
Key Talking Points:
The better operators can visualize what is happening on the production floor the faster they can get the production process up to full speed.
Wonderware Operations Software provides a powerful and broad set of .NET controls for exposing production data to operators. (How many???)
Wonderware offers you a very flexible choice of data and information display options including;
- InTouch 10.0
- Operator (operator interface application provided w/ Operations 3.4)
- 3rd Party HMI or other .NET container
- Wonderware Information Server (web portal)
(c) 2002 Invensys Systems, Inc.
19-Apr-17

20. Respond Faster to Production Issues via Planned vs
Respond Faster to Production Issues via Planned vs. Actual Production Values
Electronic management of Work Orders
Ability to change job prioritization & sequencing via Operator displays & job summary .NET Control
Recording of production events
Material consumptions
Complete “as built” records per work order
Immediate detection of deviations
Specification or plan deviations
Real-time database captures full production data record
Active alarm management system
Equipment & material
Respond Faster to Production Issues via Planned vs Actual Production Values
Key Talking Points:
Having “actual” and “planned” production values is tool in being able to respond faster to production issues.
Wonderware Operations Software Standard Edition provides electronic management of work orders, records production events and detects deviations from specifications.
Electronic management of Work Orders: Operations Standard Edition provides a list of scheduled work orders through the Job List .NET control, a configurable set of “command icons” can be incorporated into operator displays to create, select, start, stop work orders and job priorities.
Define Job Attributes for product specific parameters, custom data acquisition plans, incl. groups, assigned to step, entity, operation; performed automatically or entered manually detailed genealogy view using .NET control or genealogy report or view using Manager Built in Information Server with library of out-of-the-box reports available on demand
Recording of production events & immediate detection of deviations: Track actual job start time and end times against standards, track the exact quantity and lot numbers of materials used, record automatically or manually (Bill of Material) consumptions, record automatically or manually the number of actual Produced items.
Operations Software Standard provides a real-time plant resource model with real-time access to equipment information. Active alarm management for equipment and material also alert operators to potential problems.
(c) 2002 Invensys Systems, Inc.
19-Apr-17

21. Planned vs. Actual Production
Online Work Order Management
.NET Controls used in Operator Displays
Visibility to Planned Values
Summary of Planned vs Actual Production
Planned vs Actual Production
Key Talking Points:
Wonderware Operations Software provides online work order management through a selection of .NET controls or desktop applications. These controls allow operators to start or stop a job easily from their work location, as well as, view the status of jobs that are underway.
Wonderware ArchestrA reports delivered with Wonderware Information Server and integrated with Operations Software provides decision makers with production summary reports such as this one that allows them to compare actual production with planned production.
(c) 2002 Invensys Systems, Inc.
19-Apr-17

22. Reduce Production Errors & Increase Yield
Consistent interpretation of operating guidelines and procedures
Accurate paperless execution of work orders & jobs
Show work instructions, SOPs, drawings, NC programs
Central, detailed definition of user privileges and security roles
Assign user rights per entity or process
Job based login
Common security definition using ArchestrA security, including Operating System integration
Central definition of process and product parameters
Electronic Bills of Material
Define processes, specifications, Classes
Reduce Production Errors & Increase Yield
Key Talking Points:
Using Operations Standard Edition provides consistent interpretation of operating guidelines and procedures. Using electronic work orders and jobs with detailed specifications and the ability to show instructions and Standard Operating Procedures help eliminate mistakes and variation in the manufacturing process. Define folders of CAD drawings, numerical control programs, instructions and multimedia for each work center, operation and part.
Another way to reduce production mistakes to control the “rights” of production workers. Operations Standard allows centralized definition of user privileges and security roles. Assign user rights per entity or process, incl. job based login. Create a common security definition leveraging ArchestrA security and Operating System security.
Operations’ centralized bills of materials and specifications (product and material) allow tighter control over the manufacturing process.
You can even define manufacturing 'Processes' as certified, experimental or approved.
Record scrap with unlimited reasons for detailed tracking. Record by-products for each job. Create Processes to define how products are made independent of equipment.
Define approved material substitutes and classes of raw materials.
(c) 2002 Invensys Systems, Inc.
19-Apr-17

