Andrea Sartori Solution Architect EMEA

Andrea Sartori Solution Architect EMEA
Wonderware Operations Software improve production consistency, visibility and agility Andrea Sartori Solution Architect EMEA

Agenda The many faces of MES Introduction to Wonderware Operations
Modeling the Process Leveraging configurable business rules in defining entities, items and process Agenda Typical MES applications & Key Capabilities Integration with System Platform Summary

The Many Different Faces of MES
20-Apr-17 The Many Different Faces of MES “I need to have traceability” “I need to reduce downtime” “I need to manage recipes” “I need to improve quality” “I need to Improve yield” “I need to reduce inventories” “I need to reduce costs” “I need to reduce cycle times” (c) 2002 Invensys Systems, Inc.

Challenges Even if Need for MES Has Been Identified
20-Apr-17 Challenges Even if Need for MES Has Been Identified Can’t tell exactly what I need or how much it’s worth to me… “I need MES!” Need to reduce production losses / errors but don’t know where or how to get started Need to track what’s happening in production but it shouldn’t interfere with my production process Have defined 50+ pages of requirements but who do I select? (c) 2002 Invensys Systems, Inc.

Wonderware Provides Unique Value with Incremental Approach
Increased Business Agility and Performance through Improved Manufacturing Operations Wonderware MES & EMI Software Solutions enable: Productivity Increase from Existing Resources Lead Time Reduction Production Throughput and Efficiency Increase Manufacturing Costs Reduction Regulatory Compliance Underlying System Platform and adoption of market standards dramatically reduces total cost of ownership and enables a flexible approach to evolve as you require.

Adopting a Flexible Approach to Improve Your Manufacturing Operations
20-Apr-17 Adopting a Flexible Approach to Improve Your Manufacturing Operations How do we help our customers? 1: everything we do evolves around the physical equipment / activities on the plant floor. Part of the challenge manufacturers have is the fact that they have a heterogeneous manufacturing environment simply from the fact that different physical processes are needed to make products – requiring different machinery, different controllers / PLCs, different information system being supplied with the equipment. 2 : we help them logically represent their physical mfg. processes in a “plant model” in a IT system – independently of how diverse their environment is. This provides supervisory functions of communication, alarming, visualization, security etc. to monitor / control physical processes and activities. 3: the majority of manufacturers looking to improve their manufacturing operations will have requirements to improve equipment / line operations and performance – as the basis . We help them do this by logically evolve the existing plant model to included increase functional capabilities to perform formula mgt; dispatch and manage electronic work orders, capture of production events; identification and qualification of equipment downtime. KEY: it’s not about building another, separate application / functional silo, and the having to integrate this to the supervisory system – it’s a natural extension of the same system. 4: Once the fundamental operations are understood and under control, manufacturers will typically have requirements to understand true capacity and overall manufacturing performance across several operations / lines – many times involving statistical process control, higher level compound metrics, We help manufacturers address these requirement by adding further functional components to same plant model – the same underlying principal applies as before; it doesn’t matter where you start or where you want to end. 5: for a smaller number of manufacturers, the complexity of their manufacturing processes and activities actually require a plant system that helps them enforce certain production rules and the ability to manage WIP , routes, inventory. We can help companies with even the most complex processes to improve their manufacturing operations by adding a logical routing or process model (depending on nature of their business) to plant model. 6: the final step in improving manufacturing operations for improved business performance, is to synchronize manufacturing operations with business processes, i.e. making sure the activities performed and the information managed in the business system as well as the plant system are tightly aligned by integrating plant systems with business systems. We help manufacturers, that have the foundations in place in terms of ability to manage the required information flows to actually benefit from this integration, by automatically exchanging information with business system and by providing the ability to manage the required master data for manufacturing operations. Click 7: Overall – what differentiates our offering in the market, is the ability for our customers to grow as their business require, adopting to local plant requirements without sacrificing the benefits of reusability /standards by Enabling an incremental, low-risk deployment of increased application functionality, one step at a time. Enable an incremental, low-risk deployment of increased application functionality, one step at a time. (c) 2002 Invensys Systems, Inc.

