simatic it historian pres
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siemens.com/simatic-it
SIMATIC IT Historian
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ro uc on pera on ar ua y pera on ar
Production Production
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ompe ve pressure s orc ng manu ac urers o n a e us ness per ormance
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
The goal is to transform data into information, and information into insight.
Carly Fiorina (1954)
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SIMATIC IT Historian:
rov es a e oo s o an e an ana yze s op oor a a
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
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Integrated with SIMATIC BATCH:
rov es a e oo s o an e an ana yze s op oor a a
Batch Archive
Electronic Batch Reporting
Integrated with SIMATIC WinCC/PCS7:
Scalable Plant Intelligence Solution
Product Options
OEE-DTM (Overall Equipment Effectiveness and Downtime Management)
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Real-time dataSIMATIC IT RTDS
transforms them into valuable information
OPC Server WinCC Data Manager
( Data compression
with optional Plant Data
Archive module )
SIMATIC IT PlantPerformance Analyzer
OPC Server WinCC Archive Relational Database
s or ca a a sources
RDB
Alarms events
Long-term archive
Batch data
n rc ve r ar y app ca ons
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SIMATIC BATCHCustom data
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Applicable on data from historical data
sources
Pre-defined aggregations available(Average, Min, Max, Sum, )
Validation functions
Set the ualit code GOOD or BAD INPUT PARAMETERS
of the samples Can be applied on raw data or on
calculated data
Custom algorithms with PPA scripting
environment
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Trend Viewer Bargraph Viewer
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Production Viewer X-Y chart
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Message analyser
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Message Viewer
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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)
A Query Tool is available in order to
select batches
Search criteria can be applied to any
Batch characteristic
Batch reporting
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Pre-defined batch reports
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A Formula Editor inte rated in HDD controls allows on-the-fl anal sis based
on archived data
It is possible to save and reuse formula templates
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epor ng ramewor ex en s e unc ona y o
Production Suite by providing:
, ,
exposed according to the ISA 95 standard
ea y- o-use n us ry spec c repor
templates and report parts integrated inMicrosoft Report Builder
Access to reports through SIMATIC IT
Portal, controlled by SIMATIC IT User
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abstraction model that better works for him
Business Model
Business information
Consolidated data
SIMATIC IT terminology
Business reports
Data Model Production data
Real time data
O erational re orts
Physical Model
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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 entit iese.g. Equipment model, Orders, Materials, PPRs, Shift
, , .
Historical tags
OEE SPC and EBR data
Compliance Services and Logbook info
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The Business Model is built around the standard business terminolo of ISA 95
and provides the end-user the ability to autonomously query and retrieve
information using common business terms.
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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)
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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 1Activate KPI 1 Calculate KPI 2Calculate KPI 2 Calculate KPI 3Calculate KPI 3 Deactivate KPI 1Deactivate KPI 1
Trace Trace
Production Operation Production Step Production Step
Production Viewer allows analyzing KPIs relevant to a specific production event
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Comparison of KPIs can be done using Bargraph Viewer or Trend Viewer
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and Compliance Services
Audit Trail and/or Electronic Signature can be applied to any modification of archived data
u cus om za on o ec ron c gna ure scenar os s suppor e
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User specific, up-to-date and comprehensive information offers crucial
business advantages
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
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Product Options:
OEE-DTM
(Overall Equipment Effectivenness and Downtime Management)
SPC-SQC
(Statistical Process Control and Statistical Quality Control)
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Production Production
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Hi h Performance, hi h Qualit , hi h Availabilit
the everyday targets in the plant
need to improve maintenance and operational performances
Which is the actual performance against my performance targets?
How effectively is the organization using its assets?
Wh m ca acit is idle or non- roductive?
Are resources being used efficiently for the products currently
produced?
What is the economic impact of the inefficiency?
inefficiencies?
Why two teams, that appear to be equal, produce products that are
so different?
Does your process create waste when stopped?
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All necessary data must be available to make informed decisions
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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 product ion
Scraps during steady-state production
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OEE is a total measure of erformance that relates the availabilit of rocess to
OEE controls and reduces the Six Big Losses
productivity and quality
OEE-Category OEE-Calculation
Standby Not part of OEE calculation
own me oss va a y: s e ra o o opera ng me o p anne pro uc on me.
100% availability means the process has been running with no recorded
stops
Speed Loss Performance: is the ratio of ideal cycle time to actual cyc le time, or
alternatively the ratio of actual run rate to ideal run rate.
100% performance means the process has been consistently running at its
Quality Loss
Quality: is the ratio of good parts to total parts.
100% quality means there have been no reject or failure in parts
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OEE = Availability * Performance * Quality
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World Class OEE is considered to be 85% or more
verage o ra e n manu ac ur ng p an s s
OEE FACTOR World Class
Six Sigma is not enough!Availability 90,0 %
Performance 95,0 %
doesnt mean
OEE >= 85% !
