WW MES and Manufacturing Overview v4

(1)

© 2010 Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are proprietary marks of Invensys or its subsidiaries. All third party trademarks and service marks are the proprietary marks of their respective owners.

MES

:

The Road To Growing You Business…Organically

Michael Deng

Channel Sales Manager, ASEAN

Sunday, March 17, 201 9

(2)

What we’ll discuss today

• Wonderware MES Recap - MES 101

• Invensys offerings to manufacturers

• ERP Integration

• Case Studies

• Eco-System & GTM Approach

(3)

Okay…

Manufacturing Recap

(4)

Let’s look at an example of

manufacturing: making a cookie

• Raw materials: flour/sugar/baking powder/vanilla/chocolate chips

• Equipment: mixer, spoon, bowl, baking sheet, oven, mitts

• Labor: you

• Recipe: from package. Includes measures, time, temperature

• Batch: three sheets of cookies, 12/sheet

• Outcome: units of one (cookies)

(5)

Let’s look at another example: building a PC

• Raw materials: PC boards, components, screen, CPU, disk drive, …

• Equipment: hand assembly, electronic insertion equipment

• Labor: assembly line (automated/semi-automated)

• “Recipe”=BOM/Work Instructions: Bill of Materials lists all of the

components required, plus Work Instructions handle any special

processing, testing or packaging that must take place

• Outcome: units of one (PC’s)

(6)

Many More…

(7)

What do manufacturers have in common?

• Tracking of raw materials to finished goods

• Effectively using plant assets/resources

• Optimizing output while minimizing costs

• Maintaining customer satisfaction

• Complying with standards & industry regulations

• Maintaining their competitive edge

(8)

Agenda



Wonderware MES 101



Operations & Execution (MES) Portfolio



ERP Integration



Case Studies



Partners & Ecosystem

8

Invensys proprietary &

(9)

Again, What is MES…

“I need to

reduce

downtime”

“I need to have

traceability”

_{“I need to}

manage

recipes”

“I need to

improve quality”

“I need to

improve yield”

“I need to

reduce

inventories”

“I need to

reduce

cycle times”

“I need to

reduce

(10)

Standards Groups for MES:

Manufacturing

Execution

Systems

Manufacturing Enterprise Solutions Association

Developed S-95 Standard for MES to ERP

Integration. MES layer focuses on key

manufacturing activities—operations,

inventory, quality, labor and maintenance

activities—corresponding to the “Level 3” in

the Perdue Hierarchy Model.

(11)

Best-in-Class Use MES…

(12)

Growth surpasses traditional ERP

Mfgs continue to invest in process

improvements that affect bottom line

(quality, profitability, yields,

throughput, asset management)

MES has lion’s share of investments

MES Market Opportunity…

(13)

Industry Overview:

Needs Met for Discrete Manufacturing with MES

 “Error Proof” mfg

 Track & Trace by units

 Validation, Compliance

 Corrective Action

 21CFR Part 11, 820 compliance

 eDHR

 Closed loop CAPA

 Operator certification

 % first time right

 Failure analysis

 Integrate to automation & controls products

 Traceability

 Inventory management

 RMA/Repair

 Supplier Management

 Yield, Cycle Time, Quality improvements

 ECO execution

 Increase production

without increasing capacity

 Accelerate NPI ramp to production volumes

 Collaboration with suppliers via web

 Operational efficiency through real time data collection

 Yield/throughput improvements

Automotive

_{High Tech}

EMS

(contract mfg)

Medical

(14)

Industry Overview:

Needs Met for Hybrid/Process Mfg with MES

 eBatch Records

 Track & Trace by batches

 Integrated LIMS and PDM

 Validation, Compliance

 OEE/DTM

 21CFR Parts 11/ 820 compliance

 eBatch Record

 Closed loop CAPA

 Operator certification

 Traceability

 Increase Productivity

 Reduce Costs

 Ensure food safety

 Assure continued product availability

 Maintain brand value

 Maintain processing

flexibility with equipment mgt

 Lot tracking and recipe management enable brand protection

 Legal compliance &

preparation for future FDA regulation of industry

 Improve recipe management and

specification collaboration

 OEE/DTM

Chemical

Food &

Bev.

