Turn Control System Data into Improved Business Performance leveraging FactoryTalk Products. For Classroom Use Only! Allen-Bradley

Transcription

1 Turn Control System Data into Improved Business Performance leveraging FactoryTalk Products For Classroom Use Only! Allen-Bradley

2 Important User Information This documentation, whether, illustrative, printed, online or electronic (hereinafter Documentation ) is intended for use only as a learning aid when using Rockwell Automation approved demonstration hardware, software and firmware. The Documentation should only be used as a learning tool by qualified professionals. The variety of uses for the hardware, software and firmware (hereinafter Products ) described in this Documentation, mandates that those responsible for the application and use of those Products must satisfy themselves that all necessary steps have been taken to ensure that each application and actual use meets all performance and safety requirements, including any applicable laws, regulations, codes and standards in addition to any applicable technical documents. In no event will Rockwell Automation, Inc., or any of its affiliate or subsidiary companies (hereinafter Rockwell Automation ) be responsible or liable for any indirect or consequential damages resulting from the use or application of the Products described in this Documentation. Rockwell Automation does not assume responsibility or liability for damages of any kind based on the alleged use of, or reliance on, this Documentation. No patent liability is assumed by Rockwell Automation with respect to use of information, circuits, equipment, or software described in the Documentation. Except as specifically agreed in writing as part of a maintenance or support contract, equipment users are responsible for: properly using, calibrating, operating, monitoring and maintaining all Products consistent with all Rockwell Automation or third-party provided instructions, warnings, recommendations and documentation; ensuring that only properly trained personnel use, operate and maintain the Products at all times; staying informed of all Product updates and alerts and implementing all updates and fixes; and all other factors affecting the Products that are outside of the direct control of Rockwell Automation. Reproduction of the contents of the Documentation, in whole or in part, without written permission of Rockwell Automation is prohibited. Throughout this manual we use the following notes to make you aware of safety considerations: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment, which may lead to personal injury or death, property damage, or economic loss. Identifies information that is critical for successful application and understanding of the product. Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. Attentions help you: identify a hazard avoid a hazard recognize the consequence Labels may be located on or inside the drive to alert people that dangerous voltage may be present. Labels may be located on or inside the drive to alert people that surfaces may be dangerous temperatures.

3 Turn Control System Data into Improved Business Performance leveraging FactoryTalk Products Contents Before you begin... 4 About this lab... 4 Manufacturing Intelligence Overview... 5 Viewing a completed application... 6 Building a Model to Represent the Manufacturing System Lab: Creating a Unified Production Model Using Trend to Analyze Data from Disparate Data Sources Lab: Creating a Trend Report Lab: Creating a Basic Excel Report Lab: Creating a Template Excel Report Using Dashboards to Monitor and Improve Business Performance Lab: Viewing a Dashboard in the Portal Integration of Alarm Information Lab: Leveraging FactoryTalk Alarms and Events Viewing FactoryTalk Alarm and Events (FTAE) Reports in VantagePoint Lab: Creating Type Rules to Associate Reports with a Type Allen-Bradley 3 of 74

4 Before you begin About this lab This lab provides a look at how the FactoryTalk Product Suite can be leveraged as part of a Manufacturing Intelligence solution, giving visibility to control system data in order to improve business performance. You will see how FactoryTalk VantagePoint can connect to many different data sources including FactoryTalk Historian, FactoryTalk Metrics and the controller for live data values along with connecting to a database which could hold data from a third party system such as LIMS (Laboratory Information Management System). View pre-configured reports and learn how to use the tools to configure reports and trends. Gain additional skills on the analysis and reporting tools that are part of the product offering. This lab demonstrates equipment performance as the metric to create the real-world demo. You ll learn how to build a complete picture of your manufacturing equipment performance using FactoryTalk VantagePoint EMI and FactoryTalk Metrics. Learn how to bring together information from your historians, downtime systems and your maintenance management systems so that you can monitor Key Performance Indicators (KPIs) and drill down into more detail to understand root causes when problems occur. This lab takes approximately 90 minutes to complete. 4 of 74