Quality 99,0 %
OVERALL OEE 84,6 %
Big Room for Improvements
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ep oyment o equ pment e c enc es an ownt me management so ut on
Time model Define general time categories as a basis for Key Performance
definition
Modeler
configuration Indicators (KPI) calculation
Reason tree Define all the possible equipment status conditions (failures,
, , ,
Data collection
configuration Configure data collection in SIMATIC IT Historian
KPI configuration Customize and personalize KPI algorithms
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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
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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 brandnew ones
ese n ca ors, manage y - , are ava a e e er :
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
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spec c un
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Downtime Management:
detailed information about equipment states
, ,by equipment, status, product, or any other
context data
Downtime Analysis:
enables exploring the causes that have
enerated a roduction breakdown
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or prov es a num er o pre e ne grap cs screens spec ca y u n
order to provide out-of-the-box analysis OEE-related KPIs and equipment downtimes
re- e ne grap c o ec s are ava a e o u a ona grap cs
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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 anal sis
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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
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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
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
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.
Planned / Induced Downtime Management
MES Context Support
On Value Change Design Speed Acquisition
GUI Enhancements
Predefined Reports
Documentation enhancements
Note: SIMATIC IT OEE V1.2 SP2 is compatible with SIMATIC IT Production Suite V6.3 SP2
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,
Web Client page, or programmatically through COM or GSI methods:
anne own mes
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
e ui ment de ends on the state of another iece of e ui ment. The areused to put in Downtime status an equipment on real-time.
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anne own me s a per o o own me con gure o occur n e u ure.
e o ow ng parame ers e ne a p anne own me:
A start-time and an end-time
o n e u ure
A machine state
The piece(s) of equipment involved
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n n uce own me s a per o o own me w c was cause y ano er
downtime occurring on a different piece of equipment.
A start time set when the record is opened
A machine state
The piece(s) of equipment involved
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,
counter and design speed records:
GroupName
UserName
LotID
r er
BatchID
Shift
manually (by a programmatic interface)
automatically (by either a screen or a Production Modeler rule)
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On Value Change Design Speed
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g g p
n . . ere s e poss y o acqu re es gn spee va ues on a a
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 ac uisition
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The followin redefined a es are rovided full -inte rated in SIMATIC IT CAB
Portal:
Counters Graphic
Counters Grouped
KPI Viewer
Counters Viewer
Design Speed Viewer
DTM Viewer
Gantt Viewer
Runtime Operator Panel
Equipment Comparison
Context Management
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e o ow ng repor s are prov e :
Actual &Target
Downtime
DTM Detail
Availability details
Counter values
DTM values
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This version includes the following new documents:
OEE Developer Guide:
a comprehensive guide on how to use OEE programmatic interfaces to develop custom applications
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 Functional Overview
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Through integration with
SIMATIC IT Product ion Modeler:
SIMATIC IT OEE-DTM
key benefits:
Increase acquisition performances using high speed
acquisition rules
Customization of the application through the user-
-information
Preventing unscheduled downtimes
exits capabilities, inside the Production Modeler (PM)
rules
S eedin -u ac uisition erformances b bufferin
Improving of data synchronization and safety with data
recovery system
Maximization of production equipment utilization
mechanisms
Improvement of the acquired data contextualization
Reducing maintenance costs by optimizing planning
activities
Improving assessment and business process
Definition of high-level contexts Easy Import / Export configuration data from Excel
worksheets
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p m z ng pro uc qua y gra ng process
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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
.
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user-defined filters on contexts
Such filters can be set if
counter values where acquired with
phase.
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KPI Viewerdisplays KPIs associated to a particular piece of equipment using
one of the following graphs:
Bargraph
Trend
Stacked bargraph Pareto chart
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oun ers ewer sp ays coun er recor s n a u ar orm
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,
gives the user the possibility to edit them and export them to a CSV file
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equipment in a Gantt chart
The user can perform the following actions:
Filter data by
e ui ment
context
time interval
Zoom in and out the chart
Export and print data
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piece of equipment
Two types of trend charts can be displayed:
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.
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qu pmen ompar son g ves e user e oppor un y o compare wo
or more pieces of equipment
For each piece of equipment, the following
KPIs are displayed (if available):
OEE
Availability
Performance
Quality
Current counter values
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Note: This page provides only real-time data and can be configured to refresh itself automatically or manually.
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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
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anne own me a ows e user o se a anne own me or one
or more equipment
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ro uc on pera on ar ua y pera on ar
Production Production
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SPC project opportunities are still under evaluation on behalf of
SIMATIC IT Product Management
For further information lease contact:
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For further information please contact:
siemens.com/answers
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