Embed Size (px)
Citation preview
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
PUBLIC INFORMATION
United Pet Group Visibility Boosts Efficiency by 15%, Capacity by 3%
Dave Seckel, United Pet Group – Maintenance Electrician
Wendy Armel, Stone Technologies - Principal MES Analyst
AG
END
A
Wrap-up / Questions
Project Specifics
Situation / Goals
Customer Information
Introductions / Technologies Used
PR
ESENTER
Dave Seckel
- Maintenance Electrician
- Education
- Associate In Industrial Automation
- NEC 2008
- 15 Years working with Automated Control Systems
- 6 years with United Pet Group
- Data Collection
- Concept and Controls Design
- Production Visualization
PR
ESENTER
Wendy Armel
- Principal MES Analyst at Stone Technologies
- Education
- BSBA in Computer Information Systems
- MBA
- 14 years in manufacturing
- Data acquisition and reporting
- Discrete event simulation
- Deep knowledge of FactoryTalk Metrics
AU
DIEN
CE
Audience – How Many…
End Users
Systems Integrators
Rockwell Automation
Distributors
Other
Experience with
FactoryTalk® Metrics
TEC
HN
OLO
GY U
SED - OEE D
EFINITIO
NS
What is FactoryTalk Metrics?
OEE and Downtime Tracking
Overall equipment effectiveness (OEE) can provide you with critical insight into how well you are managing your production operations.
Downtime - identify specific causes of inefficiency, including sophisticated methods of analysis that allow you to measure or compare the performance of plants, lines, machines or even individual production teams.
AG
END
A
Wrap-up / Questions
Project Specifics
Situation / Goals
Customer Information
Introductions / Technologies Used
CO
MP
AN
Y OV
ERV
IEW
Customer Information
United Pet Group (UPG) is a company under Spectrum Brands, Inc. UPG is a leading global manufacturer of pet supplies. Located in St. Louis, MO.
Makes the following products:
Primarily bagged animal feed: bird, ferret, rabbit, hamster, guinea pig
Molded seed cakes and sticks
Process:
Bagged bird seed – blending, bagging
Molded bird seed – blending, molding and drying
AG
END
A
Wrap-up / Questions
Project Specifics
Situation / Goals
Customer Information
Introductions / Technologies Used
PR
OJEC
T Goals
Provide accurate labor usage information to reduce overtime and increase labor efficiency
Increase production rates
Replace existing stand alone data collection system
Gain visibility into plant operations
Improve efficiency and reduce costs
Complete ownership of the solution – UPG to complete all future expansions
BU
SINESS
Challenges
Focus everyone on the right issues
Provide automated data that could be easily used by operations
Provide operations with labor utilization data
Integrate with existing scale data collection system
Change the culture
Tribal knowledge -> automated collection system - FactoryTalk Metrics
Previous automated data collection system was limiting. The end users were skeptical of another solution.
FA
CTO
RYT
ALK M
ETRIC
S Technology Selection
Why did UPG select FactoryTalk Metrics?
It just made sense
Allen-Bradley PLCs and wanted to stay within the Rockwell platform
Able to see the product in action through labs and in the field
Reporting structure of FactoryTalk Metrics aligned with UPG’s reporting needs
FactoryTalk Metrics has the “horse power” to grow with the company
Reports are user intuitive
AG
END
A
Wrap-up / Questions
Project Specifics
Situation / Goals
Customer Information
Introductions / Technologies Used
PR
OJEC
T Project Approach
Consulting engagement to create design
Defined a small set of simple effective custom reports
Defined a structured methodology that was repeatable
Resulted in small pilot – S3 Bagging Line
Refined pilot to provide for base configuration
Expanded base configuration – 4 additional lines included the blending area
PR
OJEC
T Pilot
UPG evaluated the results provided by Stone and FactoryTalk Metrics
Implemented on one seed line (work cell)
Deployed 4 custom reports developed in Microsoft SQL Server Reporting Services
Labor Hours
Line Operations
Line Overview
Last 10 Line Faults
PR
OJEC
T REP
OR
T - CU
STOM
Pilot – Labor Hours
PR
OJEC
T REP
OR
T - CU
STOM
Pilot – Line Operations
PR
OJEC
T REP
OR
T - CU
STOM
Pilot – Line Overview
PR
OJEC
T REP
OR
T - CU
STOM
Pilot – Last 10 Line Faults
PR
OJEC
T EXP
AN
SION
Expansion
Remote design session on the seed blending area
Refine minor machine states for this process
Expanded data collection to the following:
3 Bag Lines
1 Seed Blending
2 BD Lines
BEN
EFITS Unexpected Results
Management uses the information during the daily meetings
Cultural acceptance is slower than anticipated by operations
Operations is not being required by management to use the data
The automated OEE is much lower than the manually calculated OEE
Automated solutions capture more granularity than a manual solution
RESU
LTS Management’s Perspective - UPG
FactoryTalk Metrics is a valuable resource to quantify and identify daily manufacturing downtime
Area supervisors can customize reports based off their individual KPIs
Helped eliminate micro stops and identify recurring failures
Helped recalibrate PM programs based off our applications
Increased overall efficiencies
Increased plant capacities
RESU
LTS Realized Results
Overtime reduction of 10%
Increased Labor Efficiency by 15%
20
15
EXP
AN
SION
Next Steps
2015 Expansion
Bagger Line
Flow Wrapper
Molding Department – 3 Lines
BEN
EFITS Benefits of FactoryTalk Metrics - Customer
Standard solution Easy to explain to new project team members
TIME – standard objects shorten implementation time frames significantly
MONEY
Out of box cost
Ongoing support
Integration
AG
END
A Lessons Learned
Take it slowly - try to not move too fast
Too many changes at once can be a bad thing
Learning the software is easier than expected
The more people involved in the design process – the more acceptance you will get. Involve all levels of the plant as early as possible.
Data Accuracy
Prior to implementation – ~60% accuracy
Automated solution - ~95% accuracy (time is 100% accurate)
AD
VIC
E TO O
THER
S Take Aways
When you are on an effort to improve, if you solve the wrong problem, you wind up with two problems. The original, plus the one you created.
Take the time to do a proper design before implementing a solution
FactoryTalk Metrics provides the data to focus on the right problem
Start with a few key reports out of the box reports to learn more about the data coming into the system
Production Overview shows throughput, availability, quality at a high level to provide areas to focus
Event reports provide details on why production is not reaching the desired levels
Custom reporting easily accomplished with industry standard SSRS
AD
VIC
E TO O
THER
S Take Aways – Production Overview
AD
VIC
E TO O
THER
S Take Aways – Event Chart Reason
AG
END
A
Wrap-up / Questions
Project Specifics
Situation / Goals
Customer Information
Introductions / Technologies Used
AG
END
A Summary
Goals
Get new data acquisition solution up and running quickly and efficiently
Keep the solution cost effective
Approach
Stick to a standard configuration as much as possible
Results
Streamlined, repeatable solution that provides valuable data to multiple levels of the organization
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Please take a couple minutes to complete a quick session survey to tell us how we’re doing.
On the mobile app:
1. Locate session using Schedule or Agenda Builder.
2. Click on the thumbs up icon on the lower right corner of the session
detail
3. Complete survey
4. Click the Submit Form button
Thank you!!
3
1
2
4
We care what you think!
www.rockwellautomationteched.com
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.
PUBLIC INFORMATION
Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Questions?
Wendy Armel
972.395.1627
www.stonetek.com Dave Seckel
Dave,[email protected]
314.523.5955
