the best of the best: wonderware conference 2015 ebook

The Best of the Best: Wonderware Conference 2015 Schneider Electric Wonderware ➔

Great Power.Great Possibilities.

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The Best of the Best: Wonderware Conference 2015 Schneider Electric Wonderware

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03. Wonderware Delivers on Promises04. Applying the Internet of Things06. Video: Pima County Wastewater Reclamation Success Story07. Video: Wonderware Operations Integration Solutions: Connectivity, Scalability, Uptime, IoT08. 7 Tips to Make the Right SCADA Choice10. Schneider Electric Releases Wonderware Alarm Adviser SP111. Improving Productivity at Nomacorc13. Information Access and Mobility15. Getting Intelligence from Your Big Data17. Video: Inside Campbell’s Global Quality Rollout18. Structuring Workflows to Improve Production20. Optimizing Asset Performance22. Video: F&N Dairies Uses Wonderware Operations Management Solutions23. Wonderware Takes Center Stage

Table of Contents

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At Schneider Electric’s software-focused conference last year, Ravi Gopinath, executive vice president of the software business, put forth a pledge of game changers that would result from merging Inven-sys’s software offerings with Schneider Electric’s portfolio. They’ve spent the past year delivering on those promises, transforming the industrial software market with leading technologies and building a strong portfolio with strong penetration rates, said Tom Comstock, vice president of marketing for Schneider Electric Software.

“We’re already delivering value to our customers across every important technology frontier that applies,” Comstock said, point-ing to 11 customer presentations at the Wonderware Conference taking place this week in Dallas.

Comstock emphasized technologies in a number of areas, including the cloud, mobility, situational awareness, industrial Big Data, asset performance management (APM) and social/collaboration/workflow.

Schneider Electric committed last year to growing its industry base, added Rob McGreevy, vice president of information, asset and operations software for Schneider Electric Software. “Our continued investment in both the manufacturing sector and infrastructure does continue,” he said. “But we’re also focusing on creating more verticalization.” That means creating more packaged solutions for specific industries, making it easier for customers to apply.

McGreevy’s side of the business is seeing a few key trends, he

said, including continued significant investment around informa-tion access and mobility, with pervasive mobility being required by all types of users; enterprise APM, with more recent emphasis on predictive maintenance and the company’s new predictive analytics tool, Avantis PRiSM; and transforming manufacturing operations.

With regard to transforming manufacturing operations, McGreevy pointed to the significant increase in mergers and acquisitions within the food and beverage industry in particular. “There’s a necessity to integrate all these plants and sites together,” he said. “If you’re doing consolidation, you have to marry ERP with MES in a much more tighter way than ever before. That means more IT/OT convergence.”

With Wonderware Development Studio Online, Schneider Electric has been taking its engineering tools and putting them into the cloud, noted Norm Thorlakson, global head of Schneider Electric Software’s HMI and supervisory software business.

Ease of use has been at the core of development on next-gener-ation supervisory systems. “We need to make our offers accessible, usable and attainable by more people,” Thorlakson said. “What Rob [McGreevy] is doing for food and bev, we’re also going to be doing with water, oil and gas, infrastructure and mining.”

There is also a strengthened emphasis this year on the Wonder-ware brand, a change that is being welcomed by customers and partners in this space, which Comstock pointed to as part of the

Wonderware team and Wonderware “state of mind.”The renewed emphasis on the Wonderware brand is no accident,

according to Phil Couling, director of HMI/supervisory software product marketing for Schneider Electric, who said the brand had admittedly been diluted by the Invensys message. But since Invensys was acquired by Schneider Electric last year, “we’ve been getting the Wonderware brand back out in front,” he said.

As part of that, they’re bringing back the WonderWorld Tour, with a North American stop in Orlando already scheduled for October 2016. £

Wonderware Delivers on Promises

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Applying the Internet of Things

Emphasizing key development efforts in mobility, industry verticalization, ease of use and more, executives from Schneider Electric Software detail advances in the product portfolio.

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What could you do differently if the cost of sensing and commu-nication reached zero? This is the question Andy Robinson of Avid Solutions asked at the start of his session at the Wonderware 2015 Conference addressing the use of Wonderware System Platform in Internet of Things (IoT) applications. His question is not a fanciful what-if proposition; it is a fast-approaching reality as interest in IoT directly influences the level of Internet connectivity throughout industry and, therefore, the costs to connect systems within a plant

and across the globe.Hanu Kommalapati, senior director of program management at

Microsoft, also spoke at the conference about extending industry capabilities with the use of IoT. In his session, he explained how technologies like Wonderware System Platform and Microsoft Azure are making it easy for industrial companies to test and employ IoT applications.

