RSBizWare PlantMetrics - indautomation.ru is accomplished through accurate reporting of ... (Overall Equipment Effectiveness) ... The OEE value can be used to assess a single machine’s

RS BizWare™ PlantMetrics™ enables manufacturers of all

types and sizes to increase production, reduce costs,

and increase quality using existing equipment and labor more

effectively. This is accomplished through accurate reporting of

real plant-floor activity.

PlantMetrics monitors plant-floor equipment and provides

accurate, timely, granular, and specific information on machine

performance. This data is the basis for understanding the real

causes of inefficiency, waste, and lost capacity.

With this understanding, process improvement initiatives can be

refined and prioritized resulting in reduced downtime, decreased

cycle time, and increased overall production.

Features• A complete system for:

- Event collection and analysis- Efficiency monitoring

• Easy, flexible, scalable configuration

• Works with any PLC or HMI using OPC standards

• Reliable, 24/7 data collection

• Data storage in an efficient, usable form

• Built-in HTML report writer

• Access to all reports with a Web browser

• Customizable and extendable

• 15 Standard KPIs (Key Performance Indicators) including OEE (Overall Equipment Effectiveness)

• Customized event data collection

Benefits• Increased capacity

- More product, revenue, and profit in the same amount of time

• Decreased manufacturing costs- Less overtime, reduced labor costs, lower per-unit costs

• Deferred capital expenditures- Make your current equipment produce more

• Decreased overhead costs- Save time in collecting data and preparing reports

PlantMetrics DeploymentPlantMetrics is designed to be tailored to each unique plant

environment allowing for flexible configuration of the plant model,

schedules, performance parameters, custom events, and reports.

RSBizWare PlantMetrics is configured by authorized users using

the RSBizWare Production Client. Configuration wizards guide the

author through the process, which can scale from very simple to

very detailed, depending upon requirements. Since PlantMetrics

Technical Data

RSBizWare PlantMetricsTarget Plant Efficiency Improvements

applications often evolve over time as new opportunities for

improvement are uncovered, previous configurations are easily

modified and new reports may be added without the need to stop

ongoing data collection.

Efficiency data

The following types of data can be configured to be collected

from the control system for calculating OEE and other default KPIs:

• Total/good/scrap production counts

• Part ID and cycle time

• Available status and shift. Defined by either:- Time pattern and exceptions, or- Shift and availability data points

• User-defined fields or “Flex Fields”

• Running indicator

• Custom events

Custom events

Aside from being an OEE analysis tool, PlantMetrics excels as an

Event-Tracking System, and custom events can be created to

monitor whatever is important in a particular plant. Examples include:

• Downtime analysis

• Predictive maintenance

• Intra-machine optimization

• Simple traceability

• Cycle-time analysis

• Defect tracking

• Quality controls

Custom events are quite often added incrementally to a running

PlantMetrics system when more detailed data is desired, as when

a particular problem area is identified.

Reporting

All RSBizWare PlantMetrics reports are available to licensed

runtime users via a standard Web browser. Reports can also be

embedded into any ActiveX® container, such as RSView® or third-

party HMI applications, providing operators with the latest data at

their terminals. This is accomplished without the need for a

commercial Web server product like Microsoft IIS because the

RSBizWare Production Server acts as a Web server.

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PlantMetrics reports can include:

• KPIs

• Total/good/scrap production counts

• Ideal production counts

• Time in custom events such as downtime, setup, changeovers, waiting, blocked, starved, idle, etc.

• Event counts

• Ideal and actual cycle times

• Faults

• MTBF, MTTR

The data can be reported by:

• Machine

• Shift

• Part number

• User-defined fields

• Hour, day, week, month, year

Users can drill into the data they want to see and modify report

content at runtime using built-in filters and toolbars. In addition

to PlantMetrics data, RSBizWare reports can contain data from

other sources or databases.

The RSBizWare Production Client is an HTML editor and is used

to create the reports. Reports can also be created or modified by

other HTML editors like Microsoft® FrontPage®.

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OEE DefinedPlantMetrics uses an OEE (Overall Equipment Effectiveness)

model to measure the performance of manufacturing equipment.

The OEE model yields a single performance rating for every

activity area (workcell, line, area, or plant) being monitored,

thereby providing a simple way to determine quickly if an

activity area is performing adequately.

The OEE value can be used to assess a single machine’s

performance over time or to compare the performance of

machines to each other.

Three components contribute to an OEE value: availability,

throughput, and quality. Each is a percentage, and the OEE

value is the product of these three percentages, and therefore

is also a percentage.

Availability is a ratio of running time to available time.

Available time may be defined by a schedule or modified by

planned downtime events such as preventive maintenance.

Throughput is the performance of a machine when it is running

compared to its ideal cycle time.

Quality is the percentage of good parts that are produced.

The OEE calculation that is used by PlantMetrics is the product

of these three components:

OEE = Availability * Throughput * Quality

OEE is a valuable method of analyzing performance because it

is widely recognized and can be applied to any type of industry,

factory, or machine. OEE is the default efficiency calculation

performed by PlantMetrics; additional or alternate calculations

can be implemented. Further, PlantMetrics supports the collec-

tion of detailed event data, which can be used to analyze the

specific causes of inefficiencies.