Tobacco

Pharma/

(15)

Industry Overview: Needs Met for Food & Bev

Manufacturing with MES

 Increase Productivity

 Reduce Costs

 Ensure food safety

 Assure continued product availability

 Maintain brand value

 % first time right

 Failure analysis

 Traceability

 OEE/DTM

 Respond to seasonal demands

 Labor Management

 Integrate disparate systems

 Yield, Cycle Time, Quality improvements in real-time

 Weigh scale integration: reduce overfills

 Increase production without increasing capacity

 Shipping efficiencies

 Maintain production volumes with KPI’s/real-time process management

 Collaboration with suppliers via web

 Ingredient management through PDM

 Integration of LIMS for Quality remediation

 HACCP

 OEE/DTM

Overall F&B

Meat &

_Poultry

(16)

Industry Overview: Needs Met for Metals & Mining

Processing with MES

 End-user Skills Shortage

 Supply Base Consolidation

 Introduction of Total Integrated Solutions Puts Pressure on Niche Participants

 Strong End-user Demand for Value-added Services

 Sensitivity to Global Commodity Prices

 Reliability & Reduced Downtime to respond to new & existing business contracts

 Capture best practices

 Enforce methodology

 Better visibility to real-time activities

 OEE for downtime mgt & throughput optimization

 Bundles s/w & services for complete solution

Industry Needs

& Challenges

(17)

A Break…………..Before We Consider MES

Golf professional Kenny Perry was leading the 2009 Masters Golf Tournament in Augusta, Georgia, on the final day with two holes to go.

At age 48, he had worked all his golfing life for this moment: a chance to win a major tournament. His second shot on the seventeenth hole ended up on the back fringe of the green, leaving him a difficult but very playable chip shot. Unfortunately,

though, his next shot ended too far from the hole for him to make par.

He bogeyed instead, a one-stroke mistake that ultimately cost him the championship.

(18)

Small Take-Away’s

• Past greatness does not guarantee a company’s future.

• In the years to come, thriving businesses will know how to

manage every part of their organisation with excellence

• The most successful executive will concentrate a majority of

their time and resources on what will keep their companies

growing and prospering in the decades ahead.

(19)

Why MES? Questions to consider



Are you a manufacturer in a regulated industry?

– Food & Beverage

– Tobacco

– Automotive

– Cement

– Pharmaceutical/Chemicals

– Medical Devices



Do you have “challenges” in your business?

– Compliancy issues (21 CFR Part 11, HACCP, BioTerrorism, TREAD)

– Cost of Quality/Product out of balance?

– Supply chain issues?

– Meeting supply/volume targets?

– Managing plant assets/resources?



Do you have legacy/custom software applications to track, trace or

document the product manufacturing?



Do you have initiatives like:

– LEAN, Six Sigma

– Cost reduction, OEE, DTM



Do you have improvement projects being driven by Operations,

Finance, or Quality? Are they X-Departmental?

–

(20)

Agenda



Wonderware MES 101



Operations & Execution (MES) Portfolio



ERP Integration



Success Stories



Ecosystem & GTM Approach

20

(21)

Wonderware Batch

Effectively Manages Flexible Batching Processes in

Process & Hybrid Industries.

Wonderware Batch

Effectively Manages Flexible Batching Processes in

Process & Hybrid Industries.

Operations & Execution Portfolio

Overview

© Invensys proprietary & confidential 03/17/2019 Slide 21

Wonderware MES

Improves Production Execution Consistency, Visibility,

Agility and Performance.

Wonderware MES

Improves Production Execution Consistency, Visibility,

Agility and Performance.

