1. © 2003 IFS AB. All rights reserved.
April 17, 2017

2. Process Automation Integration
Utilizing ABB’s 800xA and OPC
© 2003 IFS AB. All rights reserved.
April 17, 2017

3. The Integrated Plant System
Customer - Supplier
B2B / B2E
Delivery
Confirmation
Internet
Purchase
order
ERP / EAM
Customer order
Rescheduling
Analysis and
Optimization
Inventory
Maintenance
AIP
There are a lot of new possibilities when you connect the ERP/EAM systems with the automation equipment. A customer order can be put via the Internet. The ERP software is aware of the customer orders, the inventory situation and the status of the production line. An intelligent production scheduling can be created based on this and transferred directly to the production equipment. An incident or an alarm during the production can carry out a Work Order to solve the problem. At the same time a re-scheduling can be made taking into account that the production line now is limited. During production the Equipment Monitoring and other systems for analyze and optimization can be fed with data from the automation equipment. You could even define online volumes or weights as order points for your inventory parts and make each part create a purchase order based on a signal indicating that the volume or weight for reordering is reached.
The area that is called ”Vertical Integration” or ”Integrated Plant System” is an area where we will see a lot of activity in the years to come. In this borderland between traditional ERP/EAM systems and automation equipment almost nothing has been done so far. Right now we are taking the first steps into a future where these system will be integrated in real time to create better and faster decisions and decision support and to optimize the usage of any asset to its best.
Scheduling
Plant
status
Alarm or
Incident
Material
refill
Production
data
Automation equipment / Production
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April 17, 2017

4. AIP/800xA as an Integration Platform
IFS Maintenance Aspect System
Fault Report
Active WO
Object Info
OEE
Aspect System
Aspect Integrator Platform / 800xA
Aspect System
Process Portal
Asset Optimization
© 2003 IFS AB. All rights reserved.
April 17, 2017

5. Equipment cost analysis
Asset Cost Reduction
Information Availability
Seamless navigation between different information systems
Work order history
Active work orders
Business performance
By using AIP for integration between systems from different vendors, all data will be available from all participating systems. The ability for seamless navigation between different information systems and with the object as key is based on the Aspect objects integration platform.
With a single mouse click the user navigates from the objects graphical representation to the technical description, open up the active work orders, investigates the situation of spare parts for the object in the inventory, creates a fault report, etc. Every information that is of interest is there by a mouse click and presented in the same user interface. A seamless integration of different software.
Equipment cost analysis
Equipment data sheet
OEE
P&I Diagram
Electrical diagram
© 2003 IFS AB. All rights reserved.
April 17, 2017

6. Object Synchronization
To achieve Asset Cost Reduction, it is vital that the various systems that contains assets can be synchronized – both in batch and online.
AIP/800xA
IFS
V-101
Object is created and inserted in Equipment functional structure
BizAPIs
Object with a functional object aspect is created LU LU LU
The online synchronization will work in the background and create IFS-objects when an AIP-objects are created and vice versa. For this integration to work as desired, links between object types in AIP and Equipment object types in IFS and object levels have to be set up prior to activating the on-line object synchronization.
(Note: There are some restrictions that apply if you want an AIP object to be created when an IFS-object is created since this requires events to be present in IFS Equipment business logic, and these events haven’t been included nor has it been decided if and when to include these events in the standard release.)
Database
© 2003 IFS AB. All rights reserved.
April 17, 2017

7. Condition-based Maintenance
Calendar-based PM could be compared to a man that visits his doctor once a month and asks him to open up his stomach to see if everything looks good. With the risk of forgetting his scalpel or infecting the wound before stitching the stomach together again, the doctor usually says it looks alright.
The goal should be to let the factory – as well as men – ask for maintenance when it is needed.
The most obvious result of combining ERP/EAM with automation equipment is perhaps the possibility to carry out condition based maintenance.
Today most preventive maintenance is carried out based on calendar scheduling. This could be compared to a man that once a month visits a doctor and ask him to open up the stomach to see if everything looks good. With the risk to forget his scissors or infect the wound before stitching the stomach together again, the doctor usually says it look alright.
The goal should be to let the factory – as well as men – ask for maintenance when it is needed.
By monitoring field equipment we could carry out maintenance based on operational hours, number of starts, calculations of experience data, etc. This could lower the amount of maintenance and at the same time maybe increase the service level of the plant.
© 2003 IFS AB. All rights reserved.
April 17, 2017

8. Condition-based Maintenance
Seamless access to the maintenance system from the operators environment
Automation equipment triggers maintenance actions based on real time information
Fault Report Wizard
PDA event
Operator input
Direct
input
Monitoring
PM / WO Event
Asset
Monitors
Collecting
data from
field devices
Detection
In the ABB environment Maintenance triggers is developed. More or less advanced calculations can implicate that an action has to be carried out. A work order is creating based on the information calculated in the ABB environment to execute what has to be done. A maintenance trigger could be based on an alarm, an event, a situation with many parameters, etc. IFS could also feed the ABB systems with actual operational hours, etc, as a ground for triggering maintenance. Of cause the operators are able to create fault reports directly from the operators SCADA system and intelligence field devises could create maintenance triggers and report the information using the field bus structure.
In the IFS Maintenance system work orders could be handled in many different environments. Traditional Windows or Web clients but also PDA’s or WAP telephones are used to carry the information about work description, material, purchase, crafts, etc. The goal is to deliver a suitable and easy to use interface for every kind of user and to make the maintenance system a true tool for the personnel.
PM Event
Alarms / Events
IFS WO/ PM module
Parameters
Operational hours, etc.
Predictive maintenance
© 2003 IFS AB. All rights reserved.
April 17, 2017