5 Manufacturing Intelligence Overview Every manufacturing process has data associated with it. The real question is how is this information being used? Manufacturing Intelligence is all about taking this manufacturing data and turning it into useful information so that business decisions can be made to improve the overall operational efficiency. The application we have put together is for a company called BestForYou Foods, Inc. This company makes a variety of foods focused on the health conscious customer segment that is growing in popularity. The Unified Production Model (UPM) was built around the physical organizational model. It could have easily been designed around functional departments (e.g. Production, Quality, Order Management, Product Fulfillment, etc.) if this would be more appropriate to providing reporting information. Each line contains a selection of equipment. Reports are available at the equipment level but also there are reports available at the line level. We have provided a sample of some of the reports that might be available in the following sections. Allen-Bradley 5 of 74

6 Viewing a completed application Getting Started This section will walk you through some of the reports already created for this lab. This is intended to give you a feel for the type of information you can collect, analyze and report on. 1. Open the VantagePoint Portal (Start > All Programs > Rockwell Software > FactoryTalk VantagePoint > Portal). 2. From the Portal menu, select Reports > BestForYou Foods. 3. The default report that shows in the portal provides a convenient launching point for viewing the sample reports. 6 of 74

7 4. Click on the OEE Dashboard button. 5. This report is designed to provide an Overall Equipment Effectiveness (OEE) value for each piece of equipment on the line. The bar chart shows the individual components that are used to calculate the OEE value. 6. On the left side of the screen, note the Parameters tab and the Selected_Line drop-down list box. Select the first item on the list, Cleveland OH.Areas.Baking.Lines.Line 1. Allen-Bradley 7 of 74

8 7. Click the Generate Report button. 8. This same report is now showing information about the Baking Line, both Oven 1 and Oven 2. 8 of 74

9 9. Click on the Oven 1 OEE Components chart. This will display a detailed trend of the OEE components values over the last 30 minutes. 10. Close the Internet Explorer window containing the detailed OEE Trend. Allen-Bradley 9 of 74

10 11. Click on the Historian Diag button. This is a diagnostic dashboard that shows some of the critical parameters associated with the FactoryTalk Historian SE server (Production Historian). It is a tool for understanding the inner workings of the Historian server in how it collects, compresses and archives historical data values. 12. Close the Internet Explorer window containing the Historian Server Overview dashboard. 10 of 74

11 13. Click on the Alarm Summary button This Alarm Summary dashboard shows the Top 10 most frequent alarms. The default time frame is set as the last 60 minutes but can be changed using the time period selection options on the left of the page. If changes are made, the charts are updated dynamically. The table on the lower right provides the detailed alarm information for the selected alarm from the bar chart. The default display is for the most frequent alarm. If you select a different alarm from the bar chart, the information in the table will change to reflect the detailed alarm events. 14. Close the Internet Explorer window containing the Top 10 Most Frequent Alarms dashboard. Allen-Bradley 11 of 74

12 15. Click on the Downtime Report button The Downtime Equipment report is an example of a composite report where multiple reporting components are displayed. Current running status and performance information combined with downtime information provide a view of how this machine is performing. 16. Close the Internet Explorer window containing the Downtime Report dashboard. 12 of 74

13 17. Click on the Production KPIs button. The Production KPIs dashboard provides a high level view of how our manufacturing operation is running as measured by Unplanned Downtime, Process Variability and Plant Output. These Key Performance Indicators provide a quick view of the selected operational parameters with the ability to drill down into more specific information by pressing the Drill button on the selected dashboard component. We also provided additional links to other reports for more specific information. Feel free to click on any of the links to view additional report information and then close the window when you are done. 18. Close the Internet Explorer window containing the Production KPIs dashboard. Allen-Bradley 13 of 74

14 19. Click on the Control Loop button. The Control Loop Report is a template report that provides detailed information about any of the control loops in the system. This is an example of a composite report where there are multiple reporting components in a single report. The information conveyed is specific to the selected control loop. These are just a sampling of the type of reports you can create leveraging the capabilities in FactoryTalk VantagePoint. The data can come from multiple data sources (e.g. Data Historians, live data values from control devices, other information residing in a database, etc.) and is collated into a single report. Let s now move on a see how these components fit together as part of a Manufacturing Intelligence solution. 20. Close the Internet Explorer window containing the Control Loop report. 21. Close the VantagePoint Portal. 14 of 74