Kommalapati began by saying the driver he sees behind indus-try’s interest in IoT is not the appeal of the technology itself, but the fact that “any business that knows itself can be more proactive. Businesses are seeking greater self awareness,” he said.

In terms of real world IoT applications, Kommalapati said that companies tend to deploy these projects in a phased approach. “In the first stage, they connect to the cloud for telemetry—to moni-tor and track the device state and create basic rules to improve operational efficiency,” he said. “The next stage involves business intelligence—analyzing and visualizing the data collected from devices to discover patterns using predictive analytics and opera-tionalizing those insights to improve processes in real time.”

Just as interest in IoT is changing industry, Kommalapati explained that it is also changing Microsoft. To illustrate this he

highlighted the various versions of Windows 10 IoT—which range from Windows 10 IoT Core for small devices, to Windows 10 Mobile Enterprise for devices ranging from smartphones and tablets to barcode readers and other handheld mobile devices, to Windows 10 IoT Enterprise for industrial or commercial devices such as robot-ics systems, OEM machinery, and medical device equipment.

Shifting his focus to Micosoft’s Azure cloud service and how it supports the stages of IoT implementation, Kommalapati said that Azure’s Event Hubs support global device connectivity and management in the cloud using a high-scale telemetry ingestion service with HTTP/AMQP protocol support, which permits each Event Hub to handle up to 1 million publishers with 1 GB/sec ingress and manage 60+ terabytes of data a day. “If your device platform is not currently supported,” added Kommalapti, “you can use a field gateway and event-to-protocol adapter to translate that device’s data to the Event Hub.”

With this much data going into the cloud, security is an obvious concern. Kommalapati said this is why Microsoft is developing the Azure IoT Suite which can support the connection of millions of devices, handle their telemetry, and provide command and control, device registry and identification. He added that the Azure IoT Suite

Applying the Internet of Things


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As Wonderware and Microsoft extend their product capabilities for Internet of Things applications, launching these initiatives across industry are getting easier and easier.

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will also support MQTT (Message Queue Telemetry Transport), which happens to be one of Andy Robinson’s preferred methods of using Wonderware’s System Platform in IoT applications.

Robinson explained that he likes MQTT because of its light data use (headers are only 7 bytes), use of TLS and lack of an incoming connection to client for security, its three levels of quality of service, plus the fact that it is an accepted OASIS standard. In his session he also pointed out that MQTT, compared to HTTP, is 93x faster, uses

12x less battery power to send data, uses 171x less battery power to receive data, and uses 8x less network overhead.

Moving beyond the initial IoT implementation stage of device connectivity, Kommalapati touched on how Microsoft’s Azure Stream Analytics, HD Insight and Machine Learning leverage Hadoop for storing and analyzing data across hundreds or even thousands of nodes. For presentation of these systems’ data and business connectivity to it, he highlighted the role of Microsoft

Dynamics and BizTalk services.Considering all that Kommalapati and Robinson discussed in

their presentations, the close links between Wonderware and Microsoft, and the ongoing IoT-related advances made by the two companies, for companies looking to employ IoT solutions to improve their operations, the necessary tools are now available and becoming easier to use. £

Andy Robinson of Avid Solutions previews his session scheduled for Wednesday at 9:30 am (Waterford A/B) in this video where he discusses understanding core Internet of Things concepts and how to integrate them into the Wonderware System Platform. £



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Using a high performance HMI SCADA solution based on Situational Awareness and a mobile workforce and decision support system, the Pima County Regional Wastewater Reclamation Department provides management and maintenance of the county’s sanitary sewer system. £


Situational Awareness--Complexity Made Simple Make decisions at the speed of your process. Better HMI designs provide true “Situational Awareness,”which leads to greater operator effectiveness and fewer shutdowns. Properly designed HMI applications help optimize both the business value and the safety of your system.

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A new release of Wonderware Operations Integration Solutions, the next generation of device integration, greatly expands the connectiv-ity spectrum both down to the data layer as well as up to the business and ERP layers which will support an industry wide, global, IoT and Cloud-ready communication strategy. £

Video: Wonderware Operations Integration Solutions: Connectivity, Scalability, Uptime, IoT


7 Tips to Make the Right SCADA Choice

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Not all SCADA systems are created equal. As the brain of your automated operations, the right SCADA system can ease communi-cation with RTUs and PLCs, today and tomorrow.

