1. Advanced Scheduler for Wonderware MES
Chris Mollison
Scheduling Solutions

2. Introduction
Project Solution
Agenda
Benefits
Considerations
Summary

3. 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

4. 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

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

6. Introduction
Project Solution
Agenda
Benefits
Considerations
Summary

7. 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

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

9. 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.

10. 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.

11. 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.

12. 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.

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

14. 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 licenses sold
(c) 2002 Invensys Systems, Inc.

15. 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.

16. 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

17. 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

18. 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

19. Integration Example

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

21. 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

22. 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.

23. Introduction
Project Solution
Agenda
Benefits
Considerations
Summary

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

25. 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

26. 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%

27. 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.

28. Introduction
Project Solution
Agenda
Benefits
Considerations
Summary

29. 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.

30. Introduction
Project Solution
Agenda
Benefits
Considerations
Summary

31. 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.

32. 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

33. ….any questions?