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Key Performance Indicators (KPIs) are assorted variables that organisations use to assess, analyse and
track manufacturing/production processes. KPIs created within Proficy Historian use standard Tag attributes
and therefore can be viewed within any Historian client. KPIs can be used to determine and monitor
Volumes, Rates, Reject Ratios, create Soft Sensors, Scrap/Waste, Energy Monitoring, Downtime, OEE,
Emissions and much more.
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KPI Visual Management is the process of displaying critical information such as KPIs that relate
specifically to production output, efficiency and quality to staff ensuring they have a better understanding of
their process and production levels.
As Proficy Historian is an open-layered application data can be extracted by many different types of systems
including the Proficy Suite (Proficy iFIX, Portal, Proficy Historian Analysis (PHA), Vision, MES etc), Excel
Add-IN, OLE (Microsoft SSRS, Crystal Reports, ERP systems, etc). By developing the KPI at the Historian
level all clients have access to the correct value The same version of the truth.
Creating Simple Run-time KPIs such as Volume, Rate, Reject Ratio, Scrap, etc
A meter value against a time value
A percentage of a Tag in a particular state
The calculation requires a base Tag within Historian for each Asset/Meter. Sampling mode would be
Calculated and the Calculation Mode would be Total. Volume = Meter Flow Rate * Time Segment
Creating Simple Soft Sensor such as Differential Pressure Switches (DPS) to identify filter failure. The
KPI is the difference between the Filter Inlet PSI and the Filter Discharge PSI.
The calculation requires both Tags to be in Historian for each Filter/Asset/Meter. For each Tag Sampling
mode would be Current Value. DPS result = Filter Inlet PSI less Filter Discharge PSI
Creating a KPI against Expectations requires a predefined value that a current value to calculate against to
highlight the processes current performance. The target value may be stored in a 3rd party system (SQL, ERP,
LMS, etc). This KPI can be written to get the external data as part of the calculation, or often it is easier to
copy the value from the external system to an Historian Tag.
Example: Asset Runtime by 8 hour Shift (KPI: Operating Period)
Fixed Value Variable (Maintenance being the 3rd party variable) Fixed/Variable Value
Total Possible Run-Time less Scheduled Maintenance Downtime less Scheduled Breaks Downtime
480 minutes 0 minutes (maintenance) 30 15 15 minutes (Breaks) = 420 minutes
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1. Create a new Tag within Historian using the Tags tab then Add Tag Manually tab.
4. Set the collection attributes. Either polled or via a trigger Tag. Use the Enumerated Set Name to
configure an enumerated value. Finally use the Update button to save changes.
6. Once saved (Update) select the Tags Calculation tab and add the calculation using set Tags, or a
Tag formula (*Pu*). Users can type directly, or use the wizard included.
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Filter1_Differential_PSI
Servername_Calculation
Polled at 5s (timeout 1 hour)
Archive compression
Complete calculation
Manually created
There could be multiple installed
Or trigger from another tag
If 0 only save if value changes
Test after developed
Calculation Tab:
1. The first rule of calculations is that you need a Result= so if required type this in the window
2. Next add the first tag (Filter1_Inlet PSI) so click on the wizard button to the right.
a. Type = Insert a value correct leave it as it is
b. Function = Current value correct leave it as it is
c. Browse for Tag (use filter) when selected it appears in Input Tag
4. As we are going to subtract the discharge from the inlet value, type in a -sign within the calculation.
Click the Wizard button and browse for, then select the second Tag again using the current value;
(Filter1_Discharge_PSI).
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Sampling Modes: Current Value, Interpolated values, trend, Calculated and Raw data options
Calculation Modes: Count, State Count, State Time, Min, Max, Total, Average and Raw data
Hybrid Modes: This mode of sampling has the ability to switch between sampled (like
interpolated or trend) and raw data based on the actual and requested number of samples or a
specified time interval.
Query Modifiers: are used for retrieving data that has been stored in the archive. They are
used along with sampling and calculation modes to get a specific set of data. (Only Good,
Include Bad, Only Raw Samples, etc)
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Records the asset state options (stop, run, divert, maintenance, etc)
Records reason for asset stoppage stored in the PLC (electrical, etc)
Kg/Ltr used per time frame set (by Asset, Process, Factory)
Historian Predictive Tag Examples (linked to, or updated from 3rd party data-sources)
Time slots
Process Predicted Time
Production Predicted Time
Production Predicted Rate
Units / Volume Required
Asset Capacity / Level
Network Flow Capacity
Asset Scheduled Maintenance
Operating Period / Shift
Energy (Tag per type)
KPI: Energy
KPI: ACT
KPI: ACT
KPI: OE_P
Total hours an Asset can run less breaks per time period (shift/day)
Adds to Shift ID
Alarms during
the process
Document authored by The Industrial interface Company NZ Ltd
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Volume * Minutes
User defined Time Period / Shift
Tags required
Non Completed
Tags required
Quantity Target less (Quantity Count less Reject Count) plus+ Reject
Count with Quality ID = Pass
KPI: Quantity - Rejects
KPI: Rework Count = Pass
Order Count
Tags required
Rework Count
Vibration Monitoring
AOT
Asset Outage Time
Tags required
Analog: Asset ID
Asset State ID
Asset Availability
Target Cycle Time against Actual Cycle Time for Asset ID (by shift)
Volume
Tags required
Divert Volume
Tags required
Level Capacity
Tags required
Flow Capacity
Tags required
Rate (units)
Tags required
Rate (volume)
Tags required
Reject Count
Tags required
Reject Ratio
Tags required
Scrap
Tags required
Tags required
Asset Up-Time
Tags required
(A plant may have several assets that perform the same task. Monitor the Cycle Time as a performance measure between them)
TakT Time
Tags required
(The purpose of takt time is to precisely match production with demand, enables sales delivery schedules to be met)
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Asset Availability
Downtime
Unscheduled
Total asset Run Hours where state (not=) Run less Asset Availability
Tags required
Asset Alarms
Downtime
Tags required
Asset Availability
Rate
Tags required
Downtime Actual
Tags required
Historian AE Server
Downtime Bottleneck
Tags required
The report/display would also include shift and downtime reasons from SQL, ideally corresponding
AE data from Historian and downtime categories from Historian.
