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SIMATIC IT Historian
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The Four Operations of ISA 95 Level 3 The Four Operations of ISA-95 Level 3
SIMATIC IT Historian addresses Production and Quality Operations of ISA- 95

SIMATIC IT Historian addresses Production and Quality Operations of ISA- 95

Siemens AG 2013 All rights reserved.
Page 2 Author / Department

ISA 95 Standard Operation Pillar in details ISA-95 Standard Operation Pillar in details
P d ti O ti Pill Q lit O ti Pill Production Operation Pillar Quality Operation Pillar
Production Production
Market challenges Market challenges
C titi i f i f t t i iti t b i f Competitive pressure is forcing manufacturers to initiate business performance
improvement strategies
Each role in the enterprise must be empowered with accessible, meaningful and
consistent information which improves the decision making process
Improvements strategies cannot be effective without putting data into a business
context and distillingtheminto Key Performance Indicators (KPI) context and distilling them into Key Performance Indicators (KPI)
The goal is to transform data into information, and information into insight.
Carly Fiorina (1954)
SIMATIC IT Historian SIMATIC IT Historian
P id ll th t l t h dl d l h fl d t
SIMATIC IT Historian:
Shop Floor data collection and aggregation
Provides all the tools to handle and analyze shop floor data
Shop Floor data collection and aggregation
KPI calculation and validation
Long Term Archive concept
Data analysis tools
Reporting
Web based data distribution, analysis and reporting
Integrated with SIMATIC IT Production Suite
KPI management
P id ll th t l t h dl d l h fl d t
Integrated with SIMATIC BATCH:
BatchAnalysis
Provides all the tools to handle and analyze shop floor data
Batch Analysis
Batch Archive
Electronic Batch Reporting
Integrated with SIMATIC WinCC/PCS7:
Scalable Plant Intelligence Solution
Product Options
OEE-DTM (Overall Equipment Effectiveness and Downtime Management)
SPC-SQC (Statistical Process Control and Statistical Quality Control)
SPC-SQC (Statistical Process Control and Statistical Quality Control)
Data collection and aggregation Data collection and aggregation
SIMATIC IT Historian collects and aggregates data from different sources and
Real-time data
SIMATIC IT RTDS
SIMATIC IT Historian collects and aggregates data from different sources and
transforms them into valuable information
OPC Server WinCC Data Manager
SIMATIC IT RTDS
( Data compression
with optional Plant Data
Archive module )
Hi t i l d t
SIMATIC IT Plant
Performance Analyzer
OPC Server WinCC Archive Relational Database
Historical data sources
RDB
Alarms events
Wi CC A hi 3 d P t li ti
Long-term archive
Batch data
WinCC Archive 3rd Party applications
SIMATIC BATCH
Custom data
Data calculation & Data validation Data calculation & Data validation
Data aggregation functions Data aggregation functions
Applicable on data from historical data
sources
Pre-defined aggregations available
(Average, Min, Max, Sum, )
Validation functions
Set the quality code (GOOD or BAD)
INPUT PARAMETERS
Se e qua y code (GOO o )
of the samples
Can be applied on raw data or on
calculated data
Custom algorithms with PPA scripting
environment
Data/KPI Analysis Data/KPI Analysis
Pre defined viewers are available for data analysis
Trend Viewer Bargraph Viewer
Pre-defined viewers are available for data analysis
Production Viewer X-Y chart
Alarm Analysis Alarm Analysis
Pre defined viewers are available for alarm analysis
Message analyser
Pre-defined viewers are available for alarm analysis
Message Viewer
Batch analysis Batch analysis
PPA automatically stores Batch information from SIMATIC
BATCH:
Batch stepping sequence
Batch-related messages
Batch-related measures (trends)
Analyze Batch events and related data (trends, alarms, KPIs)
Compare data on different batches Compare data on different batches
A Query Tool is available in order to
select batches
Search criteria can be applied to any pp y
Batch characteristic
Batch reporting
Pre-defined batch reports
On the fly analysis On-the-fly analysis
A Formula Editor integrated in HDD controls allows on-the-fly analysis based o ua d o eg a ed co os a o s o e y a ays s based
on archived data
It is possible to save and reuse formula templates
All main mathematical operators and brackets are supported All main mathematical operators and brackets are supported
SIMATIC IT Reporting Framework
SIMATIC IT R ti F k t d th f ti lit f SIMATIC IT
SIMATIC IT Reporting Framework extends the functionality of SIMATIC IT
Production Suite by providing:
Adata management infrastructure where productiondata are stored and A data management infrastructure, where production data are stored, and
exposed according to the ISA 95 standard
R d t i d t ifi t Ready-to-use industry specific report
templates and report parts integrated in
Microsoft Report Builder
Access to reports through SIMATIC IT
Portal, controlled by SIMATIC IT User
Management Management
Hide the complexity of the physical model and let the user choose the
Hide the complexity of the physical model and let the user choose the
abstraction model that better works for him
ISA 95 terminology
Business Model
ISA 95 terminology
Business information
Consolidated data
SIMATIC IT terminology
Business reports
Data Model
Production data
Real time data
Operational reports
Physical Model
p p
The Data Model enables the end-user to interact with data without having to
The Data Model enables the end-user to interact with data without having to
understand the complexity of database logic or to be familiar with the tool where
the physical data is stored.