15 Building a Model to Represent the Manufacturing System Lab: Creating a Unified Production Model In this lab the participant will create a Unified Production Model (UPM) in FactoryTalk VantagePoint to represent their manufacturing system. In our example, the company is called BestForYou Foods Inc. and serves the Food and Beverage industry. The extensive modeling capabilities of FactoryTalk VantagePoint enables any manufacturing or business to be described in user terms such as a piece of equipment or a Batch report which may draw data from several different sources (i.e. control devices, data historians, LIMS, Maintenance systems, etc) in order to convey the required information. This allows users in all roles within the organization to access data from a single point (the UPM) with a common set of analysis and reporting tools enabling them to react to changes sooner and make better business decisions. Getting Started For the extent of this lab, you are a power user and are responsible for maintaining the FactoryTalk VantagePoint system. You have already created parts of the UPM in VantagePoint which consist of Sites, Areas, Lines and Equipment. The specific part of the model we will be working with is Oven 1 and Oven 2 on Line 1 in the Baking area of the Los Angeles CA site. Oven 1 is leveraging FactoryTalk Historian as its underlying data source while Oven 2 has been configured to use historical data archived in a SQL database, which was populated using FactoryTalk Transaction Manager. Additionally, we will leverage FactoryTalk Metrics integrated into VantagePoint as a means of getting OEE and other KPI information to report on. If an Energy Monitoring system, such as RSEnergyMetrix, was also installed, we could integrate that as part of the overall Manufacturing Intelligence solution. For this lab we will use simulation data. Exploring the Unified Production Model (UPM) 1. Launch VantagePoint Manager (Start > All Programs > Rockwell Software > FactoryTalk VantagePoint > Manager). 2. In the model browser (tree-like structure on the left), we can see the model for BestForYou Foods Inc. located under MyEnterprise. 3. Click on BestForYou Foods Inc. On the right, click on the Properties tab. Note that the TypeName is RSSamples.Model.Enterprise. Allen-Bradley 15 of 74

16 4. Under BestForYou Foods Inc., expand Sites and click on Los Angeles CA. In the Properties tab on the right, note that the property TypeName is RSSamples.Model.Site. 5. Under Los Angeles CA, navigate to Areas.Baking. In this case, Baking is an item in the model that is built using the RSSamples.Model.Area type. This is also the case with areas Filling, Packing, and Shipping. The UPM allows for the creation of data types that are specific to a given need. In our example we created a type definition (RSSamples.Model.Enterprise) that contains a Sites collection of another type called RSSamples.Model.Site. This type definition contains an Areas collection of a type called RSSamples.Model.Area and so on. What you end up with is a hierarchy that looks like: Enterprise Sites (Collection) Site A Areas (Collection) Area 1 Lines (Collection) Line 1 Equipment (Collection) Equipment 1 16 of 74

17 6. Let s take a look at some of the equipment definitions. Navigate to Oven 1 located under Los Angeles CA.Areas.Baking.Lines.Line 1.Equipment. Right-click on Oven 1 and select Edit. Continued next page... Allen-Bradley 17 of 74

18 Note that Oven 1 has the following properties KPIs for performance data such as that coming from FactoryTalk Metrics. In our example, this node is directly connected to the Metrics workcell model for Oven 1 under the System node in the VantagePoint model (System.Sources.FactoryTalkMetrics.Connectors) Zone temperatures and setpoints for production data from our data historian (FactoryTalk Historian SE) that provides both current and historical values. In our example, the historical data for Oven 1 is coming from FactoryTalk Historian. The historical data for Oven 2 is coming from a SQL database. Energy for energy related information associated with this piece of equipment such as that coming from RSEnergyMetrix. In our example, we are simply connecting the energy-related tag properties to VantagePoint simulator tags. 7. Click Cancel. 18 of 74

19 8. Navigate to Oven 2 located under the Los Angeles CA.Areas.Baking.Lines.Line 1.Equipment. Right-click on Oven 2 and select Edit. Note that the Zone Temperatures and Setpoints are coming from a SQL database for Oven 2. We are doing this to demonstrate how different data sources can be used to provide data for a common type definition for a piece of equipment (e.g. Oven) 9. Click Cancel. 10. Close VantagePoint Manager. Allen-Bradley 19 of 74