Wonderware MES & EMI Software Solutions Built on Strong Platform
Devices, Applications, Enterprise Integration Database Applications Asset Management LIM Systems Devices ERP (SAP, Oracle, Microsoft..) System Interoperability Real-Time Manufacturing Operations Management Empowering All Roles in the Plant Information / Visibility Enterprise Integration Wonderware MES & EMI Software Solutions Food & Beverage Asset Monitoring Batch Operations Quality Performance Industry Applications & Packs Wonderware MES & EMI Software Solution Offerings Key Talking Points: Wonderware offers a complete MES solution starting with broad connectivity to plant floor devices, best of breed field applications (such as LIMS systems), plant automation systems (such as InTouch) and enterprise business systems. Next, we offer a real-time manufacturing operations management system that encompasses Manufacturing Execution Systems and Enterprise Manufacturing Intelligence systems. At the core of this system is the Wonderware System Platform built upon Microsoft technology and industry standards. This integrated industrial application development environment provides a range of software services tailored to industrial application development. System Platform Clients Microsoft Technology & Industry Standards (c) 2002 Invensys Systems, Inc. (c) 2002 Invensys Systems, Inc. 8 8 20-Apr-17 20-Apr-17

Overview of: Wonderware MES Capabilities
Configurable and Modular Configure business rules that apply Select functional modules that meet requirements Build modularly based on achieving ROI Deploy and Maintain Solid infrastructure Database/Production Model Middleware/Business Rules Extensible Allows extending the out-of-the-box functionalities .Net technology adoption Layer on top of System Platform

Introduction to Wonderware Operations
20-Apr-17 Introduction to Wonderware Operations Wonderware OPERATIONS - PREMIUM Enterprise Integration Wonderware MES & EMI Software Solutions Food & Beverage Asset Monitoring Batch Operations Quality Performance Industry Applications & Packs Wonderware OPERATIONS - STANDARD System Platform Clients Microsoft Technology & Industry Standards (c) 2002 Invensys Systems, Inc. (c) 2002 Invensys Systems, Inc. 11 20-Apr-17

Improved Execution of Operational Activities
20-Apr-17 Improved Execution of Operational Activities Operations Wonderware Operations Software Dispatching and management of electronic work orders, with multilevel BOM Improved process and production consistency and repeatability Accurate inventory mgmt and operational enforcement through procedural steps (c) 2002 Invensys Systems, Inc.

Functional Overview 20-Apr-17 (c) 2002 Invensys Systems, Inc.
Performance Improve Asset Utilization by Identifying Bottlenecks Record downtime, categories, Pinpointing the Causes of Unplanned Downtime Pareto charts, visibility Comparing Line-to-Line and Plant-to-Plant Performance, including Real-time OEE Measures Operations Standard: 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 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 (c) 2002 Invensys Systems, Inc.

Building the Production Model
20-Apr-17 Building the Production Model Building the Production Model Key Talking Points: Wonderware Operations Software provides a comprehensive set of MES functionality that allows an accurate model of production processes. Briefly, let’s go through the key MES functionality provided; Entities – production equipment, manufacturing cells or production lines Items – finished goods (products) or materials that are consumed in the production process Process – one or more operations used to produce an item Operations – a specific manufacturing phase of a process Bill of Material – specifies the consumables and their sequence of consumption used in a manufacturing process Steps – procedures used during an operation Specifications – settings for production processes Work Orders – external or internal order for a quantity of a specific item Jobs - part of a work order completed on a specific entity (machine/line) Routes – graphical representation of material flow between operations and entities Highly Configurable & Customizable To Ensure A Complete & Accurate Model Of Your Production Processes (c) 2002 Invensys Systems, Inc.

Modeling the Process If we look at a simple example of a process, in this case an ice-cream manufacturing process, you start by breaking it down into logical elements

Defining Entities & Items
20-Apr-17 Defining Entities & Items Entities Production equipment or machines Production cells or lines Production assets where items are produced Items Products or materials consumed Items grouped into Item Classes i.e. Finished Goods, Raw Materials, Work In Progress Entities & Items Key Talking Points: Two of the fundamental elements of the production model are entities and items. Entities are simply the production assets used in the production process. These include production equipment or machines, manufacturing cells or production lines. The Configurator application is used to build a hierarchical representation of production assets or entities. Items are the finished goods or products generated by the production process. They are also materials consumed during the production process. Similarly to entities, items are grouped in a hierarchy. To simplify configuration, items can be grouped into Item Classes. Examples could be as general as “Finished Goods”, “Raw Materials”, “Work in Progress” or as specific as the user requires. Like Entities, the Configurator application is used to set up a hierarchy of Item Classes and Items. All of this information is stored in the Production database. (c) 2002 Invensys Systems, Inc.

Defining Bills of Materials (BOMs)
20-Apr-17 Defining Bills of Materials (BOMs) Maintains the consumption & production data for specific operations & items Lists all consumables, by-products & their quantities Consumption sequence Unlimited number, filterable, multiple versions, substitutes, inventory locations & qtys, Instructions, production qtys, storage locations Bills of Materials (BOMs) Key Talking Points: Bills of Materials provide the consumption and production data for specific Operations and Items in the Wonderware Operations Software. BOMs are accessible from the Process Window. An unlimited number of BOMs can be created. BOMs list all consumables, by-products and the sequence of consumption. It also lists the quantity of products or materials consumed during an operation. Users can filter a list of BOMs, you can create an unlimited number of versions of a specific BOM, you can list material substitutes for specific consumables, you can provide instructions and list raw material inventory locations as well as finished goods inventory locations. (c) 2002 Invensys Systems, Inc.

