©2009 ge fanuc intelligent platforms all rights reserved proficy workflow powered by proficy soa...

©2009 GE Fanuc Intelligent PlatformsAll Rights Reserved

Proficy WorkflowPowered by Proficy SOA

Optimize Production withWork Process Management


What If?Employees could:

Work 24/7

Make decisions consistently according to established business and production practices

Ship products on time, under cost, with the highest possible quality?

Proficy Workflow

Eliminates the constraints of: Time

Economics

Resources

Human limitations


Proficy WorkflowGE’s Work Process Management System

Capture manual and automated processes with one tool – without custom code

Act quickly based on real-time events – “Manage by Exception”

Simplify system creation, deployment and management for lower TCO

Leverage proven GE and Microsoft technology and support


Proficy Workflow is…

A system for improving and optimizing industrial and manufacturing practices

Combining automated and manual processes through authoring, execution and analysis capabilitiesNon-Programmers can quickly create automated processes that impact your business every day


What is a Workflow?

“The automation of a process … during which information or tasks move from one participant to another for action … according to a set of rules.”

Proficy Workflow:Work Process Management


3 Simple Steps• Graphically define logical

execution steps in a process and the events that trigger the workflow

• Include manual and automatic interactions with operators, equipment and machines.

• Proficy Workflow ensures proper execution and records the outcome.

Define Workflows to Digitize Production

Solve production problems immediately – without demands on IT.


Proficy WorkflowResults of Managing Work Processes

Lean your processes – improve, eliminate and automate steps

Automate information flow from Plant2Enterprise and Enterprise2Enterprise

Integrate people and their roles / functions

Customize to individuals’ work styles and decision making

Manage and audit your production processes more effectively and consistently


Mix Automated and Manual TasksWorkflow – Process Production Order

Task 1

Task 2

Task 3

Task 4

Set Up Machine, Download

Recipe

Visually Inspect Product

Package Product

Pallet and Ship


Orchestrate high-level processes and manage the data between systems

Digitize GMP Tasks

Digitize SOPs and Work Instructions

HACCP Monitoring Procedures and Corrective Action

Alarm and Event Response, Corrective Action

Manual Assembly Error-Proofing

Plant Task Management

Decision Wizard

Line, Workcell, Machine Setup

Use Proficy Workflow to…


Orchestrate Entire Production Processes

Define Brewery Setup

WorkflowProcess Batch

Create/Modify Site Recipe

Create/Modify Master Recipe

Create Batch

Create/Modify Control Recipe

Process Batch

Complete Batch

Process Visibility!


Authoring a Workflow


Proficy Workflow Components

Workflow AuthoringWorkflow Execution

Task Client

Workflow Design and Definition

Workflow Instantiation,Monitoring and Control

Interaction with Users, Equipment and Applications

WorkflowIntegratedAuthoring

Environment

Workflow Definition

WorkflowExecution Engine

Hosted Applications

Process Equipment

System Workflows

Interactive Workflows


Authoring a Workflow1. Document your new or existing

process

2. Identify, eliminate or reduce non-value-added activities

3. Describe the event, or combination of events, that will trigger the Workflow to execute

4. Define the conditional process logic that will dictate the appropriate types of actions

5. Identify recipients, and what data they require to make the correct decisions and complete their tasks


Workflow Authoring Environment


Task List with Navigation

Transforming Your Business


Business Process ManagementSignificant Results from BPM

“We reduced processing time from 6 weeks to 48 hours and the associated labor by 70%.”

“We increased transaction capacity by 50% and reduced staff and processing time by 30% each.”

• Improve conformance• Ensure compliance• Increase throughput• Reduce rework• Reduce resources• Reduce work in progress• Improve understanding• Reduce training requirements• Reduce progress chasing• Improve ability to meet dates

Proficy Workflow takes BPM to the industrial / manufacturing layer.


Proficy Workflow Applies at All Levels

Level 4

Level 1

Level 2

Level 3

Business Planning & Logistics

Plant Production Scheduling,Operational Management, etc

Manufacturing Operations Management

Dispatching Production, Detailed ProductionScheduling, Quality Assurance, ...

DiscreteControl

BatchControl

ContinuousControl 1 - Sensing the production process,

manipulating the production process

2 - Monitoring, supervisory control and automated control of the production process

3 - Workflow / recipe control, stepping the process through states to produce the desired end products. Maintaining records and optimizing the production process.

Time FrameShifts, hours, minutes, seconds

4 - Establishing the basic plant schedule - production, material use, delivery, and shipping. Determining inventory levels.