In a session Tuesday morning at Schneider Electric’s 2015 Won-derware Conference in Dallas, John Krajewski will discuss how to take advantage of the latest technology and trends for HMI/SCADA (HMI SCADA-02, Sept. 22, 9:30 a.m.).

As somewhat of a preview, here are seven guidelines from Schneider Electric to help you make the right SCADA choice.

1. It should communicate easily with your existing hard-ware. Many SCADA systems offer only OPC connectivity. But given that the vast majority of industrial operations use a mix of old and new hardware from several different vendors, it wouldn’t be surprising to find that your older equipment doesn’t support OPC. If you don’t ensure that the SCADA package offers a variety of na-tive drivers, you could end up having to find the necessary drivers yourself for your legacy systems, or buy an expensive OPC wrapper.

2. It should support your needs for today and in the fu-ture. Unlimited I/O licensing can help you scale for future produc-tion growth, as long as your industrial system is built to handle it. Make sure the SCADA system has been thoroughly tested to handle

7 Tips to Make the Right SCADA Choice

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Schneider Electric Releases Wonderware Alarm Adviser SP1

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a large number of I/O points to avoid slow response times and other problems caused by a SCADA system not designed for such use.

3. SCADA software should be a low-risk investment. Soft-ware that’s a low-risk investment does not mean simply software this is lower-priced. The initial cost of your SCADA hardware is just a small percentage of the lifetime cost of the equipment, and having throwaway software does not further that investment. Be sure to select a SCADA system with large graphic libraries, customizable reports, and a familiar programming language.

4. Support must be available when and where you need it. If a SCADA system goes down, the consequences can be serious, ranging from lost data that can affect regulatory compliance to un-

scheduled downtime that impacts customers. It’s important to pick a SCADA vendor that will provide support when and where you need it. You will also want to make sure there’s a large network of system integrators certified to provide regular training and coursework.

5. Your SCADA supplier must continue to be in business. With such an important investment as a SCADA system, you want a supplier that will be in business for as long as you are. Another consideration is the provider’s experience in your industry. You don’t just need someone to install the system; you need someone who understands your industry’s particular needs.

6. Upgrades should be simple. SCADA systems must be able to adapt to changing requirements and technologies, and back-

wards compatibility is key. Make sure your vendor offers a long history of 100 percent backwards compatibility to make upgrades easy and preclude you from having an orphaned solution.

7. Security is critical. There have been many instances of SCADA systems being comprised by intrusions, either from the Internet or internal sources. With the mission-critical nature of a SCADA system, protecting it from unauthorized users and hack-ers is vital. The vendor’s commitment to security is a big factor in safeguarding your system.

For more details about how best to meet your SCADA require-ments, read “7 Tips for Selecting the Right SCADA System for Your Needs.” £

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New alarm analysis software for industrial applications from Schneider Electric helps analyze the most important SCADA and HMI alarms, eliminate nuisance alarms, and improve operator awareness. £



Improving Productivity at Nomacorc

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Manufacturing execution systems (known by the acronyms MES and MOM—for manufacturing operations management) are among the fastest growing technologies in industry today, accord-ing to ARC Advisory Group. The reason for such high levels of inter-est in these technologies lies in the value they provide in terms of creating a real-time operations infrastructure for better operations visibility, productivity and throughput, quality management, and

real-time asset utilization—all of which can lead to additional profits for the companies that use them. In addition, ARC reports that users claim the return on investment of MES/MOM solutions is often achieved within six to nine months.

So what happens when you already have such systems in place but know there is room for improvement in your operations? That’s the scenario Chris Monchinski of Automated Control Concepts described during his presentation at the Wonderware 2015 Confer-ence. He explained that Nomacorc—the leading producer of syn-thetic wine bottle corks—was already a savvy Wonderware user when Automated Control Concepts was contacted to help them extend their current systems beyond production monitoring. “They wanted more than monitoring,” Monchinski said. “They wanted to modify operator behavior and drive continuous performance. They needed data to maintain accuracy and uptime. But they also wanted the system to be modular to simplify maintenance.”