The following MES relevant information are
available for reporting purposes
S95 entities
e.g. Equipment model, Orders, Materials, PPRs, Shift
Calendars Personnel etc Calendars, Personnel, etc.
Historical tags
OEE, SPC and EBR data ,
Compliance Services and Logbook info
The Business Model is built around the standard business terminology of ISA 95
gy
and provides the end-user the ability to autonomously query and retrieve
information using common business terms.
Web based analysis & Reporting Web-based analysis & Reporting
Client Application Builder (CAB) allows providing the right information at the right moment Client Application Builder (CAB) allows providing the right information at the right moment
to the right users through a web-based client interface at Zero Administration Cost
Embed pre-defined viewers in CAB screens
Display data by means of dedicated interfaces
Graphically build queries using Smart Query Builder
(SQB)
KPI Management KPI Management
KPIs managed through to the integration with Production Modeler: KPIs managed through to the integration with Production Modeler:
Assign KPI to Equipment Classes (site, area, cell, unit) in the Plant Model
Schedule KPI calculation directly from Production Modeler rules
PPA automatically contextualizes KPIs against manufacturing events or elements
(production runs, batches, production orders, equipments, )
Activate KPI 1 Activate KPI 1 Calculate KPI 2 Calculate KPI 2 Calculate KPI 3 Calculate KPI 3 Deactivate KPI 1 Deactivate KPI 1
Trace
Trace Trace
Trace
Production Operation
Trace
Production Step
Trace
Production Step
Production Viewer allows analyzing KPIs relevant to a specific production event
Comparison of KPIs can be done using Bargraph Viewer or Trend Viewer
FDA 21 CFR Part 11 Support FDA 21 CFR Part 11 Support
FDA 21 CFR Part 11 regulation is supported through the integration between Historian FDA 21 CFR Part 11 regulation is supported through the integration between Historian
and Compliance Services
Audit Trail and/or Electronic Signature can be applied to any modification of archived data
F ll t i ti f El t i Si t i i t d Full customization of Electronic Signature scenarios is supported
SIMATIC IT Historian key benefits SIMATIC IT Historian key benefits
User specific, up-to-date and comprehensive information offers crucial
business advantages
Improve performance visibility for proactive and timely decision making at Improve performance visibility for proactive and timely decision making at
each corporate level
Faster and better understanding and solving problems
Reduce downtimes and idle-times
Optimization of production processes
Quality performance improvements
Reduction of paper based activities
Reduction of production costs
Support compliance to regulations and normative practices
SIMATIC IT Historian Product Options: SIMATIC IT Historian Product Options:
Product Options:
OEE-DTM
(Overall Equipment Effectivenness and Downtime Management)
SPC-SQC
(Statistical Process Control and Statistical Quality Control) ( y )
The Four Operations of ISA 95 The Four Operations of ISA-95
SIMATIC IT OEE-DTM addresses Production and Quality Management of ISA-95 Q y g


ISA 95 Standard Operation Pillars in detail ISA-95 Standard Operation Pillars in detail
Key questions for manufacturers Key questions for manufacturers
High Performance, high Quality, high Availability
the everyday targets in the plant
need to improve maintenance and operational performances
g , g y, g y
Which is the actual performance against my performance targets?
How effectively is the organization using its assets?
Why my capacity is idle or non-productive? Why my capacity is idle or non productive?
Are resources being used efficiently for the products currently
produced?
What is the economic impact of the inefficiency?
Howmuch revenue has been lost due to the operational How much revenue has been lost due to the operational
inefficiencies?
Why two teams, that appear to be equal, produce products that are
so different?
Is your factory fully utilized? Is your factory fully utilized?
Does your process create waste when stopped?