RSBizWare creates a default zero-administration Web page

(called QuickWeb) containing all defined reports. RSBizWare Web

pages can also be embedded into corporate intranet Web pages

or in portal products like RSProduction™ Portal. Reports can be

printed, saved to files, or emailed on an ad-hoc or scheduled basis.

Finally, the open nature of the RSBizWare data model permits the

use of other reporting tools, including:

• Microsoft Excel (using RSBizWare Excel Add-In)

• Microsoft Office components

• Microsoft Reporting Services

Data CollectionPlantMetrics can collect data from any OPC-compliant device or

HMI application. All data is collected in real time and RSSql™ is used

as the data-collection engine. PlantMetrics data is stored in an

open SQL Server™ or Oracle® database with a documented schema.

Once data collection begins, it continues 24/7 and monitors workcells

continuously so that events are never missed. Virtually any changes

can be made to the PlantMetrics application without interrupting

data collection (requires the use of FactoryTalk® Directory™ and

FactoryTalk Live Data™).

Key Performance Indicators (KPIs) Depending upon PlantMetrics configuration, up to 15 default KPIs are available for reporting. The KPIs include:

In addition to the default KPIs, other performance indicators can be derived from collected data.

• Good Parts %

• Scrap Parts %

• Ideal Capacity

• Running %

• Downtime %

• Fault %

• Availability %

• Performance %

• Quality %

• Failure Rate

• OEE (Overall Equipment Effectiveness)

• MTBF (Mean Time Between Failure)

• Available % (vs. Schedule)

• MTTR (Mean Time To Repair)

• Failure Frequency Rate

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Security RSBizWare PlantMetrics includes a complete security system.

RSBizWare users and groups can be created or imported from

the operating system. A verified login is required to access all

functions, including viewing reports. Users are restricted to viewing

only those reports for which they have been granted rights.

Special functional privileges can be granted to users or groups.

Only users with PlantMetrics Authoring licenses are allowed to

configure PlantMetrics or create reports.

FactoryTalk Technologies FactoryTalk is a manufacturing information platform that integrates

plant-wide control systems and connects the enterprise with the

production facility.

The FactoryTalk Automation Platform:

• provides common services (such as diagnostic

messages and access to real-time data) and shares

plant resources (such as tags and graphic displays)

throughout a production facility.

• allows defining plant-floor resources once, and then

allows simultaneous access to those resources across

product boundaries.

• supports centralized security services.

RSBizWare PlantMetrics, like all Rockwell Software products,

takes advantage of various FactoryTalk technologies to make

implementation and management of a multi-product Rockwell

Software system easier and more cost effective. FactoryTalk

technologies that are currently leveraged by PlantMetrics include:

• FactoryTalk Directory – a common, shared address book

of factory resources

• FactoryTalk Admin Tool

• FactoryTalk Live Data – reliable, enterprise-wide access

to real-time manufacturing information

• FactoryTalk Activation

• FactoryTalk Data Model™

• RSAssetSecurity™

System Requirements Server hardware

The RSBizWare products are highly configurable and scalable

applications, and hardware requirements for a server vary

considerably depending upon the size and architecture of the

application. For example:

• The server and database components of an RSBizWare

application can be resident on a single computer,

or distributed between multiple computers. The computer

requirements for each architecture will be different.

• PlantMetrics applications can vary quite widely in size

and in the amount of data collected and stored. The

licensed workcell count ranges from 5 to 200, and there

is no license limit on the number of custom events.

• The number of clients accessing the system and viewing

reports has an impact on hardware requirements.

The specifications for server computers listed here are to be

considered minimums for a very small RSBizWare application

where all services are running on one computer or for larger

applications where there is a separate database server.

To use the RSBizWare Production Server effectively,

your server computer should be a “server class” machine

and must have at least:

• 2.0 GHz Pentium® 4 processor (multiple processors are supported)

• 1 GB of RAM

• 300 MB of free hard disk space to install RSBizWare

• 300 MB to install Microsoft SQL Server

• 400 MB to install the Oracle client software

• Additional disk space, as required, to accommodate

database growth

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Though it is not required to have a separate machine to store the

RSBizWare database, it is recommended. If you intend to have a

separate database server, you should be aware of the following

recommendations:

• Dual processors (Pentium III Xeon or better)

• 1 GB RAM

• Data storage options: RAID (For small implementations, RAID 1

is recommended. For large implementations, RAID 10 is

recommended. RAID 10 is the best option, but the most expensive.

SQL Server can run well with RAID 1 arrays; one RAID 1 for data

files and one RAID 1 for transaction log.), or storage on an array

of disks. If you use an array of disks for storage, we recommend

the following:

- SQL Server – At least 2 SCSI drives using different controller

cards, one drive to store the Transaction Log and one drive

to store the data files.

- Oracle – It is a good idea to separate the following files onto

different disks for the best performance:

Disk 1 - Data files

Disk 2 - Index files

Disk 3 - Temp files

Disk 4 - Rollback Segment files

Disk 5 - System tables and Control files

Your Rockwell Automation salesperson or system integrator should

be able to help you in assessing the hardware requirements for

your particular application.