Wonderware Quality

Improves Product Quality and Consistency Through

Real-Time Statistical Process Control and Analysis.

Wonderware Quality

(22)

Operations & Execution Portfolio

Overview (cont.)

© Invensys proprietary & confidential 03/17/2019 Slide 22

Wonderware Mobile Solutions

Accelerates and Sustains Operations Improvements

Through Mobile Procedural/Work Task Management.

Wonderware Mobile Solutions

Accelerates and Sustains Operations Improvements

Through Mobile Procedural/Work Task Management.

Wonderware Enterprise Integration

Facilitates Integration of Plant Floor Applications to

Enterprise Solutions.

Wonderware Enterprise Integration

Facilitates Integration of Plant Floor Applications to

Enterprise Solutions.

ArchestrA Workflow

Orchestrates Plant-Level Business Processes Across

Disparate Domains (People, Processes & Systems).

ArchestrA Workflow

(23)

Operations & Execution Portfolio

MESA’s 11 Functions of MES

(24)

(25)

Wonderware MES

MESA 11 Point Coverage

Operations & Execution Portfolio

Solutions “Powered By” MES…

► _{Track & Trace}

► _{Error Proofing}

► _{“Paper-on-Glass”}

► _{Electronic Batch}

Records (EBR)

► _{Electronic Work}

Instructions

► _{Procedural Execution}

► _{Labor Mgt.}

► _{Receiving & Inspection}

► _{Order Management}

► _{WIP Management}

► _{Inventory Management}

► _Shipping

► _{Quality Data Collection}

► _{Weigh & Dispense}

► _{Batch Processing}

► _{Recipe/Spec. Mgt.}

► _{Master Data Mgt.}

► _HACCP

(26)

E

(SAP, Oracle, Microsoft..)

Manufacturing Operations Management:

Operations Mgt Solution Offerings

Information /

Visibility

System

Interoperability

Manufacturing Operations Management

Microsoft Technology & Industry Standards

System

Wonderware HMI, MES & EMI Software Solutions

(27)

Operations & Execution Portfolio

MES – Operations Value Proposition

27



_{Improves Manufacturing Agility}



_{Drives Consistent Production Execution}



_{Captures Comprehensive Manufacturing}

Genealogy



_{Improves Decision Support & Planning within}

(28)

Operations & Execution Portfolio

MES – Operations Features

Product Definition

 Ability to Define Raw, Semi-Finished or Finished Goods

 Attach Multiple BOM Definitions (versions) to a Product

 Attach Multiple Specifications (versions) to a Product

 Synchronize Products Definitions with External Systems

Product Definition

 Ability to Define Raw, Semi-Finished or Finished Goods

 Attach Multiple BOM Definitions (versions) to a Product

 Attach Multiple Specifications (versions) to a Product

 Synchronize Products Definitions with External Systems

Bill of Material Definition

 Multi-level BOM (n-tier)

 Define Multiple Substitutes per BOM Item

 Define Co-Products / By-Products

 Configure Specific Material Processing and Tracking Business Rules per BOM Item (e.g. backflush, maintain inventory, must consume from previous step, etc.)

Bill of Material Definition

 Multi-level BOM (n-tier)

 Define Multiple Substitutes per BOM Item

 Define Co-Products / By-Products

 Configure Specific Material Processing and Tracking Business Rules per BOM Item (e.g. backflush, maintain inventory, must consume from previous step, etc.)

(29)

Operations & Execution Portfolio

MES – Operations Features (cont.)

Production Management & WIP Execution

 Full Production/Process Order Management

 Define and Execute Product Specific Production Routings

 Record and Track Production, Consumption and Labor

 WIP Status and Characteristics

Production Management & WIP Execution

 Full Production/Process Order Management

 Define and Execute Product Specific Production Routings

 Record and Track Production, Consumption and Labor

 WIP Status and Characteristics Inventory Management

 Configure Business Rules for Tracking

Inventory on the Plant Floor (e.g. maintain composite lots, etc.)