All necessary data must be available to make informed decisions
The Six Big Losses The Six Big Losses
In manufacturingplants the most common causes of efficiency loss have been In manufacturing plants the most common causes of efficiency loss have been
identified and
classified as the Six Big Losses
Six Big Losses Category Comment
Breakdowns
Setup / Adjustments
Downtime Loss
Downtime Loss
Difference between Breakdown and Small Stop
Includes tool changeovers
Small Stops / Idling
Reduced Speed
Speed Loss
Speed Loss
Only stops under (5) minutes and no maintenance
Process not running at its theoretical speed
Startup Rejects
Production Rejects
Quality Loss
Quality Loss
Scraps in warm-up, startup or other early production
Scraps during steady-state production
OEE Calculation OEE-Calculation
OEE is a total measure of performance that relates the availability of process to
OEE controls and reduces the Six Big Losses
OEE is a total measure of performance that relates the availability of process to
productivity and quality
OEE-Category OEE-Calculation
Standby
D ti L
Not part of OEE calculation
A il bilit i th ti f ti ti t l d d ti ti Downtime Loss Availability: is the ratio of operating time to planned production time.
100% availability means the process has been running with no recorded
stops
Speed Loss
Performance: is the ratio of ideal cycle time to actual cycle time, or
alternatively the ratio of actual run rate to ideal run rate.
100% performance means the process has been consistently running at its
theoretical maximum speed
Quality Loss
theoretical maximum speed
Quality: is the ratio of good parts to total parts.
100% quality means there have been no reject or failure in parts
OEE = Availability * Performance * Quality
World Class OEE World Class OEE
A erage of OEE rate in man fact ringplants is 60%
World Class OEE is considered to be 85% or more
Average of OEE rate in manufacturing plants is 60%
OEE FACTOR World Class
Six Sigma is not enough!
99 %in Quality
Availability 90,0 %
Performance 95,0 %
99 % in Quality
doesnt mean
OEE >= 85% !
Quality 99,0 %
OVERALL OEE 84,6 %
Big Room for Improvements
Engineering an OEE DTM Solution Engineering an OEE-DTM Solution
D l f i ffi i i d d i l i
Plant model
Equipment hierarchy is shared with SIMATIC IT Production
Deployment of equipment efficiencies and downtime management solution
Time model
Define general time categories as a basis for Key Performance
Plant model
definition
Equipment hierarchy is shared with SIMATIC IT Production
Modeler
configuration
Indicators (KPI) calculation
Reason tree
configuration
Define all the possible equipment status conditions (failures,
stops states reasons )
configuration
stops, states, reasons, )
Data collection
configuration
Configure data collection in SIMATIC IT Historian
KPI configuration
Customize and personalize KPI algorithms
g
SIMATIC IT for OEE SIMATIC IT for OEE
SIMATIC IT OEE-DTM is a product option of SIMATIC IT Historian, and it is wholly
and seamlessly integrated within the entire MES solution
SIMATIC IT for OEE, through integration with the entire SIMATIC IT environment,
allows:
the calculation of all standard and custom KPIs
to fully support the Downtime Management
to perform active and corrective actions to react to efficiency decreases
to improve economic Return on Investments (ROI)
to maximize the plant performance
KPI Evaluations KPI Evaluations
SIMATIC IT OEE-DTMmanages efficiency-related and downtime-related KPIs SIMATIC IT OEE DTM manages efficiency related and downtime related KPIs
Pre-defined standard KPIs algorithms:
Availability rate, Performance rate, Quality rate, OEE,
MTTA, MTBF, MTTR, MTBA, and more
Possibility to create new custom KPIs algorithms,
combining the existing ones or implementing brand
new ones
All th i di t db SIMATIC IT OEE DTM il bl ith All these indicators, managed by SIMATIC IT OEE-DTM, are available either :
for executives (who, having an extended vision of the overall plant, manage indicators and charts)
for operators (who mainly monitor run-time views, customizing downtime parameters, and have a restricted view of a
specific nit)
specific unit)
Downtime Management and Analysis Downtime Management and Analysis
Downtime Management:
detailed information about equipment states
canbe displayed updated and filtered can be displayed, updated, and filtered
by equipment, status, product, or any other
context data
Downtime Analysis:
enables exploring the causes that have
generateda productionbreakdown
generated a production breakdown
Runtime Analysis Runtime Analysis
SIMATIC IT f OEE id b f d fi d hi ifi ll b ilt i SIMATIC IT for OEE provides a number of predefined graphics screens specifically built in
order to provide out-of-the-box analysis OEE-related KPIs and equipment downtimes
P d fi d hi bj t il bl t b ild dditi l hi Pre-defined graphic objects are available to build additional graphics
SIMATIC IT Client Application Builder provides the engineering and run-time platformfor SIMATIC IT Client Application Builder provides the engineering and run-time platform for