9. Overall Equipment Efficiency
It’s all about how to increase profit through cost reduction activities as well as real performance enhancements!
Time $
Maximum performance
Lost profit
Real performance (OEE)
Maintenance, Engineering and Procurement costs
© 2003 IFS AB. All rights reserved.
April 17, 2017

10. How is production capacity used?
Total available time
Planned stop time
Planned stop time
Planned production time
Unplanned stop time A
Available operating time
Reduced speed P
Net operating time Q
Quality losses
Value adding
operating time 32 19
© 2003 IFS AB. All rights reserved.
April 17, 2017

11. Overall Equipment Efficiency – Without automation integration
Manual OEE Data acquisition leads to poor quality of the OEE index!
Availability
Manual registration - If remembered!
Performance
OEE
Database
An event occurs: - Start/Stop - Speed change - Quality loss
Yield (Quality rate)
OEE is an important key figure in any continues process. It calculates the production as part of the theoretical maximum production limit for the plant.
The calculation is based on registering of start, stop, change in speed and quality losses. By registering the stop time, the time where we run at a speed under the max and counting the quality losses we calculate an OEE index. We also have the possibility to drill down to see the reasons from which we have created the existing losses.
The problem is that all of the registration is done manually – with a poor quality of data as a result.
OEE index = Availability x Performance x Yield
© 2003 IFS AB. All rights reserved.
April 17, 2017

12. Overall Equipment Efficiency – With automation integration
Real-time data acquisition of OEE events by utilizing OPC
Availability
Monitoring
Performance
Operator adds data and submits registration
Yield (Quality rate)
Collecting OEE data from process equipment
By letting the automation equipment feed the ERP system with real time data from the production we would at any time get all OEE data registered. We could present a pre-entered window for the operator to submit – and with the possibility to add data before doing so.
This would dramatically increase the quality of the data and for the first time ever we could trust the index that is calculated.
Start / Stop - events
OEE
Web portlet
OEE
Database
Speed change - events
Quality losses
© 2003 IFS AB. All rights reserved.
April 17, 2017

13. Demo Integrated Plant System
Level 1: Connectivity
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April 17, 2017

14. Asset Information – Demands, Spare parts, Inventory
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April 17, 2017

15. In this slide the operator highlights one of the objects in the process portal – a screw conveyor…
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April 17, 2017

16. By right-clicking, he brings up the aspect menu and selects Equipment Data to retrieve detailed information about teh object from the maintenance system.
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April 17, 2017

17. The functional object form is displayed
The functional object form is displayed. In this form, information about demands, supplier warranties and spare parts is displayed. For each spare part, information about quantity on hand from the inventory also is shown.
© 2003 IFS AB. All rights reserved.
April 17, 2017

18. Work Order Planning
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April 17, 2017

19. In this slide, the operator have brought up the aspect menu for the screw conveyor. When selecting the “Active Work Orders” aspect, the system will open up the maintenance system, showing active work orders for the selected object.
© 2003 IFS AB. All rights reserved.
April 17, 2017

20. This slide shows the active work orders for the object
This slide shows the active work orders for the object. In this window, the operator also finds information about status for each work order and planned start date. It is also possible to access more detailed information about a specific work order by using the action-menu in the work order form or by clicking the line number to the left of a work order.
© 2003 IFS AB. All rights reserved.
April 17, 2017

21. Document Management
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April 17, 2017

22. The ”Connected Documents” aspect, provides access to all documents associated with an object.
© 2003 IFS AB. All rights reserved.
April 17, 2017

23. By using the action menu for a document, the operator can easily get a copy of the document, in this case a circuit diagram.
© 2003 IFS AB. All rights reserved.
April 17, 2017

24. The view copy of the circuit diagram, in this case a pdf-file, is displayed in Acrobat reader. From this view, the operator can print the document for further actions.
© 2003 IFS AB. All rights reserved.
April 17, 2017

25. Fault Reporting
© 2003 IFS AB. All rights reserved.
April 17, 2017

26. Filing fault reports in teh maintenance system is only a mouse-click away. The fault report wizard can either be started from an object or from an alarm. In each case, as much information as possible will be inherited from the object/alarm and thus predefined in the wizard to reduce the amount of information that is needed to enter in the wizard and to avoid typing errors.
© 2003 IFS AB. All rights reserved.
April 17, 2017

27. When the wizard is completed, the operator receives a receipt that the fault report has been created. In this case Fault Report #
© 2003 IFS AB. All rights reserved.
April 17, 2017

28. By bringing up the Active Work Orders aspect...
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April 17, 2017

29. ...the operator can see that the new fault report (#200123) has been filed in the maintenance system in status Fault Report. In the status field, the operator can follow the status of the fault report from fault report, through observed, planned, etc. up to the point when the work order is completed. The operator also have instant access to information about when the work is planned to be carried out. When the work is completed and possibly costs are authorized, the work order will end up in the history. Historical work orders are also available as an aspect.
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April 17, 2017

30. Read More?
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31. © 2003 IFS AB. All rights reserved.
April 17, 2017