 Can track bulk, lot or serialized inventory items

 Ability to Transfer, Split, Combine, Receive, Ship and Reclassify Inventory Items

Inventory Management

 Configure Business Rules for Tracking

Inventory on the Plant Floor (e.g. maintain composite lots, etc.)

 Can track bulk, lot or serialized inventory items

 Ability to Transfer, Split, Combine, Receive, Ship and Reclassify Inventory Items

MES 4.0

 Ability to Define Fixed or Mobile Inventory Locations

 Ability to Monitor the State of Inventory Locations

 Track the Movements and Location of Mobile Storage Devices

Storage Management

 Ability to Define Fixed or Mobile Inventory Locations

 Ability to Monitor the State of Inventory Locations

(30)

Operations & Execution Portfolio

MES – Operations Features (cont.)

Equipment / Machine Setup

 Common Equipment Setup Templates

 Enable Consistency in Equipment setup

 Ability to Capture a “Golden” Setup

 Ability to Enforce Steps and/or Procedures Equipment / Machine Setup

 Common Equipment Setup Templates

 Enable Consistency in Equipment setup

 Ability to Capture a “Golden” Setup

 Ability to Enforce Steps and/or Procedures

Procedure Step Manager

 Guide an Operator Through a Manual or Semi-Automatic Procedure at a Particular

Manufacturing Operation

 Configure Required “Step Actions” (e.g. consume material, acknowledge message, view document, etc.)

Procedure Step Manager

 Guide an Operator Through a Manual or Semi-Automatic Procedure at a Particular

Manufacturing Operation

 Configure Required “Step Actions” (e.g. consume material, acknowledge message, view document, etc.)

MES 4.0

Production Event Tracking

 Ability to Capture Production Events Including Counts, Weights, Scrap and Reason codes

 Ability to Report and Drill Through History, Enabling Genealogy, Traceability

Production Event Tracking

 Ability to Capture Production Events Including Counts, Weights, Scrap and Reason codes

(31)

Operations & Execution Portfolio

MES – Operations Features (cont.)

Enable Plant Document & Work Instruction Definition

 Define Electronic Folders with Associated Documents and Work Instructions (multiple versions)

 Configure Document Viewers to Use for Specific Document Types

 Manage Links to Other Documents

 x

Enable Plant Document & Work Instruction Definition

 Define Electronic Folders with Associated Documents and Work Instructions (multiple versions)

 Configure Document Viewers to Use for Specific Document Types

 Manage Links to Other Documents

 x

Work Instructions & Document Management

 View Many Different Document Types (e.g. PDF, MS Documents, Web Page, etc.)

 Link Work Instructions and Documents to

Products, Production Orders, Operations, Work Centers or Procedural Steps

Work Instructions & Document Management

 View Many Different Document Types (e.g. PDF, MS Documents, Web Page, etc.)

 Link Work Instructions and Documents to

Products, Production Orders, Operations, Work Centers or Procedural Steps

(32)

Operations & Execution Portfolio

MES – Performance Value Proposition

32

confidential



_{Reduce Capital Expenditures}



_{Improve Asset Utilization}



_{Increase the Capacity}



_{Leverage Best Practices}

(33)

Operations & Execution Portfolio

MES – Performance Features

Equipment Utilization

 Ability to Detect and Capture Utilization Events

 Ability View Equipment Events

 Ability to Monitor and Record Equipment State

 Ability Automatically or Manually Assign Reason Codes Equipment Utilization

 Ability to Detect and Capture Utilization Events

 Ability View Equipment Events

 Ability to Monitor and Record Equipment State

 Ability Automatically or Manually Assign Reason Codes

Equipment Performance

 Ability to Calculate OEE for Equipment / Line

 Ability to Trigger Events and Display

 Ability to Analyze Event Frequency and Duration

 Ability to Assign What States Affect OEE Calculation Equipment Performance

 Ability to Calculate OEE for Equipment / Line

 Ability to Trigger Events and Display

 Ability to Analyze Event Frequency and Duration

 Ability to Assign What States Affect OEE Calculation

Production Progress

 Provide a Clear Indication of Job or Production Order Progress to the Operator in Real Time