Nomacorc was already using Wonderware System Platform, MES and QI analyst to monitor its production operations, which produce more than 7 million synthetic corks a day. Nomacorc’s products are constructed by combining two layers of extrusion on top of each other to create a breathable synthetic cork for wine bottles. The company’s product has been a boon to the

wine industry because cork is an organic product that can be contaminated and/or react adversely with wine. Prior to the introduction of synthetic corks, it’s estimated that 10-15 percent of all wines were contaminated with cork taint.

Monchinski explained that Nomacorc operations are make-to-order, “so they track production performance and quality closely.

Improving Productivity at Nomacorc

Nomacorc, a manufacturer of synthetic corks for wine bottles, and a long-time Wonderware user, sought to upgrade its production systems beyond for operator behavior modification and continuous improvement.

Nomacorc Improves Productivity with Multi-site, Multi-country Wonderware MES/Performance Deployment


Information Access and Mobility


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The company’s goals for its next-generation production system included having: a repository for process, alarm and OEE (overall equipment effectiveness) data; a common format for all HMI systems with support for multiple languages (as the company has plants in different countries); a common underlying framework to support common communication to all PLCs and HMIs, al-lowing for these systems to send data to business systems; and new alarming communications.

To deliver on these goals, Monchinski said the project started by using Wondware System Platform’s Base Template Library to replace the custom bind scripting approach to data objects

in the production systems. A data concentrator approach was used to develop UDTs for data transfers that would match Nomacorc’s standard object footprints. This was key to connecting Nomacorc’s blender system, which uses propri-etary Modbus/TCP and, therefore, has only one data connection port.

• Other key development steps in the project included:

• Configuring the InTouch HMI with all-new graphics, but adding security attributes to ensure that operators did not make unwant-ed changes to the new graphics.

• Connecting shift tracking to MES for better

shift management and OEE reporting.• Adopting use of the ISA 95 model to map all

reasons for downtime and scrap for im-proved equipment scheduling and efficiency.

• Tracking production of good and bad prod-ucts by using the PLC to total production data and trigger the system to log it.

• Integrating Microsoft Dynamics ERP to the production system with scripts and triggers to determine necessary web services calls between the systems. With this connection, schedules and order statuses are integrated between the ERP and Wonderware MES/Performance.

As a result of these upgrades, Nomacorc operators can now:

• Get real-time feedback on automatic and manual scrap conditions;

• Set OEE targets on the dashboard; and• Drill down into dashboard objects to get

Pareto details.In addition, Nomacorc’s Qlikview app is able to

co-exist with the new system and now includes ERP, MES and process data. This is “a source of truth for Nomacorc,” said Monchinski, “because it allows them to break down data by reason code and test and verify the data. They can even add comments into it now.” £

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Having access to information in your production systems means you can influence outcomes, said Saadi Kermani, product manager, Wonderware Information Management, in his session on mobility technology at the 2015 Wonderware Conference. “Everyone needs

access to information—that’s always been the business issue. What’s changing is the context in which that information is needed because the pace of business is getting faster and we’re expected to do more with less,” he added.

“Another factor that’s changing across industry is people,” said Kermani, and by that he meant the Millennials in particular. The key differences in the Millennial workforce, according to Kermani, is that the Millennials will typically only spend a year or two in their current job before moving on and they will bring with them their key job tool—a smartphone and/or tablet. “They only want to know what their job is and where’s their app to do it with,” he said. “SmartGlance fits this model.”

SmartGlance is Wonderware’s mobile down-loadable app that provides access to plant data—such as process or operational data, metrics, key performance indicators (KPIs) and reports—on mobile devices regardless of the device’s platform, i.e., Android, iOS, Windows, etc. Kermani noted that SmartGlance is not about “generating new

data, but about getting the right data to the right people when they need it. With this information in hand, users can do analysis of the data and take action by contacting people who have responsi-bility for it in the plant,” Kermani said.

“SmartGlance helps you monitor your equipment against production goals, such as OEE (overall equipment effectiveness),” Kermani added. “It alerts you to potential process or equipment is-sues and reduces the time and effort to address them with remote visibility across teams.”

Asked about the security of SmartGlance, Kermani explained that SmartGlance accesses plant data via the Mobile Reporting Connector, which accesses the data via a single outbound encrypt-ed port. “No data goes into your system via SmartGlance,” he said. The Mobile Reporting Connector (MRC) for SmartGlance is used to create users and groups of users (such as quality, production, field engineers, etc.) who can receive specified, relevant system data via SmartGlance at established frequencies.