the user interface, since the user interface is built on top of standard technology (namely .Net
from Microsoft) a wide range of third-party graphic objects can be embedded in any GUI
interface for OEE analysis
interface for OEE analysis
Easy and flexible engineering phases Easy and flexible engineering phases
Time Model:
through its graphical representation, it provides an easy way to create
the complex model
Reason Tree:
it defines in details the hierarchy of all the possible machine states within
the defined time categories for individual or for groups of equipments
Shift Calendar (SHC) Management:
strong integration between equipments and calendars are defined in the
SHC component
Comprehensive and detailed analysis phases Comprehensive and detailed analysis phases
Production Counter Analysis: Production Counter Analysis:
Produced units, scraps, reworked units and any other
production counter can be displayed and summarized,
according to the different grouping criteria
Current production can be compared with theoretical
production production
Reporting: Reporting:
SIMATIC IT for OEE makes use of SIMATIC IT Report Manager in
order to provide flexible and effective performance reporting
(customized according to the user needs)
Reports can be launched directly from the web
Focus on whats new in SIMATIC IT OEE v1 2 SP2 Focus on whats new in SIMATIC IT OEE v1.2 SP2
Planned / Induced Downtime Management
MES Context Support
On Value Change Design Speed Acquisition
Web Client integrated in SIMATIC IT CAB Portal Web Client integrated in SIMATIC IT CAB Portal
GUI Enhancements
Predefined Reports
Documentation enhancements
Note: SIMATIC IT OEE V1.2 SP2 is compatible with SIMATIC IT Production Suite V6.3 SP2
Planned / Induced Downtime Planned / Induced Downtime
Two special types of downtime records definedeither through a dedicatedOEE Two special types of downtime records, defined either through a dedicated OEE
Web Client page, or programmatically through COM or GSI methods:
Pl d D ti Planned Downtimes
which cause OEE to disregard the status information retrieved from the field
for the specified time span, are used when an equipment have predefined
planned time where it is off-line.
Induced Downtimes
used to model a bottleneck situation, where the machine state of a piece of
equipment depends on the state of another piece of equipment. They are q p p p q p y
used to put in Downtime status an equipment on real-time.
Planned Downtime Planned Downtime
A Pl d D ti i i d f d ti fi dt i th f t A Planned Downtime is a period of downtime configured to occur in the future.
Th f ll i t d fi l dd ti The following parameters define a planned downtime:
A start-time and an end-time
(b th i th f t ) (both in the future)
A machine state
The piece(s) of equipment involved
Induced Downtime Induced Downtime
An Ind ced Do ntime is a period of do ntime hich as ca sed b another An Induced Downtime is a period of downtime which was caused by another
downtime occurring on a different piece of equipment.
A start time set when the record is opened
An end time set when the record is closed An end time set when the record is closed
A machine state
The piece(s) of equipment involved
MES Context Support MES Context Support
The following predefinedMES Contexts are managedfor downtime The following predefined MES Contexts are managed for downtime,
counter and design speed records:
GroupName
UserName
LotID
O d ID OrderID
BatchID
Shift
UserComment UserComment
The user can set the context values either: The user can set the context values either:
manually (by a programmatic interface)
automatically (by either a screen or a Production Modeler rule)
On Value Change Design Speed
Acquisition Acquisition
I OEE V1 2 SP1 th i th ibilit t i d i d l d t In OEE V1.2.SP1 there is the possibility to acquire design speed values on data
change:
the user must define two RTDS points (one to trigger the design speed reading
and one to retrieve the design speed value)
Now, the user can easily define all
the parameters of design speed
acquisition, beyond product id
and context acquisition q
Web Client integrated in SIMATIC IT CAB Portal
The following predefined pages are provided fully-integrated in SIMATIC IT CAB
Web Client integrated in SIMATIC IT CAB Portal
g p p g p y g
Portal:
Counters Graphic
Counters Grouped
KPI Viewer
C Vi Counters Viewer
Design Speed Viewer
DTM Viewer e e
Gantt Viewer
Runtime Operator Panel
Equipment Comparison
Context Management
Pl dD ti
Planned Downtime
Predefined Reports Predefined Reports
Th f ll i t id d The following reports are provided:
Actual &Target
Downtime
DTM Detail
Availability details
Counter values
DTM values
Documentation enhancements Documentation enhancements
This version includes the following new documents:
OEE Developer Guide:
a comprehensive guide on how to use OEE programmatic interfaces to develop custom applications p g p g p pp
OEE Installation Manual:
a dedicated installation manual for SIMATIC IT OEE