 Ability to Calculate OEE Other Key Parameters

 Ability to Estimate Expected Completion Date and Time

Production Progress

 Provide a Clear Indication of Job or Production Order Progress to the Operator in Real Time

 Ability to Calculate OEE Other Key Parameters

(34)

Performance Software – Our Differentiators

• Fully-integrated product line based on InFusion

• Perceived “best in class” performance

• Adapts to majority of industry needs for performance management

• Maintains independence: can overlay to other control systems,

enterprise systems, asset management systems

• Scalable: from single-site to enterprise-wide. Supports corporate

drivers for standardization, uniformity in practices.

• Ecosystem/partner network: Leverage 3,000 Systems Integrators,

plus channel partners such as Microsoft Dynamics

• Mobile devices: Feed iPhone, iPad, Windows devices with rich,

intuitive mobile reporting

• Enterprise-level Condition Monitoring: Address using .NET based,

configurable application with proven ROI

(35)

Performance Software In a Nutshell

• Performance software offerings from Invensys Operations

Management have the widest footprint of anyone in the

industry

• No one has

Workflow

,

Asset Performance Monitoring

—products normally outside of the automation &

operations stack—in addition to MES, Quality, Batch, EMI,

and other traditional Level 2/3 focused products

• Scaled array of Reporting Products allows customers to

choose the solution that best fits their current or future

needs.

• With the addition of workflow, we can offer “closed loop”

remediation for customers, allowing them to better

respond to unscheduled events as well as existing

industry or government regulations

(36)

Agenda

36



Wonderware MES 101



Operations & Execution (MES) Portfolio



ERP Integration



Case Studies



Partners & Ecosystem

(37)

Plant Manager

Global Distributed Manufacturing

Is The New ‘Norm’

MANUFACTURING

PLANT MANUFACTURING_PLANT

MANUFACTURING

Plant Manager Product Variability -

Inconsistent quality: by plant, by product, by shift

Difficulty meeting tighter customer specifications – Can’t match quality to orders No visibility – Can’t see plant

wide production status due to 10 - 200 disparate shop floor info systems

Varying process conditions lead to

Higher energy

use

Lack of predictability

Can’t see business performance to plan, and recommend new plans to affect results

Capacity erosion – high off-grade produced and wide quality swings

REVENUE

Inflexible production process contributes to Missed Opportunity Hidden capacity obscured

(38)

Enterprise

Integration

Wonderware Enterprise Integrator



Transactional integration with ArchestrA

real-time data model



Reduced Cost of Ownership using industry

standards ISA-95 and B2MML

Wonderware Supply Chain Connector



Out-of-the-box integration using

pre-defined mappings.



Simple, yet powerful integration capabilities

in a standardized formats

(39)

Agenda

39



Introduction to “MES 101”



Operations & Execution (MES) Portfolio



ERP Integration



Case Studies



Partners & Ecosystem, Success Stories

(40)

Case Study:

Pepsi Bottling Ventures of Garner

Decreases Downtime and Improves Quality with Wonderware Software Solution

Invensys

• Develop a Performance and Downtime tracking system;

• Eliminate guesswork and assumptions through collection of consistent and reliable data;

• Justify Return On Investment for future capital plant projects;

• Develop an enterprise level platform for future expansion.

Challenges

• Implement the new system across 1 new line and 4 legacy lines in the plant;

• Downtime data was recorded manually and information gathering was subjective and inconsistent;

• Manually recorded data created more questions than answers.

