The Bread Line Demonstration
Plant Manager
Process Engineer
Are we
meeting
OEE targets?
Which recipes
are having quality
issues?
Quality targets?
Are the Oven
Temps
Optimized?
Batch losses
resolved?
Energy Manager
How much
energy are we
using?
Maintenance Manager
Is the weather
affecting my
energy consumption?
Are we reaching
our Sustainable
Initative Goals?
Are some machines
consuming more
energy than others?
What machines
are causing
the most issues?
What is my
MTTF?
What
machines
need service
The Factory
Bread Line 1 – Anaheim, California
Natural Gas
Electricity
PROOF OVEN
MIXER
Weather
PACKAGING
Ingredients
Bread
Water
Scrap
Consumables
Alarms and
Events
Process
Data
Production
Data
OEE and
Downtime
Weather
Data
Energy
Consumption
Batch
Data
~10min Batches
1hr Shifts
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Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Smart Devices and
Tablets 4
• Mobile O/S
• Mobile Favorites
Windows 8 KPI
• Windows 8.1
Desktop Clients
• Workstation O/S
• FT View SE Client
Wireless
Router
Managed Ethernet Switch for Control System Network (CSN) – FT Live Data & Ctrl to Ctrl Communications
FT View SE Server
• Server O/S
• FT View SE Server
• RSLinx Enterprise Server
• RSLinx Classic
• FT Tag-based Alarm Server
• FT Historian SE FTLD Interface
• MSSQL Express
Microsoft SQL Server 2
• Server O/S
• SQL Server Standard
• SQL Server Reporting
Services
Domain Controller 1
• Server O/S
• For the Ctl Sys Domain
FT VantagePoint Server
• Server O/S
• FT VantagePoint Server
• FT VantagePoint Mobile
• FT VantagePoint Portal
• Excel 2013 (32bit)
FT Metrics Server
• Server O/S
• ODBC Data Source
• FT Metrics3
• Report Expert
FT Historian SE Server
• Server O/S
• Historian SE Server
Engineering Workstation
• Workstation O/S
• FactoryTalk View Studio
FT Directory Server
• Server O/S
• FT Directory Server
• MS SQL Express 3
Managed Ethernet Switch for Control System Network (CSN) – FT Live Data & Ctrl to Ctrl Communications
Mix Area
• ControlLogix
Proof Oven
• ControlLogix
FT Energy Metrix Server
• Server O/S
• Energy Metrix
Packaging Line
• ControlLogix
Unified Production Model (UPM)
Key Value Propositions – the UPM
 Integration of all data sources and reports
 Organized by Equipment
 Sites, Areas, Lines, Assets
 Key Performance Indicators for each Bread Line
 Organized by Reporting Role
 Energy Manager
 Maintenance Manager
 Plant Manager
 Process Engineer
 Modeled equipment for easy access to data from
various data sources (FTHistorian, FTMetrics…)
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Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Portal Content
Key Value Propositions – Navigating the Menu
 Themed Portal
 Access to the UPM via Menu Link
 Access to Role Based Reporting also via Menu
Link
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Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Portal Content
Key Value Propositions – the Portal UPM
 Portal Tree organized by as per UPM
 Integration of Reports from various Data Sources
 FTHistorian, FTMetrics
 FTEnergyMetrix and Custom Database
 Demonstration of various reporting tools
 Dashboards
 Trends
 Excel Reports
 SQL Server Reporting Services
 Integration of Mobile Dashboards and Reports
 Portal Tree organized by Reporting Roles
PUBLIC
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Portal Content
Key Value Propositions – Dashboards
Drill from the Baking Overview
to the Line Overview to the
Equipment Detail Dashboards
Visualize Operation
of the Baking Line,
Performance and
Process Variables
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Combine Energy
and Performance on
a single Dashboard
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Portal Content
Key Value Propositions – Line Reporting with Excel
Drill through to
current Batch Details
Current Line Performance
with high level details
Combined material and
Performance detail on
Batch Details report
PUBLIC
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Portal Content
Key Value Propositions – Trending Process and Performance Variables
Trend of overall
Line Performance:
OEE and Units Produced
Trend of Proof Oven
Temperatures
PUBLIC
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Portal Content
Key Value Propositions – Role Reporting – Plant Manager
Line State (Idle, Slicing…)
based on Packaging Machine, with
ability to filter by Product and State
PUBLIC
Provides Performance details
for each Machine in the Line
Provides Performance details
for the Site, with drill down
capabilities
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Portal Content
Key Value Propositions – Role Reporting – Maintenance Manager
The Top 10 report provides a
quick overview as to what to
focus on to improve
overall performance
PUBLIC
The Faults This Week report
includes Mean Time to Failure and
Mean Time to Repair
Report on your Top Alarms
by Duration from the Alarms
and Events Database
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Portal Content
Key Value Propositions – Role Reporting – Energy Manager
For the Packaging Machine,
we can monitor and report on
Energy Consumption
Energy analysis based on
BatchID, Product, State or Shift
Overall weather conditions at site
- weather has a great affect on overall
Energy consumption at this Site
PUBLIC
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Portal Content
Key Value Propositions – Role Reporting – Process Engineer
Detailed review of
Ingredients used
Trend of ingredients used
Alarm Report
PUBLIC
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Mobile Content
Key Value Propositions
PUBLIC
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Thank you!
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Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.