OEE Web Client Documentation:
new contextual documentation accessible directly from OEE Web Client pages
Additionally, the following existing documents have been substantially updated:
OEE Concept Guide OEE Concept Guide
OEE Functional Overview
SIMATIC IT OEE DTM benefits SIMATIC IT OEE-DTM benefits
Through integration with
SIMATIC IT Production Modeler:
SIMATIC IT OEE-DTM
key benefits:
Reducingefforts to collect real time production
Increase acquisition performances using high speed
acquisition rules
Customization of the application through the user-
Reducing efforts to collect real-time production
information
Preventing unscheduled downtimes
exits capabilities, inside the Production Modeler (PM)
rules
Speeding-up acquisition performances by buffering
Improving of data synchronization and safety with data
recovery system
Maximization of production equipment utilization
p g p q p y g
mechanisms
Improvement of the acquired data contextualization
Reducing maintenance costs by optimizing planning
activities
Improving assessment and business process
performance
Definition of high-level contexts
performance
Easy Import / Export configuration data from Excel
worksheets
O ti i i d t lit di
Optimizing product quality grading process
Counters Graphic Counters Graphic
Counters Graphic displays the value of one or more counters (sum) associatedto Counters Graphic displays the value of one or more counters (sum) associated to
a piece of equipment in a trend graph
Additionally, it is also possible
to display the equipment units
design speed in the trend,
if it was configured during the
engineeringphase engineering phase.
Counters Grouped Counters Grouped
Counters Grouped displays counter values in tabular formgroupedaccording to Counters Grouped displays counter values in tabular formgroupedaccording to
user-definedfilters on contexts
Such filters can be set if
counter values where acquired with
contexts during the engineering contexts during the engineering
phase.
KPI Viewer KPI Viewer
KPI Viewer displays KPIs associated to a particular piece of equipment using
one of the following graphs:
Bargraph
Trend
Stacked bargraph
Pareto chart
Counters Viewer Counters Viewer
C t Vi di l t d i t b l f Counters Viewer displays counter records in tabular form
Design Speed Viewer Design Speed Viewer
Design Speed Viewer displays design speed records in tabular form and it also Design Speed Viewer displays design speed records in tabular form, and it also
gives the user the possibility to edit them and export them to a CSV file
DTM Viewer DTM Viewer
DTM Viewer let the user to visualize and manage the DownTime records DTM Viewer let the user to visualize and manage the DownTime records
Gantt Viewer Gantt Viewer
Gantt Viewer displays downtime records related to one or more pieces of Gantt Viewer displays downtime records related to one or more pieces of
equipment in a Gantt chart
The user can perform the following actions:
Filter data by
equipment equipment
context
time interval
Zoom in and out the chart
Export and print data
Runtime Operator Panel Runtime Operator Panel
Runtime Operator Panel gives a general overviewon the efficiency of a Runtime Operator Panel gives a general overview on the efficiency of a
piece of equipment
Two types of trend charts can be displayed:
Production Chart Production Chart
to view the values of all the counters
associated to the piece of equipment
OEE Chart
to view all OEE indicators associated
to the piece of equipment.
Equipment Comparison Equipment Comparison
E i t C i i th th t it t t Equipment Comparison gives the user the opportunity to compare two
or more pieces of equipment
For each piece of equipment, the following
KPIs are displayed (if available):
OEE
Availability
Performance Performance
Quality
Current counter values
Note: This page provides only real-time data and can be configured to refresh itself automatically or manually.
Context Management Context Management
Context Management can be used to set the current values for one or more
contexts which were defined during the engineering phase
By doing so, it is possible to modify
contextualization of:
design speed,
counter
downtime records downtime records
Planned Downtime Planned Downtime
Pl d D ti ll th t t Pl d D Ti f Planned Downtime allows the user to set a Planned DownTime for one
or more equipment
The Four Operations of ISA 95 The Four Operations of ISA-95
Production and Quality Management in ISA 95: Process & Product Analysis Production and Quality Management in ISA-95: Process & Product Analysis


ISA 95 Standard Operation Pillar in detail ISA-95 Standard Operation Pillar in detail
SIMATIC IT SPC SIMATIC IT SPC
SPC project opportunities are still under evaluation on behalf of
SIMATIC IT Product Management g
For further information please contact: p
ProductManagement.simatic-it@siemens.com
Contacts Contacts
For further information please contact:
productmanagement.simatic-it@siemens.com
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