MES Solutions

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Slide 1 11 March 2014 Invensys proprietary & confidential

Why MES? Questions to consider

Are you a manufacturer in a regulated industry?
Food & Beverage Tobacco Automotive Cement Pharmaceutical/Chemicals Consumer product,

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? If so, then they may be a good MES candidate

What is MES

I need to have traceability

I need to manage recipes I need to reduce costs I need to reduce inventories

I need to improve quality

I need to improve yield

I need to reduce cycle times

I need to reduce downtime

Where The Offerings We Will Discuss Fit Within The InFusion Enterprise Control System
Execution Integration & Collaboration Platform
Manufacturing Execution Systems

Batch

Enterprise Asset Management

Mobile Workforce Management

Software Applications Applications Software

Performance
Enterprise Integration Workflow Operator Training Open Device Integration Web Portal Application Toolkit Historian DCS PAC Enterprise Manufacturing Intelligence
Performance Measurement and Reporting

Visualization

Quality

Asset Performance

Third-Party Offerings

Optimization
Design Advanced Process Control Simulation / Optimization

Control
SCADA HMI

Automation

Safety
Safety Instrumented Systems
General Purpose Safety

Turbomachinery Control

Measurement & Instrumentation

Instrumentation Controllers Recorders

11 Functions of MES Fully Covered by Invensys

ISA Model Level 3
WW Operations Software
Sales & Service Management Enterprise Resource Planning

ISA Model Level 2

Operations/ Detailed Scheduling

Resource Allocation & Status

Avantis
Dispatching Production Units

MES
Product Tracking & Genealogy

Document Control

WW Performance Software

Performance Analysis

WW QI Analyst System Platform

WW Enterprise Integrator

Labor Management

Maintenance Management

Process Management

Quality Management

Supply Chain Management

Data Collection Acquisition

ArchestrA Workflow

Control

Wonderware& MES Operations Execution Portfolio

MESA 11 Point Coverage Solutions Powered By MES
Track & Trace Error Proofing Paper-on-Glass Electronic Batch WIP Management Inventory Management Shipping Quality Data Collection Weigh & Dispense Batch Processing Recipe/Spec. Mgt. Master Data Mgt. HACCP

Records (EBR) Electronic Work Instructions Procedural Execution Labor Mgt. Receiving & Inspection Order Management

Manufacturing Operations Management: Operations Mgt Solution Offerings

System Interoperability Manufacturing Operations Management Information / Visibility Empowering Success of Production Workers

Devices, Applications, Enterprise Integration

ERP (SAP, Oracle, Microsoft..)

ArchestrA Workflow Enterprise Integration Intelligence (EMI)

Database Applications Asset Management

Wonderware HMI, MES & EMI Software Solutions

Batch Operations

Food & Beverage Performance

Quality

System Platform
LIMS Systems

Clients

Industry Applications & Industry Packs

Microsoft Technology & Industry Standards

Devices

Operations & Execution Portfolio

MES Operations Value Proposition
Improves Manufacturing Agility by providing real-time production execution information and alerts to the right people, at the right time Drives Consistent Production Execution through strict enforcement of electronic manufacturing procedures (process, operator, equipment & materials) associated with semi-finished and finished goods enforces best practices Captures Comprehensive Manufacturing Genealogy by collecting a complete production routing history (including assets), labor history and material usage history improves compliance and governance Improves Decision Support & Planning within the Supply Chain by providing real-time order, material (raw material & WIP), equipment and labor status
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Operations & Execution Portfolio

MES Operations Features MES 4.0
Operations Product Definition
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.)

Mobility

Operations & Execution Portfolio

MES Operations Features (cont.)
MES 4.0
Operations Production Execution
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 Storage Management 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

Mobility

Operations & Execution Portfolio

MES Operations Features (cont.) MES 4.0
Operations Equipment Operations
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

Mobility

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.)
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

Operations & Execution Portfolio

MES Operations Features (cont.) MES 4.0
Operations Work Instructions
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 x 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

Mobility

Operations & Execution Portfolio

MES Performance Value Proposition

Reduce Capital Expenditures by identifying the most productive assets for continued operation Improve Asset Utilization by identifying production bottlenecks more quickly and increasing supplier accountability Increase the Capacity of your existing assets by pinpointing the causes of unplanned downtime and improving operational efficiency Leverage Best Practices by comparing line-to-line and plant-toplant performance, including real-time OEE measures

Empower Operators by providing visibility to real-time asset performance KPIs that enable them to take action

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Operations & Execution Portfolio

MES Performance Features
MES 4.0
Performance
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 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

Mobility

Accurate Management of Batch Processes Wonderware Operations Software

Simple batch management with recipe definitions using site specific processes Accurate equipment setup with automatic download of set points

Batch

Wonderware InBatch
Powerful batch execution engine with dynamic allocation of shared equipment for even the most complex batch processes Graphical recipe definitions according to S88 with unit procedures, operations and phases for equipment independent master recipes

Reduce Variances with Specification and SPC Management Wonderware QI Analyst

Quality
Real-time and historical SPC with comprehensive charts and custom run rules with alarm generation upon violations Minimize costly scrap and rework through detection of process variations and better understanding of actual process capabilities