Server software

The following software is required for server functions:

• Microsoft Windows NT® 4 Server (Service Pack 6 or higher) or

Windows Server™ 2000 (Service Pack 3 or higher) or Windows

Server 2003 Standard Edition

• Microsoft Internet Explorer 6.0 (Service Pack 1) (provided)

• Database software – either:

- SQL Server 2000 Standard Edition Service Pack 3a (provided), or

- Oracle 8.1.7 or Oracle 9.2.0.1.0

• FactoryTalk Activation (provided)

• FactoryTalk Automation Platform (provided)

• Adobe® Acrobat® Reader 7.0 to view documentation (provided)

• Microsoft Data Access Components (MDAC) 2.8 (provided)

• TCP/IP network connectivity

Client hardware

To use the RSBizWare Production Client effectively, your personal

computer must meet the following hardware requirements:

• 200 MHz Pentium II processor or better

• 64 MB of RAM

• 50 MB of free hard disk space

• 800 x 600 resolution monitor

Client software

To view RSBizWare reports with a Web browser, the following

software is required.

• Microsoft Internet Explorer 6.0 Service Pack 1 (provided)

• TCP/IP network connectivity

To use the RSBizWare Production Client to configure PlantMetrics

and create reports, the following additional software is required:

• Windows NT Workstation or Server (SP6+), or Windows 2000

Professional or Server (SP3+), or Windows Server 2003 Standard

Edition, or Windows XP (SP1+)

• Microsoft Data Access Components (MDAC) 2.8 (provided)

• Adobe Acrobat Reader 7.0 to view documentation (provided)

• HTTP 1.1

Control system requirements

• OPC 1.0- or 2.0-compatible control system.

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Catalog Numbers PlantMetrics Servers

Servers are licensed based on a workcell count. All servers contain

Microsoft SQL Server 2000 Standard Edition and one PlantMetrics

Authoring Client. Workcell counts are additive up to the 200

workcell maximum.

9358-PLTM2100ENE RSBizWare PlantMetrics Server with

5 Workcell Limit


10 Workcell Limit


25 Workcell Limit


50 Workcell Limit


100 Workcell Limit


200 Workcell Limit

PlantMetrics Authoring Client

An Authoring Client license is required for each user who will

configure the PlantMetrics application or create/modify reports.

One is included with each PlantMetrics Server.

9358-PLTMATHENE RSBizWare PlantMetrics Single-User

Authoring Client

RSBizWare Runtime Clients

RSBizWare Runtime Client licenses are required for all users who

access “live” PlantMetrics or Historian reports through a Web

browser, HMI, or any other means. These are concurrent user

licenses and include the appropriate SQL Server 2000 license.

Unlimited-user versions are available for 1-, 2-, or 4-CPU systems.

One unlimited version is available with no SQL Server license.

9358-BIZ1C0PENE RSBizWare Single-User Runtime Client License

9358-BIZUC0PENE RSBizWare Unlimited-User Runtime Client

License without a Database Server License (For users who

already have Oracle or SQL Server Processor licenses.)


License with SQL Server 2000 Standard Edition Single-Processor

Runtime Database license


License with SQL Server 2000 Standard Edition Dual-Processor



License with SQL Server 2000 Standard Edition Quad-Processor


What’s included

RSBizWare PlantMetrics server licenses include:

• RSBizWare software CD

• Microsoft SQL Server 2000 Standard Edition CD

• Microsoft SQL Server 2000 Service Pack 3a CD

• FactoryTalk Activation software CD

• Microsoft SQL Server 2000 Client Access License (CAL)

• RSBizWare PlantMetrics Server license (obtainable via FT Activation and the Internet)

• RSBizWare PlantMetrics Authoring client license (via FT Activation)

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ImplementationBecause each factory is unique, PlantMetrics applications

can vary widely in scope and complexity. A PlantMetrics

application should initially be implemented with the assistance of

Rockwell Automation’s experienced consultants or a certified

integrator. A small PlantMetrics system (5-25 workcells) can usu-

ally be implemented in 1-3 weeks. The level of effort depends

upon the scope of the PlantMetrics application, and it is often

completed in phases. PlantMetrics does not require any specific

changes to the PLCs or control system, but changes may be

required if the data for PlantMetrics monitoring is not currently

being collected by the control system.

Get More InformationTo learn more about PlantMetrics and the RSBizWare product

suite, please visit: www.software.rockwell.com/rsbizware.

Publication PLTMT-TD001A-EN-P – April 2005

Supercedes Publication 9398-PLTMTD-JUL00

Copyright © 2005 Rockwell Automation, Inc. All rights reserved. Printed in USA.

Rockwell SoftwareFor more information on the latest pricing or a demonstration of any Rockwell Softwarepackage, please contact your local Rockwell Automation sales office or Allen-Bradleydistributor. For the very latest on Rockwell Software products, visit us at:

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RSBizWare PlantMetrics - indautomation.ru is accomplished through accurate reporting of ... (Overall Equipment Effectiveness) ... The OEE value can be used to assess a single machine’s