The MRC enables the “connection of multiple historians, cre-ation of reports, and tag insertions with no SQL server knowledge required,” Kermani said. “You can also use MRC to give nicknames to tags, since tag names can be long.”



Getting Intelligence from Your Big Data

A confluence of trends around the cloud, mobile technologies and a changing workforce is impacting how industry accesses production data for decision making and planning.

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In reference to timing, Kermani noted that sending updates every 30 seconds is as fast as data can be pushed with SmartGlance. “If you need data more frequently, InTouch Access Anywhere is the preferred solution,” he said.

Kermani also pointed out the simple licensing structure for SmartGlance. “There’s only one question for SmartGlance when it comes to licensing,” he said, “and that is: How many people will use it? That’s it. With that you get unlimited tags, reports, and devices. Just pay per number of users on an annual subscription basis.”

Highlighting the stand-alone applicability of SmartGlance, Kermani noted a use case in the oil and gas industry where a company is applying SmartGlance to pull OSISoft PI System historian data to make it available to workers around the company’s sites and in the field. “They’re able to do this with SmartGlance on its own. They have no other Wonderware software currently installed,” he added. £



Wonderware Online: high availability and business continuity


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One of the biggest problems with Big Data is simply that it’s big. Where this is a really big deal is getting a handle on how to put it all to work. With so much data coming from a range of disparate sources, it can be difficult to create the necessary context to make business decisions based on real-time operations metrics.

Wonderware Intelligence tackles that by helping manufactur-ers collect data from many different places—whether historians, ERP systems, quality systems or other sources—and put it into context to present key performance indicators (KPIs) in intuitive dashboards.

“A customer may need KPIs where bits of that data needs to come together, get rationalized and accumulated,” said Maryanne Steidinger, director of product marketing for asset, operations and information software at Schneider Electric. “Intel-ligence accesses the source data and puts it into context.”

At the Wonderware 2015 Conference this week in Dallas, Schneider Electric Software released the latest version of its enterprise manufacturing intelligence software, Wonderware Intelligence 2014 R2.



Video: Inside Campbell’s Global Quality Rollout

Schneider Electric’s latest iteration of its Wonderware Intelligence software helps customers make faster, more advanced queries on their industrial Big Data.

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The newest version collects, calculates and contextualizes data and metrics from multiple sources across the manufactur-ing operation, puts it into a centralized storage and updates it all in near real time. Optimized for retrieval, the information can be used to monitor KPIs via customizable dashboards, as well as for drill-down analysis and insights into operating and overall business performance.

The improvements addressed in the newest version of Intel-ligence include:

• The ability to use stored procedures to increase the speed of queries.

• The ability to dynamically use start and end times for more precise queries.

• Streamlined administrator rights for the Intelligence service.Where Intelligence previously operated on a first-in-first-

out (FIFO) basis, it now accesses the most recent information first, which improves the query time and overall performance, Steidinger explained.

Intelligence enables customers to really understand the important aspects of their manufacturing operations—like quality, throughput, variance, productivity, etc.—by rolling it all into a dashboard personalized for various enterprise and plant roles.

“Wonderware Intelligence is an easy-to-use, non-disruptive solution that improves how our customers visualize and analyze

industrial Big Data,” said Graeme Welton, director of Advansys (Pty) Ltd., a South African company that provides specialized industrial automation, manufacturing systems and business intelligence consulting and project implementation services. “It allows our customers to build their own interactive dashboards that can cap-ture, visualize and analyze key performance indicators and other

operating data. Not only is it more user-friendly, it has better query cycle times, it’s faster and it has simpler administration rights. It’s an innovative tool that continues to drive quality and value.”

Though the dashboards are personalized to put the right data into the hands of the right person, they nonetheless provide everyone in the operation the same version of the truth drawn from a single data warehouse. The interactive and visual nature of the dashboards significantly increases the speed and confidence of the users’ decision-making, which allows them to improve their productivity, reduce operating costs and increase profitability.

“By not having to manually collect, calculate and store data, and then having easy access to and the right context for that data, users are able to improve their processes and optimize their energy con-sumption, often providing a return on investment within weeks of implementation,” said Christian-Marc Pouyez, Intelligence software product manager for Schneider Electric Software. “For example, its easy access to operating performance data allows users to compare trends so they can identify the root cause of some unscheduled downtime or other incident. Preventive measures can then be em-ployed to eliminate future incidence, which means better overall performance. In fact, some customers have seen their productivity increase by more than 20 percent, while their manufacturing and productions costs, including their energy usage, have dropped more than 10 percent.” £

How New Belgium Brewing Reduced Downtime and Increased Efficiency with Wonderware MES After discovering its bottling line was only producing at 50 percent of capacity, New Belgium Brewing applied Wonderware MES to address the problem and generated additional production benefits in the process.