20 Using Trend to Analyze Data from Disparate Data Sources Lab: Creating a Trend Report The goal of this lab is to have the participant build a trend and potentially identify correlations in data coming from disparate data sources, in this case FactoryTalk Metrics and FactoryTalk Historian. The lab goes through the steps of browsing the Unified Production Model (UPM) in FactoryTalk VantagePoint and trending equipment performance data from FTMetrics and production data from FTHistorian. Viewing FTMetrics data in VantagePoint Trend In this lab, you are the Plant Manager (Plant Manager AA). While trending the hourly OEE of a piece of equipment, Oven 1, over a 24-hour period of time, you notice that the OEE of the oven had at one point in time dropped quite a bit to a value below the average. You sit down with a senior engineer (Engineer BB) and analyze some of the performance parameters to determine what may have contributed to the drop in OEE. You not only determine what faults caused the drop in OEE but also gain some insight into how the average OEE may be improved. 1. Launch VantagePoint Trend (Start > All Programs > Rockwell Software > FactoryTalk VantagePoint > Trend). Note: For this next exercise, we have created a default trend template that has the Start and End time frames already set for the given period we want to explore. 2. In the model browser, navigate to My Enterprise.Public.Engineering. Engineer BB. In the item list, double click on the item Initial Start Period to open the trend chart. You will see that the chart is empty but has the reference time of 5/22/2010 1:00:00 AM to 5/23/2010 1:00:00 AM. 20 of 74

21 3. In the model browser, navigate to MyEnterprise.[BestForYou Foods Inc.].Sites.Los Angeles CA.Areas.Baking.Lines.Line 1.Equipment.Oven 1.KPIs. 4. In the items pane below, use the vertical scroll bar to scroll down and find the OEE tag. Allen-Bradley 21 of 74

22 5. Double-click on or drag and drop the OEE tag to the trace window on the right. You will see the following trend data on the chart. We want to look at the information on a time grouped interval of one hour. To do this, we will be applying a context tag to the trend chart Note: A context tag allows for FTMetrics data to be grouped, for example, by hour or shift. There are a few grouping options available to you in the context tags folder. Day, Hour, Month, and Shift are self-explanatory; OneValue groups all the data for the selected time period and returns a single value. 6. Right-click on the chart and select Properties > Chart. 22 of 74

23 7. Change Chart Title to Use current trace and click OK. 8. Click on the Context tags folder located here MyEnterprise.[BestForYou Foods Inc.].Sites.Los Angeles CA.Areas.Baking.Lines.Line 1.Equipment.Oven 1.KPIs.Context tags. 9. Drag the Grouping by hour context tag and drop onto the trace window. You are now viewing the OEE of Machine 1 grouped by hour. Allen-Bradley 23 of 74

24 10. Click the OEE tag in the tags list (bottom of trend) to give it focus. Move the mouse cursor to where the OEE value drops. Note that the drop happens around 5/22/2010 8:00 AM and the value is 0.50 (or 50%) compared to the average OEE of about 0.79 (or 79%) without the drop. 11. Click the Pan Right (or scroll right) button. Note the second drop in OEE around 5/23/2010 9:00 AM. 24 of 74

25 12. First Pan Left to return to where you were (start time of 5/22/2010 1:00:00 AM). Then, change the End timeframe to 5/23/2010 7:00:00 PM (don't miss changing the AM to PM!) and click the Refresh button (exclamation mark in-between the times). Now you can view both drops together. Allen-Bradley 25 of 74

26 Saving a Trend and a Capturing a Time Period of Interest (as a Time Period item in the model) In our scenario, it s the end of a long day and you wish to save your work. Additionally you think it might be a good idea to capture the Start and End timeframes for further analysis of the data. 1. Click File > Publish. 2. Browse to MyEnterprise.Public.Management.Plant Manager AA. Name your trend report OEE Drop Trend and click Publish. 3. Close Trend (File > Exit). 26 of 74

27 Opening a Trend and using a Time Period item It is the next day now. You are reviewing your trend together with a senior Engineer, Engineer BB to further investigate what may have caused the drop in OEE. 1. Launch VantagePoint Trend (Start > All Programs > Rockwell Software > FactoryTalk VantagePoint > Trend). 2. Navigate to MyEnterprise.Public.Management.Plant Manager AA and double-click the OEE Drop Trend report to open it in the trace window on the right. Allen-Bradley 27 of 74

28 3. Navigate to MyEnterprise.[BestForYou Foods Inc.].Sites.Los Angeles CA.Areas.Baking.Lines.Line 1.Equipment.Oven 1.KPIs.Events.MachineFaults.Blocked and double-click the IsActive tag to add it to the trace window on the right. 4. Similarly, navigate to MyEnterprise.[BestForYou Foods Inc.].Sites.Los Angeles CA.Areas.Baking.Lines.Line 1.Equipment.Oven 1.KPIs.Events.MachineFaults.Starved and double-click the IsActive tag to add it to the trace window on the right. Also, click the Stack Y-axes button. Note that the OEE drops when the Blocked or Starved faults were active. 28 of 74

