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EMEA USERS CONFERENCE 2017 LONDON #OSISOFTUC ©2017 OSIsoft, LLC
Conference Theme and Keywords
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EMEA USERS CONFERENCE 2017 LONDON #OSISOFTUC ©2017 OSIsoft, LLC
Presented by
Breaking New Ground
With Enterprise PI System
Dan Moore
Billy O’Connor
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EMEA USERS CONFERENCE 2017 LONDON #OSISOFTUC ©2017 OSIsoft, LLC
Agenda
• About DePuy Synthes
• Business Challenge/Use Cases
• J&J Regional PI Instance
• DePuy Automation System Control Tower
• Key OSIsoft Products Used
• Results Obtained and Business Impact
• Next Steps
• Conclusion
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DePuy Synthes Background
Company of Johnson & Johnson - Global Presence
World’s Largest Health Care Company
119,000 Employees
250 Operating Companies In 57 Countries
Selling Products in More Than 175 Countries
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Manufacturing - Global Supply Chain - Innovation Centre
DePuy Synthes Cork Site
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DePuy Synthes Product Portfolio
2% Shoulders
24% Hips 74% Knees
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DePuy Synthes Core Technologies
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Business Challenge
• Lack of data to make informed decisions
• Lack of visibility into manufacturing and process data
• Numerous data sources, no central repository – Manually recorded excel sheets
– Chart recorders
– SCADA’s
– Utilities Applications
– Etc.
• Restricted access to data
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Uses Cases
• Asset Utilization
• Downtime tracking
• Process Data Collection
• Environmental & Facilities Data Collection
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System Architecture
• Regional J&J PI Instance
Hosted in J&J Data Center
• Local API Nodes Per Site
(Redundant Pair)
• Multiple Sources
– Separate VLAN’s
– PLC’s
– CNC Controllers
– Databases
• Unrestricted Access to
PI Client Tools for J&J Users
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Leveraging J&J PI System Standards
• Standard Naming Convention
– Universal S88 based tag naming across J&J
• Content Standard
– PI AF Templates & S88 Enterprise Structure
• Visualization Standards
– Content driven visualization templates
• Global Adoption and Utilization Framework
– Formal Process for driving training, usage and value realization
• Standard Qualification Documents & Protocols
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Automation Systems Control Tower
• PI ProcessBook Displays Published in PI Coresight
• Home Screen – DePuy Synthes Global Orthopaedics
Overview
• Currently have Cork Site
Qualified
• Warsaw & Raynham
POC on-going
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Automation Systems Control Tower
• Building Overview Screens - Machine Status Colour Coded
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Automation Systems Control Tower
• Drill Down to Individual Asset Display. Asset Utilization Data.
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Automation Systems Control Tower
• Environmental Data Monitoring. Critical to Quality Parameters.
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Automation Systems Control Tower
• Machine Process Parameters Monitoring for Engineering Analysis
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Automation Systems Control Tower
• Critical Assets Identified and Highlighted for Review in Weekly Management Review
Meeting
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Automation Systems Control Tower
• Dashboards used with Mobility
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AF Template Structure
• Rapid Development Time
Due to template Approach
• Analysis and Event Frames Built
Into All Templates
• Templates Built to Leverage
Across All Sites
Grinder
Template
Tumbler
Template
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Element Relative Displays
• Dashboards Built Element Relative,
One Dashboard Developed
for >90 Assets
• Template Display With ?CurrentElement Appended to the URL
• https://YourCoresightmachine/Coresight/#/PBDisplays/13044?CurrentElement
=\\AFServer1\DePuy Synthes GO\DePuy Cork\Poly\MILL0039
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Downtime Tracking in Event Frames & PI DataLink
• All equipment templates include downtime event frames
• Downtime events used to capture start time, stops time,
duration, machine state & alarm code/message.
• PI DataLink used to empower engineers to investigate
unplanned downtime events
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Downtime Tracking in Event Frames & PI DataLink
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Asset Availability Data PI DataLink
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EMEA USERS CONFERENCE 2017 LONDON #OSISOFTUC ©2017 OSIsoft, LLC
Business Impact
• Asset Utilization
– 11% Increase.
– Decrease in unplanned
downtime.
• Environmental Data Monitoring
– Variations in relative humidity in
dip room linked to increase in
upstream scrap.
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• Data Access & Retrieval
– 80% reduction in data retrieval
time.
– Provided managers, engineers
and operators increased
visibility in machine data.
• Behaviour Impact
– Empowered engineers to
understand and investigate the
manufacturing process in more
depth.
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Next Steps
• OSIsoft MTConnect
Connector Development
• Trend SPC Measurement Data
• Collect facilities energy monitoring data
• Trial Started on two more DePuy Sites
• Merge With MES Data To Calculate Full OEE Metrics
• Expose Data to Data Lake for More Advanced Analytics Using PI Integrator
• Roll Out Automation System Control Tower to all DePuy Synthes Sites in Global Orthopaedics
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EMEA USERS CONFERENCE 2017 LONDON #OSISOFTUC ©2017 OSIsoft, LLC
Picture / Image
RESULTS CHALLENGE SOLUTION
COMPANY and GOAL
Company
Logo
Breaking New Ground With
Enterprise PI System
DePuy Synthes is a global leader in
orthopaedic medical device products, and
wanted to improve asset utilization
No central repository for machine data. Lack of visibility into asset utilization
Used an enterprise PI System
as a standard method to
access real time data and to
analysis asset utilization
Data can now be accessed by operators, utilities and management from any location and any device
• Rapid deployment due to use of
PI AF templates & element relative
displays
• Unrestricted access for J&J users
to all data
• Improvement in asset utilization
• Increased visibility into machine &
process data
• Standard data collection approach
developed for all sites
• Numerous data silos
• No standard for data collection
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EMEA USERS CONFERENCE 2017 LONDON #OSISOFTUC ©2017 OSIsoft, LLC
Dan Moore
Senior Automation Engineer
DePuy Synthes, J&J
Billy O’Connor
Senior Systems Engineer
DePuy Synthes, J&J
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Questions
Please wait for the
microphone before asking
your questions
Please remember to…
Complete the Online Survey
for this session
State your
name & company
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EMEA USERS CONFERENCE 2017 LONDON #OSISOFTUC ©2017 OSIsoft, LLC
Thank You