KPI Examples Oee
The below examples are included to complete a detailed Downtime solution, not to develop a custom OEE
solution that could end up costing more than Proficy Efficiency, a GEIP off-the-shelf OEE module. We will
refer to these KPIs as Oee.
Oee_P %
Performance
Tags required
Oee_Q %
Quality
Tags required
Analog: Count
Oee %
OEE = A * P * Q
Oee_A %
Availability
Tags required
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Tags required
Electricity Peak
Identification
Rank time slots from high value to low value per day/shift over a
month (or year to see seasonal trends)
User defined Time period
Process Electricity
Breakdown
Tags required
Predicted Electricity
Usage
Tags required
Tags required
Electricity
Monitoring
Tags required
The above are used for all energy types (CNG, LPG, Diesel, etc)
Process Emissions
per time slot
Total Emissions
per time slot
Process Emissions
by user defined time
Total Emissions
by user defined time
Daily Emissions
Monitoring
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We have chosen these examples as the information would be required in multiple different report types and
not just for Downtime Monitoring. Often the FactoryID, MachineID and AssetID are part of the Tagname
and therefore do not require a separate Tag to be captured.
Document authored by The Industrial interface Company NZ Ltd
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SM
BS
15
245
Sawmill
Bin Sorter
Machine code
Equipment code
Plainer
In-feed Hydraulics
If your site has not deployed a detailed Tagnaming convention we can use other Historian fields to store the
asset/device name for reporting purposes.
Example of an iFIX Tag:
IFIX1_BATCH_TANK1LEVEL
Example of the description:
Chemical Tank #1 Level
Only very limited information is available via the Tagname. Should you wish to add more descriptive
information this can be added to the Spare Configuration field for the Tag stored within Historian.
To retrieve this data when building a report you will need to query the CollectorGeneral2 field.
To enable a report search by location the query maybe used several times however each one will
search for a different part of the entry; Saw Mill, Bin Sorter, Plainer, etc. For instance if we wanted
to create a downtime report for an area (all assets within the Plainer process/machine) we need to
be able to associate the Tag with the plant area. Alternately just use the Machine/Process name.
Note: Step Value on the above Tab enables square-tooth data representation often seen within HMI
displays rather than sharp saw-tooth representation. Especially good for digital On/Off, Stop/Run views.
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SQL Server Reporting Services (SSRS) - Use the standard tools provided out-of-the-box.
SSRS utilises an OLE connection to access Historian data and is perfect for daily, weekly, monthly, annual
reports where data requests are generally not changed (predefined attributes). SSRS is great for reports that
many people access/view using tabular grids and data links. Historian supports direct connectivity, SQL
Linked Server and Pass Through options enabling any configuration to be deployed maximising any
previous investments made.
Tabular Grids
Datalinks
Some specific objects (Dials, Levels, etc) that support OLE connections
Often a complete Proficy Vision solution will include Proficy Portal, PHA, SSRS and some .Net displays.
Proficy Historian Excel Add-in - The included MS Excel Add-in offers administrative and reporting
capabilities. Both topics are covered within the Historian Electronic Books. There are also sample reports
included with the Historian install that can be easily modified to perform a variety of tasks. Reports
developed in Excel can be converted to a web report and viewed with Proficy Vision.
Sample Reports on the Historian Server: C:\Program Files\Proficy\Proficy Historian\Samples
Alarm and Events, Batch, Daily, Statistic Analysis example reports
The Historian OLE DB Provider is a data access mechanism (defined by Microsoft) that allows you to
query Historian product data using Structured Query Language (SQL) statements or other client reporting
tools. It adds tremendous value to the Historian product by providing simple access to data from within the
SQL environment, without the need for complex scripting.
Furthermore Proficy Historian OLE DB Provider includes standard Linked Server functionality that
enables a remote Historian Server to appear as a local SQL Table again simplifying data retrieval and report
development.
For example there could also be an existing solution developed utilising a relational database (SQL,
MYSQL, Oracle, etc) that you simply want to enhance. Use the OLE DB Linked Server option to add your
Historian data to the existing system.
A test tool Historian Interactive SQL Tool is installed for testing your scripts before adding
them to your displays / reports.
There are OLE query examples within the Historian Electronic Books under the heading
List of Examples.
For any assistance, or additional explanations please contact your GE Intelligent Platforms representative
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