29 5. Start a new trace window (File > New). 6. Navigate to the Plant Manager AA folder located here MyEnterprise.Public.Management.Plant Manager AA. Double click the OEE Drop Time Period item to add it to the trace window. Note the start and end fields have been updated to reflect what was saved in the Time Period item. 7. Navigate to the folder MyEnterprise.[BestForYou Foods Inc.].Sites.Los Angeles CA.Areas.Baking.Lines.Line 1.Equipment and add the following items Oven 2.KPIs.Context tags.grouping by hour Oven 2.KPIs.OEE Oven 2.KPIs.Events.MachineFaults.Blocked.IsActive Oven 2.KPIs.Events.MachineFaults.Starved.IsActive Oven 1.KPIs.OEE Oven 1.KPIs.Events.MachineFaults.Blocked.IsActive Oven 1.KPIs.Events.MachineFaults.Starved.IsActive Allen-Bradley 29 of 74

30 8. Click the Stack Y-axes button. Note that the OEE for Oven 2 drops when the Starved or Blocked conditions are active. Same holds true for Oven 1 OEE. This seems to confirm that OEE can be improved if the Starved and/or Blocked conditions on these ovens can be eliminated or at least reduced. 9. Close Trend by selecting File > Exit from the menu. You do not need to save any of the trends you created. 30 of 74

31 Using the Excel Add-In to Create Data and Context Rich Reports Lab: Creating a Basic Excel Report In this lab the participant will create and publish a FactoryTalk VantagePoint Excel report using data retrieved from FactoryTalk Metrics. Getting Started and First History Function Call In this scenario, you are the Plant Manager. You have been thinking about the faults that occurred during the time you noticed the two drops in OEE. You would like to know which faults happened most frequently and which ones were in the faulted state for the longest period of time. 1. Open Microsoft Office Excel Open C:\Class Files\Excel Report Template.xlsx (do not by mistake open Excel Report2 Template.xlsx) 3. Verify the workbook appears as follows with tabs as specified at the bottom. 4. Click cell A1, click the Add-Ins tab, then click VantagePoint and select Insert Function. Allen-Bradley 31 of 74

32 5. In the dialog that appears, select History in the top left corner and click the Next button in the bottom right corner. 6. Navigate to MyEnterprise.[BestForYou Foods Inc.].Sites.Los Angeles CA.Areas.Baking.Lines.Line 1.Equipment.Oven 2.KPIs. 32 of 74

33 7. In the items list below, double-click the StateName tag to add it to the list on the right. 8. Click Next. 9. Select Use this Range. Click New. Allen-Bradley 33 of 74

34 10. Navigate to MyEnterprise.Public.Management.Plant Manager AA. In the items list below, double-click OEE Drop Time Period to select it. 11. Click Next. 12. Uncheck Skip advanced options. Ensure the Narrow option is selected for the data format. 34 of 74

35 13. Click Next. 14. Click Next (no changed to the Apply Aggregate Sampling dialog). 15. Check the Apply SQL Post Processing option. Select Count in State query, returns Count of Occurrences, Tag Value. 16. Click Finish. The data shows each of the faults that occurred in the window of time specified by the start and end date times in the selected Time Period item (OEE Drop Time Period) and the respective number of occurrences for each fault. Allen-Bradley 35 of 74

36 Second History Function Call 17. Continuing on from the previous section, first click on Cell A Add a new function call (Add-Ins > VantagePoint > Insert Function) 19. Ensure History is selected. If not, select it. 20. Click Next. 21. Select Tags2 in the Range column. In the Range Details section below, we can see that this range contains the fully qualified name of the tag selected earlier (StateName). 22. Click Next. 36 of 74

37 23. On the Time Selection dialog, select the Use this Range option. Select TimePeriods2 in the Range column to reuse the previous Time Period selection. 24. Click Next. 25. On the Data Options dialog, ensure Skip advanced options is not checked, then click Next. 26. Click Next on the Sampling Options dialog. 27. Ensure Apply SQL Post Processing is checked. This time select Sum In State query, returns Sum (Duration) (seconds), Tag Value. Allen-Bradley 37 of 74