23. Execution of Work Orders
Create a Process
Create a Work Order from the Process
Start and Monitor the Status of a Work Order
Execution of Work Orders
Key Talking Points:
Operations Software makes it easy to create and execute work orders or jobs.
We first define a process and attach it to an product (called an item).
Next we open up the work order creation dialogue and we fill in information like work order number, the start and required production quantities, the production time frame, the production priority and other information – including any notes you want to add.
Then we start and monitor the status of the work order from the Work Queue dialogue which is part of the Operator application delivered with Operations Software 3.4 or this information can be included in an InTouch window using .NET controls provided with Operations Software 3.4.
(c) 2002 Invensys Systems, Inc.
19-Apr-17

24. Central Definition of Process & Product Parameters
Electronic Bills of Material
Specifications
Processes
Central Definition of Process and Product Parameters
Key Talking Points:
A big part of centralized definition of process and product parameters in Operations Software is provided through electronic bills of materials like this one.
And also through electronic product and material Specifications like this one.
And lastly through electronic set up of production processes and the associated process routing as shown in this screen.
All of these features of Operations Software help deliver centralized process and product definition and this can reduce errors and make you more responsive to external and internal forces.
(c) 2002 Invensys Systems, Inc.
19-Apr-17

25. Operations Premium Edition - Functional Overview
Standard
Work Order Execution
Specifications
Bill of Materials
Improve Inventory Turns and Reduce Inventory Cost
Accurate recordkeeping, visibility
Reduce Order Lead Time
Dynamic allocation of production assets
Enforcement of production rules / steps
Reduced Time-to-volume for New Products
Map entity model, product / process context
Improved Compliance & Governance
Electronic system records, history
Parameters Download
Data Collection
Inventory
Operations Premium Edition – Functional Overview
Key Talking Points:
For comprehensive MES, Wonderware offers the Premium Edition of Operations Software.
In addition to all of the features provided by the Standard Edition, the Premium Edition adds inventory management capabilities, certifications of process activities, management of labor, and definition of manufacturing procedures or steps.
Using Operations Premium should help you improve your inventory performance, reduce lead times, reduce time to market of new products and help improve compliance to government regulatory requirements.
Certifications
Labor Management
Steps
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26. Improve Inventory Turns & Reduce Inventory Costs via Accurate Records and Increased Visibility
Accurate records of actual material consumptions and production levels
Automatic data collection
Broad inventory mgt functionality; receiving, shipping, scrap, hold, transfers, splitting/combining, re-classifying lots
Detailed definitions of materials
Bills of Materials
Material substitutes
Status information on raw materials, Work in Progress (WIP) & finished goods
Immediate access to real-time inventory status
Improve Inventory Turns & Reduce Inventory Costs
Key Talking Points:
Inventory performance can be improved by using the wide list of inventory management functions available in the Premium Edition such as receiving, shipping, scrap, hold, transfers, splitting or combining, re-classification of lots and a selection of standard inventory reports or views.
Also, Operations Software’s ability to automatically collect accurate production data from PLCs, bar code or RFID readers along with manual data entry by operators ensure a store of invaluable inventory data.
Electronic bills of materials, documented specifications and approved material substitutes, and real-time status information on raw materials, Work in Progress and finished goods enable plant operators and decision makers better manage inventory performance.
Operations’ real-time Inventory Grid .NET control provides a view of current inventory, including filtering capabilities, and a view of required and available material prior to starting a job.
(c) 2002 Invensys Systems, Inc.
19-Apr-17

27. Reduce Production Lead Time through Dynamic Allocation of Production Assets
Electronic production order management
Ability to perform prioritization & sequencing
Enforcement of production rules
Flexible operational planning based on accurate, detailed information
Actual production resource information
Dynamic allocation of production assets
Based on actual availability of material, equipment or personnel
Reduce Production Lead Time
Key Talking Points:
By understanding in real-time your production capacity you can reduce production lead times.
Operations Premium provides highly accurate and detailed production data so you can more efficiently operate your production processes and reduce production lead times.
Operations’ electronic work order management system provides a list of jobs and the ability to sequence jobs based on their priority. Jobs can be dispatched to a group of machines, manufacturing cell or a specific machine. You can automatically hold a job based on material availability or production limits.
The Premium Edition allows detailed definition of production rules using operational steps or procedures including employee certification/validation on step completion.
Operators can be given a view of the current status of all orders and available inventory and any alarms.
Planners can be provided accurate data on cycle times, yields and consumptions which can be used by planners to improve 'standard costs & times‘. Planners can use the real-time information from Operations to more fully understand their production capacity and in the development a real-time plant resource model.  
(c) 2002 Invensys Systems, Inc.
19-Apr-17