Time FrameMonths, weeks, days, shifts

Middleware Type

Transformations and

Orchestration

Production Transformations

Engineering and Spec Changes

Corrective ActionMaintenance

Task Management

Digitized Work Instructions

Task ExecutionStation-Level Control

Manual Data Entry

Alarm Analysis and Action

Mfg Intelligence DataCondition Monitoring


Alarm Corrective Action – Fix production faster and gain greater visibility- Workflows automatically send tasks to people or other systems to correct for alarms

Rapid development of Digitized Work Instructions with Validated Entry- Ensure production complies with defined processes

Eliminate Scripting for Defining Processes, Using Proficy Workflow instead - Approximately 30-50% faster than HMI scripting, and easier to maintain

Adding Value to Any HMI System


Automate the process of Engineering Spec Changes

- Changes are routed for approval and ensures everyone knows about critical changes

Exception Management / Event Triggered Corrective Action Workflow

- Take action only as needed, improve response time & record corrective actions

Event Triggered QA Sampling Request

- Digitize your QA plan, distribute sampling tasks across the plant and ensure compliance

Enhance maintenance systems with work order workflows and EAM integration

Eliminate scripting languages; achieve faster, broader development with workflows

Adding Value to Any MES System


Adding Value to Any ERP SystemFully utilize your ERP – Workflow uses production and ERP data to drive processes

Use Workflows to collect data from users and equipment, and push into your ERP

Workflows orchestrate ERP and production data exchange based on real-time events

Workflow tasks bridge across information and functional silos within ERP

Workflow improves inventory by managing material usage at a more granular level

Workflow drives process visibility – know where orders are at in the plant – right now


Other Workflow Use ExamplesManual Instructions for equipment cleaning, then change state

of machine readiness within the workflow

General tasks as workflows, better than email requests, trackable

Workflow managing engineering changes

Workflow managing site recipe -> master recipe -> control recipe

Electronic Job Router, process a shop order end-to-end, route through workcenters, download CNC programs and provide setup information


Lean and Six Sigma Initiatives

“Industry is missing out on billions of dollars in potential savings, sales, and profits each year through ineffective application of Six Sigma tools and methodologies.” – Aberdeen Group

You cannot improve that which you cannot measure!You cannot effectively measure that which you cannot

digitize!

Workflow closes the loop on process improvement

with actual process execution data


Proficy Workflow:Powered by Proficy SOA –

Real-Time Middleware


Powered by Proficy SOAAn Industrial Service Oriented ArchitectureReal-Time Middleware

Centralized Configuration and Management Environment

Diverse Client and 3rd Party Hosting Container

Real-Time Services Bus

Service Provider Interface for 3rd Party and Legacy System Integration

Global Data and Services Repository

Role-Based Security

Event Services

Diagnostic Services

Object-Relational Persistence Engine

S88/S95 Data Models

Application Development Foundation


Proficy Real-Time Services Bus

Proficy SOA Data and Services Repository

Events Displays/Forms

Alarms

Data and Services Repository

Application Packaging Event Mgmt

S95 Data Models

Client UI Container

LicensingLocalization

App Dev Foundation

Role-Based Security

Config Data Storage

Historical Data Storage

GE FanucSoftware/Hardware

3rd Party Services

Legacy Systems


Proficy SOA Enables Composite Applications

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GE Proficy Integration

CIMPLICITY – iFix – Batch

Proficy Rx – HistorianPortal – Plant Apps -

BatchChange Mgmt – Tracker

Enterprise Connector

3rd Party IntegrationOPC – WonderWare -

SAPRockwell – Siemens –

OracleB2MML – Maximo

LIMS – Custom Systems

Composite Application Examples• Electronic Batch Records• Manual Assembly Error Proofing• Electronic Work Instructions• Alarm Corrective Action• HACCP Compliance

Proficy SOAProficy SOA

Proficy Proficy WorkflowWorkflow

Composite AppsComposite Apps

Data & Services Repository

Historian Tags - Web Pages

ERP Orders - Equip Model

Variables, Events - OPC Data

Plant Apps - HMI Tags Work Orders - Portal

Displays

Core Services Capabilities• Historical Data Storage• Application Packaging• Event Management• S95 Data Models• Client Container• Security• Licensing• E-Signature• Data Object Modeling• Localization• Application Dev Foundation


Enable Building Solutions / Templates

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Proficy SOA: Real-Time Middleware

Horizontal Industrial FrameworkConfiguration - Control – Historical -

Compliance

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Industry Example: Life Sciences / Pharma Solution Set

• Spec’d Solution• Operational Reports• Bill of Materials • Project Checklist • Project Reports• Documentation• Support Plan

Proficy Workflow – Application Development Framework

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30% Customer-Specific Template

70% Industry/Solution Template


Event Management

Published Events from other systems such as CIMPLICITY, iFix, Plant Apps, and OPC Servers

Time-based Events: minutes, hours, days...

Calendar-based Events: modeled after MS Outlook Appointment scheduling

Conditional Events: logical expressions, composites


Data Models – S95 Compliant

Equipment ModelPersonnel ModelMaterial ModelProduct DefinitionProduct ParametersPersonnel SpecificationsEquipment SpecificationsMaterial SpecificationsProcess SegmentsProduct SegmentsWork Order


System Security

Role-Base Security

Security requirements overlaid on the resource

Can impose security constraints on any named (published) resource.

Centralized authorization enforcement

User Authentication: Windows Domain User or Proficy Platform User


www.gefanuc.com/workflow

©2009 ge fanuc intelligent platforms all rights reserved proficy workflow powered by proficy soa...

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