38 28. Click Finish. 29. This time the data shows the faults that occurred within the selected window of time and the duration in seconds each of the faults was on. Note: We have taken the data returned from the History functions and re-formatted it in tables provided in columns F and G. This information will be used in the next exercise to create some report charts 38 of 74

39 Adding Report Charts 1. Select the Report Charts sheet. You will see that some formatting has already been completed. 2. Select Cell A4. Click on the Insert tab in the ribbon. Click Pie > Pie in 3D as shown below. Allen-Bradley 39 of 74

40 3. Note that the Design tab is selected automatically in the ribbon. Click Select Data. 4. For the Chart data range field, click the browse button. Select sheet Report Data, Cells F1 to G6 and press the Enter key. 40 of 74

41 5. Click OK. Drag the pie chart to the left and resize it so that the top-left corner is at around A4 and the bottomright corner is at around G Click Cell H4. Add another pie chart (Insert > Pie > Pie in 3D). 7. Click Select Data. 8. For the Chart data range field, click the browse icon. Select sheet Report Data, Cells F11 to G16 and press the Enter key. Allen-Bradley 41 of 74

42 9. Click OK. Drag the second pie chart to the right and resize it so that the top-left corner is at around H4 and the bottom-right corner is at around N16. These report charts show both the occurrence frequency for each given type of fault in addition to showing the accumulated amount of time that a given fault occurred over the timeframe being analyzed. 42 of 74

43 Adding Purchase Order Information from a SQL database You wish to add some data about recent purchase orders to your report. A power user has created a SQL query item in VantagePoint and has provided you with its Fully Qualified Name (FQN). 1. Select the Purchase Orders worksheet and click on Cell A4. 2. Launch the Wizard Add-Ins > VantagePoint > Insert Function. 3. Select Database Query and click Next. Allen-Bradley 43 of 74

44 4. Navigate to System.Sources.Db.MsSql.IncuitySample.Queries. Double-click on MostRecentPOs to select it. 5. Click Next. 6. You will see the actual SQL query that will be performed. At this point, you could edit the query or run a test to see the results of the query when it is executed. Click Next 7. Click Finish. 44 of 74

45 Publishing it to the Portal When creating a report, most times there are worksheets created for internal calculations that you do not want to display as part of your published report. These worksheets can be hidden so they do not show when published. 1. Select the Report Data worksheet, then right-click and select Hide from the menu. 2. Similarly, hide the Parameters worksheet. 3. In the Report Charts worksheet, select Cell A1. Click on the Add-Ins tab in the ribbon. Click VantagePoint > Publish. 4. Select the A report with no parameters option. Click Next. Allen-Bradley 45 of 74

46 5. In the model browser, navigate to MyEnterprise.Public.Management.Plant Manager AA. In the Name field, enter Oven 2 Machine State By Frequency and Duration. 6. Click Next. 7. Check the Browse to published report option. 46 of 74

47 8. Click Finish. The published report launches in the VantagePoint Portal. Other users can now view your report by just connecting their web browser to the VantagePoint Portal. The Frequency chart shows that the Machine Faults (Blocked and Starved) happened very infrequently compared to the other faults. The Duration chart shows that the Machine Faults were on for longer periods of time compared to the other faults showing that this might be the key area to focus on first to improve overall machine performance. Note that you can click the Purchase Orders tab to view that report as well. 9. Close Internet Explorer. Close Excel. You do not need to save the report. Allen-Bradley 47 of 74

48 Lab: Creating a Template Excel Report In this lab the participant will create an Excel report that is tied to a VantagePoint type. This allows for the report to be run against any item in the VantagePoint model of the same type. In our example, we will build an oven report. The lab steps through selecting a default item (in our case, Oven 1) and VantagePoint automatically detects the type (in our case, RSSamples.Model.Equipment). When the report is published, other items in the model built using the same type will be selectable from a drop-down list on the left. Once a new item is selected, the report can be re-generated against the selected item. Getting Started and Retrieving Historical Data You are Engineer BB in this scenario. You have been asked to build a Template Report showing an oven s total time, available time, running time and down time for the last half hour. You understand how VantagePoint Template Reports work so you build a single report using the Equipment type. Once this Template Report is built, you or anyone else can re-run this report against any oven in the model. The default item choice is arbitrary (the type is not!) but you choose to start with Oven Start Microsoft Office Excel Open C:\Class Files\Excel Report2 Template.xlsx. Verify workbook appears as follows. 3. Click cell A1. Click the Add-Ins tab in the ribbon then from the VantagePoint menu, click Insert Function. 48 of 74