28. Reduced Time to Volume for New Products via Enforcement of Production Rules
Rapid binding of process capabilities and product definitions
Integration of ArchestrA plant model with Operations’ production model
Detailed definition of sequencing of operating activities
Manual/auto tasks
Steps (procedures)
Accurate records for cycle times, yields, consumptions during initial production runs
Common system environment for model definition, execution and operations
Ability to define Process “State” as experimental or production
Ability to Certify resources according to defined process “State”
Reduced Time to Volume for New Products
Key Talking Points:
Wonderware Operations Premium Software provides the capability to build a detailed production model and integrate it with your plant data model so you have the detailed information and reports you need to streamline your production processes and reduce the time to volume for new products.
We have integrated Operations Premium Software with the Wonderware System Platform to allow the synchronization of your production model and plant data model.
Operations Premium allows the detailed definition of production steps and their sequencing (both automated and manual tasks).
Accurate data on cycle times, yield and material consumption during early production runs or during start-up give production engineers the information they need to fine tune production processes – saving time. They can even define process “States” such as experimental or production and to certify specific production resources for these states.
All of these features provide the information engineers and operators need to reduce the time to volume and stay ahead of the competition.
(c) 2002 Invensys Systems, Inc.
19-Apr-17

29. Improved Compliance & Governance via Complete Production Records
Complete electronic system records for production, quality and processes
Rapidly respond to unforeseen events, such as product recall or audits (internal, external)
Internal process harmonization
Share best practices and scale across multiple installations
Help ensure safe operations with enforcement of SOPs
Comply with environmental, health and safety standards
Improved Compliance & Governance
Key Talking Points:
Operations Premium also provides a rich feature set for responding to regulatory requests and complying to governmental requirements.
Operations’ complete electronic data record of the production process allows rapid response to product recalls or audits. Genealogy and traceability reports can be configured to quickly document the production process.
The production model from Operations can be used as base or as a best practice for new production activities saving time and helping accelerate validation of new regulated processes.
Operations Premium also offers certification capabilities for critical or validated processes. This capability helps manufacturers comply with environmental and health and safety standards by ensuring specific production steps are performed properly.
(c) 2002 Invensys Systems, Inc.
19-Apr-17

30. Genealogy & Traceability Reporting
Operations Software’s complete data record & easy retrieval make responding to governmental information requests straightforward & easy
Improved Compliance & Governance
Key Talking Points:
Wonderware Operations Premium Software helps generate a complete record of your production process. This data can then be used to generate various reports including Genealogy and Traceability reports which can be made available over the web to internal or external personnel such as regulators.
Operations Premium Software along with Wonderware Information Server provide standardized functionality to easily configure and make available Genealogy and Traceability reports. Here we see the report configuration screen for creating Genealogy Reports
(c) 2002 Invensys Systems, Inc.
19-Apr-17

31. Summary Comprehensive MES Functionality Fully Scalable
Bill of Material, Work Orders, Events, Data Collection, Specifications, Set Point Download, Inventory, Certifications, Steps/Procedures, Labor Management, User Management, Genealogy, Traceability, Web Reporting
Fully Scalable
Functionality – Standard & Premium Edition, Supply Chain Connector, MES Clients
Physical Scalability – equipment, lines, plants
Highly Integrated
Wonderware Connectivity
Historian, System Platform MX, OPC, Suite Link
Wonderware’s System Platform
Single Industrial Application Development Environment
Wonderware InTouch
World’s leading HMI
Summary
Key Talking Points:
So, to wrap things up we want to emphasize that Wonderware has a comprehensive MES functionality with bill of materials, work orders, data collection, specifications, set point download, inventory management, steps and procedures, labor tracking, user management and web reporting.
We offer our MES functionality in a Standard Edition and a Premium Edition and each can be scaled from a single machine to an entire plant site.
Our Supply Chain Connector provides added connectivity to plant information systems and basic ERP connectivity.
Wonderware also offers MES clients so you can embed Wonderware MES information into your existing portals or other .NET container applications.
Lastly, the real differentiator for the Wonderware Operations Software solution is its integration with Wonderware’s System Platform, InTouch, Information Server and Wonderware’s plant connectivity tools. Wonderware’s single industrial application development environment saves time, allows functionality levels, enables engineering re-use and provides the lowest total cost of ownership.
(c) 2002 Invensys Systems, Inc.
19-Apr-17

32. Software Solutions for Real-Time SuccessSM
(c) 2002 Invensys Systems, Inc.
19-Apr-17