Solutions and Products

• Wonderware Historian Client; • Wonderware InTouch HMI;

• Wonderware Performance Software; • Wonderware System Platform.

Results

• Produce over 30 million cases of Pepsi products a year; • PBV Garner has grown from producing & distributing 189 different products to over

500;

• Total payback for investment estimated at 2.8 years; • Solution assists in achieving sustainability goals and helps reduce the plant’s carbon footprint;

• Process Visualization immediately available to all levels of plant management and staff;

(41)

Background

Slide 41

• Built in 2002, PBV Garner has grown from producing and distributing189 different

products to over 500 today. Flavor changes, bottle changes and secondary

packaging changes are a daily occurrence.

• The previous paper-based system relied exclusively on manually entered data.

Depending on the operator’s workload and ability to accurately measure machine

performance, this data was subjective and inconsistent.

• With four existing production lines in place, PBV added a new Direct Blow Fill (DBF)

Line for the Aquafina and other non carbonated products. This line not only filled the

bottles with purified water, but it actually made the bottles, as well.

(42)

Case Study: Pepsi Bottling Ventures

confidential

4 2

• By implementing an algorithm that allowed for the propagation of

downtime codes from machine centers all the way to the line, the

Wonderware solution proved to be a strong value proposition for PBV

to accurately analyze their data and see what was really impacting

critical production operations.

• The solution :

• Wonderware System Platform (including Wonderware Historian

Server),

• Wonderware Performance software,

• Wonderware InTouch HMI and

(43)

Case Study: Pepsi Bottling Ventures

confidential

4 3

Before:

PBV’s wide range of products, with ongoing packaging and flavor

changeovers, makes line efficiency a primary objective. Before the

implementation of Wonderware throughout the plant, line efficiency was

an evasive concept. Operators were never quite sure if they were

ahead of or behind schedule. Therefore, the scheduling of changeovers

was a guessing game.

Now:

By pinpointing downtime, PBV can gain percentage points against

efficiencies. By driving efficiencies up, costs are driven down. Overall

production improvement across all five lines enables PBV to focus their

resources on meeting and maintaining Pepsico’s quality guidelines

(44)

Furthermore…

confidential

4 4

Access to Accurate Data = Production Improvement

• Just as important as accuracy of data is accessibility to data.

Real-time production data is displayed throughout the plant, production

office and even in the employee break room on large, flat-screen

displays.

• PBV has found that workers are paying attention to what is happening

on their lines, even while on break, and know whether they are ahead

of schedule or behind. This motivates them to continually monitor their

line efficiencies and make adjustments as necessary to meet their

goals.

(45)

Case Study: Valmet Automotive

Wonderware MES, Operations and Performance – Car Factory MES Project in 3 Months

Invensys

• Bi-directional data transfer between automation and ERP systems;

• Electronic documentation of production; • Bill of materials (BOM) management;

• Traceability of materials and end-products; • Product quality management.

Challenges

• The shortest possible implementation time; • Systems integration;

• Ease of use.

Solutions and Products

•

Wonderware InTouch HMI;

• Wonderware Operations;

• Wonderware Supply Chain Connector; • Wonderware System Platform.

Results

• Modular and easily modified system that is integrated with other systems in the car factory; • Flexible management of production data and BOMs;

(46)

Case Study: Valmet Automotive

System Architecture

confidential

(47)

Case Study: Valmet Automotive

confidential

4 7

Valmet Automotives MES solution:

• Wonderware Operations and Performance

• MES programs (System Platform, Operations, Supply Chain Connector and InTouch suites).

Value to Valmet :

• Easily connected to automation and IT solutions from different manufacturers;

• Bi-directional data transfer between the automation and ERP systems;

• Production data acquisition and presentation, ready-made reporting tools;

• Configurable and fully compatible program packages with good basic functionality, easily enhanced to complete the project within schedule;

(48)

Case Study: Valmet Automotive

Results

confidential

4 8