Defining Processes Methods of Producing an Item
20-Apr-17 Defining Processes Methods of Producing an Item Process Definitions link Items with; Operations, Steps, Specifications, Physical Entities & Routings Process Window Create & maintain process definitions Check In/Check Out Process diagram Process versions & templates Status – Approved, or Experimental Process – method of producing an Item Key Talking Points: A Process is the entire method or plan for producing an Item (or product). A Process Definition links Items with manufacturing operations, procedures, routes, material specifications and manufacturing equipment. The Supervisor application provides the Process Window. This window is used to create and maintain process definitions. System administrators can check in/out process definitions during maintenance efforts. A process diagram is also provided that can be clicked on to expose the entities used, the operations and the routing. Process versioning is available as well as the ability to create process templates that can be used to quickly add and configure similar manufacturing processes. You can also assign a Process Status including; Approved, Experimental, Certified and Disabled. Work orders can be created from the Process Window to begin a specific manufacturing process. (c) 2002 Invensys Systems, Inc.

Can involve one or more entities Standard operations allow templates
20-Apr-17 Defining Operations Can involve one or more entities Standard operations allow templates BOMs, Specifications, Steps Operations Key Talking Points: A manufacturing Process in Wonderware Operations Software is broken down into a specific set of Operations. Operations are specific manufacturing phases that involve one or more Entities (equipment), Bills of Materials, specifications and Steps or manufacturing procedures. Standard Operations can be created and used as templates for faster configuration of similar products or items. Operations are typically created using the Insert Operation command from the Process Window. The Operations tab found in the Process Window allow configuration of an Operation. (c) 2002 Invensys Systems, Inc.

Modeling the Process Using the key elements of the Wonderware MES datamodel, you end up with a logical, accurate representation of what’s going on in the real world on the plant floor.

Typical MES Applications
20-Apr-17 Typical MES Applications Production Rules Enforcement Track & Trace While MES have many faces as discussed in the introduction, we have highlighted 4 typical MES project types, just as examples. There are of course more flavors of MES projects, incl. specification management, quality control, yield and cycle time improvements etc. These 4 examples of MES projects illustrate how key MES capabilities can be applied in different situations and also that MES is not just about a ‘big bang’, ‘all-or-nothing’ approach. In the following slides we will take a closer look at key capabilities within Wonderware MES, that enable you to accurately model the physical process, and that enable these distinct project types. Work Order Exec. (c) 2002 Invensys Systems, Inc.

Creating & Executing Work Orders
20-Apr-17 Creating & Executing Work Orders Work orders, jobs, queue and route 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.

Production and Consumption Tracking with Full Genealogy
Manage the recording of production, consumption and equipment used within a work order Supports flexible routings including parallel operations, splits and combines, as well as inventory Genealogy control was established to display consumption and production related information tied to a work order

20-Apr-17 Inventory Management Configurable business rules on how to manage and consume inventory Wide range of functions Split Lot Window Combine Lots Ship Window Inventory Management (cont.) Key Talking Points: Besides Receiving and Transferring items in inventory, waste can be transferred out of inventory and recorded into the database so reports be generated showing the amount of waste coming out of the system. The Split Lot window allows a quantity of an item to be moved to another lot or storage entity (location). You can also change the grade or status of some quantity of an item. The Combine Lots window allows the combination of some quantity of an item from multiple lots into a single lot. The Ship window allows the removal of a quantity of inventory to reflect a shipment of finished goods. The Reclassify window allows the reclassification of inventory to a different grade, status or expiration date. The Inventory window also allows you to filter inventory to control the amount of inventory information displayed on in the window. Operations Software provides a rich offering of inventory management functionality. (c) 2002 Invensys Systems, Inc.

Procedural Workflow Functions
Create additional workflow or instructions as part of an operation Link BOM and specifications to “steps” Link documents, data entry or actions to steps Manage an automated, semi-automated or manual process

MES Reporting 75+ pre-configured reports in Manager
20-Apr-17 MES Reporting 75+ pre-configured reports in Manager Production, Rejects Consumption, Waste, Labor Traceability, Genealogy Certification History, Audit Trail Inventory, Yield and more Reporting Key Talking Points: The Operations Software Manager application is integrated with Wonderware Information Server (part of the System Platform) provides extensive reporting capabilities. 75 pre-configured reports are available with full filtering and date/time range capability. Reports for Production, Consumption, Waste, Labor, Inventory, Traceability and Genealogy are available. (c) 2002 Invensys Systems, Inc.