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Campbell’s is 18 months into a global quality solution rollout that will provide standardized statistical process control methodologies for the company’s production lines. Michael Kershaw and Barry Dickerson from system integrators Crossmuller Technology and Callisto Integration describe the journey. £


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Structuring Workflows to Improve Production


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No matter how technologically advanced your processes may be, your company’s ability to produce is only as good as its workflow processes. Without good workflow procedures—and supporting technology to ensure these procedures are followed—your risk of downtime, decreased throughput and loss of revenues is greatly increased.

At the Wonderware by Schneider Electric 2015 Conference, Keith Chambers and Juan Carlos Garcia of Schneider Electric explained how coordinated work-flows are an inherent part of a successful manufactur-ing operation. In their presentation, they showed how Wonderware’s industrial workflow software, based on Skelta BPM, supports plant floor collaboration, escala-tion management and exception handling.

“This software, which provides fully integrated workflow definitions, forms and analytics, is used to coordinate how people can work together optimally,” said Chambers. “While InTouch (human machine

interface software) collects and visualizes data, Workflow uses this data to coordinate actions across production, maintenance, quality, warehouse/logis-tics, and environmental health and safety operations.”

The Workflow editor allows for the creation and editing of workflows specific to your operations that are then assigned to an object in the ArchestrA devel-opment environment. Events and scripts within the object can trigger workflows in InTouch or on Skelta devices. “Workflows can include forms for task-based user interactions and collaboration,” said Chambers, “and they can be integrated directly into Wonderware MES, InBatch, and Avantis Enterprise Asset Manage-ment as well as Office and SharePoint 2013.”

Some of the operations examples Chambers highlighted as ideal applications for Workflow software across industry include the release of new recipes or formulas to the production floor, approving the release of a new product, execut-

Structuring Workflows to Improve Production

Using workflow software for error proofing of operator actions, compliance with standard operating procedures for production, environmental health and safety directives, and reduced regulatory risk.


Optimizing Asset Performance

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ing maintenance work orders, starting up or shutting down a process, managing demand/supply activities such as kanban, and responding to alarms.

The benefits of using Workflow software, according to Chambers, include error proofing of operator actions and responses, compliance with standard operating procedures for production, precise following of environmental health and safety direc-tives, improved transparency into operator actions and reduced regulatory risk.

For a real world example of how effective good workflow procedures can be, consider the success Fujirebio Diagnostics Inc. has ex-perienced since installing the Wonderware Workflow software. Fujirebio Diagnostics is an FDA-regulated supplier of biomarkers (blood tests) for oncological purposes that help physicians, laboratory professionals,

and patients better manage disease. The company’s 160,000-sq.-ft. facility produces about 75 million tests annually.

Though Fujirebio has been a leader in its field for two decades, the company achieved a major milestone in 2013 when it replaced its manual, paper-based process of periodically recording temperature readings for specific good manufacturing processes (GMP)-related equipment with a new computerized system. By automating this manual process, Fujirebio created a major opportunity to save time and paper and retain compliance by automating the ac-quisition of equipment data and generating electronic reports for review and approval.

The company’s project to address this was called the Electronic Initiative and the first phase involved the implementation of what it called the Equipment Monitoring

System or EMS. The software used in the Equipment Monitoring System is the Won-derware System Platform with the Won-derware Workflow. Prior to implementa-tion of the EMS, workers typically spent up to 15 hours reviewing GMP packs. After installation, workers only spend minutes on the data because they are reviewing by exception and not having to worry about missing key items. In total, the company estimates they are saving about 1100 man-hours per year by using the EMS. The software also enables Fujirebio to comply with 21 CFR 11 regulations for electronic records and electronic signatures.

Looking ahead, the EMS provides Fujirebio with an infrastructure for other electronic data capture projects such as MES/MOM, process automation and ERP integration. £

Fujirebio Diagnostics, Inc. - a Wonderware Workflow success story




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Although the Internet of Things has only more recently become a “thing,” anybody in industry well knows that manufacturing operations have been gathering reams of data for decades. But truly taking hold of the capabilities that data has to offer is what has become an ever-nearer real-ity as connectivity and analytics improve.