Wonderware Operations Software

Central administration of process and product specifications with versions and min/max limits per BOM entity

Asset Mgt with

Avantis Asset Performance Avantis EAM Suite

Avantis.PRO
Enterprise Asset Management Maintenance MRO Inventory Procurement Integration Toolkit

Avantis.DSS
Maintenance & Reliability Decision Support KPI Portal

Avantis Approvals
Document Approvals workflow

Avantis Asset Intelligence

Asset Health Aggregation and Visualization

Avantis Condition Management

CbM Extensions Multi-variable Rules

Avantis Continuous Monitoring

Voltage & Current Analysis Stress Wave Analysis

Slide 26

Wonderware EMI Strategy Enterprise Manufacturing Intelligence

User-friendly Configuration & Administration
Production/Process Information Platform

Wonderware & Non-Wonderware Data sources

Share content & Collaborate

Incremental approach

Self-service access to information & content authoring

Wonderware Intelligence (EMI)

Multiple databases and/or multi-site deployment Easy configuration of Information Model contextualizing multiple data sources Self-Service browsing of information model, analytics and dashboard creation Integrate content previously created
Multi-site
Dashboards Analytics Information Browser

Site

Wonderware Intelligence: Problems Solved

User Problems
Inconsistent Metrics Data overload Disparate Data Sources
Naming scheme inconsistency

Intelligence
Central and Customizable Metric Definition Data Aggregation and Alerts Data contextualization Master data referencing and data cleansing Broad Data Connectivity Business-friendly Model Access Layer Pre-Aggregated Data Data caching and storage Self-service dashboards, reports and analytics Domain specific tools, Applications and Templates

User Problems
Complex Data Access Slow Data Access Production Systems Impact Dependence on IT Department Long solution Development

Diverse Data Sources

What is ArchestrA Workflow Software?

Manufacturing Business Process Mgt. (BPM) Framework for the Invensys Operations Management Portfolio Visualize/collaborate/improve operations

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ArchestrA Workflow for Quality-Example

Jay

Start

Jay Receives a Complaint Call

Jay Runs the Batch Genealogy Report

Material with Issue is Identified

Jay submits Hold Lots Form

Workflow is triggered

John

John is notified to continue investigation

Greg

Notification sent to Greg

System Notifies Greg for Approval

John fills out Hold Lot Investigation form and submits for approval

Greg reviews Batch Report

Inventory system notified To put specific Lots on Hold!

Legend

Has Greg Approved the Audit Report?

No

Assigned back to Greg (ALERT)

Jay (Supervisor in charge) Greg (Quality Manager) John (Quality Inspector, part of Gregs team) Action/Notification/Event

Yes

Alert

System Updates the Company SharePoint KB

Workflow Ends

Successful Completion

ArchestrA Workflow Software

How Do We Package It?
Microsoft Integration DB Integration

ArchestrA Workflow Standard or Enterprise Edition

User Directory Other Integration

Platform & Application Integration Connectors System Platform Mobile Batch EMI MES ROMeo

Enterprise Integration

ArchestrA Workflow Add-Ons

Microsoft Integration Forms Designer

Global Distributed Manufacturing Is The New VP Norm BU

Varying process conditions lead to Higher Lack of predictability Cant see business performance to plan, and recommend new plans to affect results

Production Processes Shared Information Orders Shipped

CIO

energy use

Capacity erosion high off-grade produced and wide quality swings

VP Sales VP Manuf.
Plant Manager

Planners

Plant Manager

Plant Manager

MANUFACTURING PLANT

Product Variability Inconsistent quality: by plant, by product, by shift

MANUFACTURING PLANT

MANUFACTURING PLANT

Missed orders

CUSTOMER

Orders changed Field Sales

Orders returned

Customer Service NEW CUSTOMER

Hidden capacity obscured by inefficient grade transitions & conservative operation

No visibility Cant see plant wide production status due to 10 - 200 disparate shop floor info systems

SPOT MARKET CUSTOMER

Difficulty meeting tighter customer specifications Cant match quality to orders

Inflexible production process contributes to Missed Opportunity

Tight Alignment with Business Processes Wonderware Enterprise Integrator

Transactional integration with ArchestrA real-time data model Reduced Cost of Ownership using industry standards ISA-95 and B2MML

Enterprise Integration

Wonderware Supply Chain Connector

Out-of-the-box integration using predefined mappings. Simple, yet powerful integration capabilities in a standardized formats

Ecosystem
More than 3,000 partners
Complementary hardware, software Systems Integration & Consulting Suppliers, distributors, OEMs

Complete solutions providers Global/regional coverage

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A Customer Success Story

Major Beverage Container Manufacturer
Leading producer of plastic beverage containers Products in such demand they can sell more than they can produce

Direct bottom line results

Raised OEE by 3% in first year $200,000 ROI on an initial investment of $80,000 Payback in 5 months

Success Story 2
Major Paper Producer
One of worlds largest producers of paper products $22 billion annual revenue Legacy system relied on manual entry of downtime fault reasons Planned large capital expenditure to eliminate production bottleneck Implemented Wonderware software as interim measure

Direct bottom line results

Within 3 months, identified problem areas in

bottleneck machines Due to increased efficiency, able to cancel large capital expenditure (> $1.5 Million)

11 Invensys proprietary &