Enhanced Economy of Scale and Economy of Scope
20-Apr-17 Enhanced Economy of Scale and Economy of Scope System Platform as Reproducible Platform & Logic Engine Repeatability / consistency / min. customization Standards based Concept of templates and deployment Different Elements of Integration Business logic User interfaces Different Approaches to Integration Scripting to API/middleware Intelligent .net controls for visualization Just as important as the scope of our conversation, is identifying why we should take the time to discuss integration between these products. The primary driver is this: each of these products, System Platform and Operations / Performance 3.4 are very strong in certain areas. But, combining the strengths of each product provides the most scalable, flexible, and repeatable solution possible, while also reducing the total engineering effort needed to design and maintain the system over its entire lifecycle. System Platform gives us an environment where we can template not only the common elements utilized in our production process, but also provides us with the ability to template logical elements and activities…like the recording of material consumptions. And we can do this generically…in a way that isn’t specific to a single process. When properly designed, these templates can then be utilized in multiple processes providing us with several benefits. Because we code the activities at the template level, there’s significantly less code to write than if this were being done on a process by process, or even machine by machine basis. We also benefit from the scalability inherit to this model. Another benefit is our ability to either create these templates to adhere to some industry standard for naming and data/process flow, or to define our own standard. Either way, the standard is enforced by our templates, helping to ensure compliance. A secondary reason for integrating these products also exists, and it relates to how people will interact with the system. For those environment which have not previously had much or any automation, integrating these products into their processes can be made fully automatic…but the investment to do so is typically pretty significant. It is more likely that some user interaction will be needed—by at least some level of management and the operators that run the lines. In situations such as this, the key is to provide an intuitive and easy to use interface. Operations and Performance comes with a usable interface that can be used to allow management and operators the ability to interact with the system…but InTouch for System Platform provides interface customization far beyond the abilities of the operations and performance. Said another way, if any significant customization is wanted, InTouch is a much more flexible environment where intuitive, easy to use interfaces can be created; and it is less complicated than creating a custom interface using Visual Studio. Of course, a lot of the environments where Operations and Performance will be sold into will already have some level of automation. The problem we face here is how to minimize the perceived change. Operator acceptance can make or break any system change that is implemented; so it is critical that the integration of Operations and Performance be done in a way that minimizes what the operator has to do differently. [NEXT] (c) 2002 Invensys Systems, Inc.

Operator Interface Options
20-Apr-17 Operator Interface Options Operator Application .NET Controls Embed the control(s) into ArchestrA Symbols Deploy multiple instances as required 15 minutes No code Very simple It is working Operator Interface Key Talking Points: There are two primary ways to display Utilization information to operators; using the Operator application provided with Performance Software 3.4 or via various .NET controls and embedding these controls within InTouch windows. Actually any .NET container can host these controls. The end result is a highly useful graphical display that shows real-time important production information. [EMPHASIS: Minimize the changes to the existing HMI while maximizing the value of the system through the exposure of information] If the operator is used to a simple, three step process for running a batch or work order through the system—like is the case in Wonderbrew where they [CLICK] reset the equipment to a ready state, [CLICK] scan in their input material or materials, [CLICK] and then start the equipment—adding numerous steps or requiring them to then switch over to a totally different program will be met with significant resistance. Instead, what we need to look at doing is integrating the new capabilities into what the operator is already accustomed to doing…[CLICK] minimizing the amount of change necessary while at the same time maximizing the exposure of useful information. (c) 2002 Invensys Systems, Inc.

Integration – Reporting
MES Data Accessible From Information Server Key MES reports migrated to Information Server Production by Entity Downtime Analysis OEE Shift Trend Genealogy by Work Order Extensible Easily create report instances for specific users Wired for Analysis Drill through by passing parameters Determine root cause of production problems “Zero Footprint” Web-Based Reporting Key Talking Points: In addition to the Manager application that is integrated into Wonderware Information Server 3.0, Information Server also leverages Microsoft Reporting Services 2005 to provide ArchestrA Reports. ArchestrA Reports provide flexible report templates for OEE, Downtime and Production Events. ArchestrA Reports can be extended to provide a convenient and efficient way to build a collection of plant specific production reports. ArchestrA Reports are “drillable” using parameter passing so plant workers can get to the root cause faster.

The Power of WW’s Integrated Production and Process History
20-Apr-17 The Power of WW’s Integrated Production and Process History Changes to the temperature set point (c) 2002 Invensys Systems, Inc.

In Summary: Wonderware Provides Unique Value with Incremental Approach
Increased Business Agility and Performance through Improved Manufacturing Operations Wonderware MES & EMI Software Solutions enable: Productivity Increase from Existing Resources Lead Time Reduction Production Throughput and Efficiency Increase Manufacturing Costs Reduction Regulatory Compliance Underlying System Platform and adoption of market standards dramatically reduces total cost of ownership and enables a flexible approach to evolve as you require

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

Andrea Sartori Solution Architect EMEA

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