Predictive analytics and their ability to enable predictive rather than reactive maintenance is a big game changer for manufacturers. Schneider Electric has been putting a lot of emphasis on optimizing the enterprise asset performance management (APM), and its Avantis PRiSM is the latest addition to that effort, capturing all the high-fidelity process data to diagnose asset health, noted Rob McGreevy, vice president of information, asset and operations software for Schneider Electric Software.

Avantis PRiSM predictive analytics monitor the real-time health and performance of criti-cal assets to predict equipment failure or decay points. The capabilities provided by artificial intelligence, advanced pattern recognition and sophisticated data mining can reduce mainte-nance costs and increase availability, reliability and capacity.

In a Tuesday morning session at the Wonder-ware Conference, titled, “Past, Present, Predict, Prevent” (OPS/INFO-03, Sept. 22, 10:45 a.m.), Keith Chambers, Sean Gregorson and Paul Shelton will explain how Avantis PRiSM can help you achieve greater reliability and perfor-mance from your production assets.

Avantis PRiSM can provide early warning notification and diagnosis of equipment issues days, weeks or months before failure—



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Avantis PRiSM predictive analytics is the latest tool in Schneider Electric’s arsenal geared toward improving the health and performance of critical assets.

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White Paper: Bridging the Gap in the Batch Market Recipe management plays an important role in the success of batch manufacturing. However, a huge gap exists between the simpler HMI/SCADA recipe management solutions offered and full blown batch management and control packages. This white paper from ARC Advisory Group discusses how Wonderware Recipe Manager Plus software can fill that gap.

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warnings that could go unnoticed by traditional maintenance practices.

“The value prop on this is super high,” McGreevy said, speaking to industry media and analysts during a briefing at Schneider Elec-tric’s 2015 Wonderware Conference. “93 percent of our customers have reported equipment failures.”

In one case, for example, a utility was experiencing sporadic issues with a steam model turbine; the condition escalated and eventually resulted in the shutdown of the unit for corrective

action. But upon completion of the maintenance, a similar cycle of sporadic issues began again, in addition to new problems.

Analyzing the unit’s raw historical data with Avantis PRiSM, it was clear that such a tool, had it been in place, could have provided early warning that turbine thermal expansion issues were developing and becoming chronic over the year. Through a modeling exercise, the tool was able to detect the fault pat-terns with early warnings six months prior to failure. The model showed that the bearing vibrations were a symptom while

thermal expansion issues were the primary cause of the prob-lem. Proactive remedial maintenance would have corrected the thermal expansion problem before it led to bearing vibration issues and the shutdown of the unit.

Not only would significant maintenance costs have been avoid-ed, but the utility would have increased sales through increased unit availability. Estimated savings in this case are in the millions of dollars—a result of 35 days of avoided downtime and associated repair costs. £



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F&N Dairies/Thailand needed plant to business connectivity to enable product traceability, ensure product quality, streamline pro-duction and boost overall customer satisfaction for their Carnation, Teapot and Bearbrand products. £



Wonderware Takes Center Stage

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At the 2015 Wonderware Conference in Dallas, Schneider Electric showed a strengthened em-phasis of its Wonderware brand. Schneider has spent the past year delivering on the promises made by Ravi Gopinath, executive vice president of Schneider Electric Software, after the company’s acquisition of Invensys, building a strong software portfolio with strong penetration rates. This was the message delivered at the conference’s opening general session by Tom Comstock, vice president of marketing for Schneider Electric Software, and backed up by presenters—including several customers—throughout the week.

In his closing keynote before football great Terry Bradshaw took the stage, Gopinath emphasized that the integration of Invensys within Schneider Electric over the past year and a half has gone “ex-

ceedingly well” as the company works to harmonize and converge the various SCADA platforms. Making reference to a proposed merger of Schneider’s software business with Aveva, Gopinath reassured conference attendees of Schneider’s continued commitment to software, noting the renewed abil-ity to “start to fully monetize the intrinsic value of the software business.”

As a sign of the restrengthening of the Wonder-ware brand, Comstock also announced a return to the WonderWorld Tour. Mark your calendar now for the North American stop, taking place Oct. 3-6, 2016, in Orlando, Fla.

For more information on Wonderware solutions please visit: http://software.schneider-electric.com

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Wonderware Takes Center Stage

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