49 4. In the dialog that appears, select History from the Option list. Check the Use advanced Type Mapping features option checking this option means that you are about to build a Template Excel report, based on a specific Type. 5. Click Next. 6. Click Items that contain Core.Tags. In the model browser on the left, navigate to MyEnterprise.[BestForYou Foods Inc.].Sites.Los Angeles CA.Areas.Baking.Lines.Line 1.Equipment.Oven 1. Note that the selected VantagePoint type was automatically identified as RSSamples.Model.Equipment. We are building a Template Excel report using this Type and Oven 1 is our default item. 7. Click Next. 8. Click Next. Allen-Bradley 49 of 74

50 9. Click Next. You should now be at this screen. 10. Select the node KPIs below Oven 1. In the items pane below, find the DownTime tag and double-click it to add it to the list on the right. 50 of 74

51 11. Similarly, add these tags in this order first, RunningTime, then AvailableTime, and finally TotalTime. Confirm all four of these items are listed on the right. 12. In the model browser on the left, expand the KPIs node and click on Context tags. In the items pane below, double-click the Grouping by one value Context Tag to add it to the list as well. Allen-Bradley 51 of 74

52 13. Click Next. 14. Check the Make this an External Parameter when published option. In the Name field, enter Selected_Oven you must use this exact name for the report parameter in order for the upcoming labs to work! 15. Click Next. 16. Change the time period selection to Last 30 Minutes. 52 of 74

53 17. Click Finish. Note that we have already added formatting in columns F and G by taking the values in column C and converting from seconds to a time format of hh:mm. Allen-Bradley 53 of 74

54 Adding a Report Chart 1. Select worksheet Report Charts. 2. In Cell A4, enter the formula =Parameters!A1 and press the Enter key. We are grabbing the fully qualified name of the selected oven from the Parameters worksheet. 3. Select cell A6. Click on the Insert tab in the ribbon. Click on Bar and select Clustered Bar. 54 of 74

55 4. Click on Select Data. 5. Click the browse button. Select worksheet Report Data, Cells F2 to G5 and press the Enter key. Allen-Bradley 55 of 74

56 6. Click on the Switch Row/Column button and then click OK. 7. Resize the bar chart so that the top-left corner is at around Cell A6 and the bottom-right corner is at around I of 74

57 8. In the bar chart, right-click on one of the 4 bars and select Add Data Labels. 9. Right-click on one of the 4 bars again and select Format Data Series. Allen-Bradley 57 of 74

58 10. Move the Gap Width slider all the way to the left. We want no spaces between the bars. 11. On the left, click on Fill and select the Vary colors by point option. Click Close. 58 of 74

59 12. Right-click on the legend and select Delete. 13. Hide all worksheets except the Report Charts worksheet to hide a worksheet, right-click on the worksheet name and select Hide. 14. Click on Cell A15. Publish this report (Add-Ins > VantagePoint > Publish). Allen-Bradley 59 of 74

60 15. Ensure A report with parameters is selected. 16. Click Next. 17. Click Next. 18. Browse to the folder MyEnterprise.Public.Engineering.Engineer BB. Name the report Oven Efficiency Template Report you must use this exact name for the report and you must publish it to this exact location in the model in order for the next few labs to work! 60 of 74

61 19. Click Next. 20. Check the Browse to published report option and click Finish. The published report launches in the Portal. In the Parameters tab on the left, note that Oven 1 is selected by default. Also, note that in the report itself on the right, the fully qualified name (FQN) is that of Oven Now change the drop-down list selection to Oven 2 and click the Generate Report button. Note that the FQN in the report has changed to that of Oven 2. Additionally, note that the report has now refreshed with data for Oven Close VantagePoint Portal. Close Excel (do not save the Excel workbook). Allen-Bradley 61 of 74

62 Using Dashboards to Monitor and Improve Business Performance Lab: Viewing a Dashboard in the Portal In FactoryTalk VantagePoint, you can create rich and interactive dashboards to enable yourself and others to monitor Key Performance Indicators (KPIs) and take action if the KPIs are unfavorable or appear to be deteriorating. You can create drilldowns to other VantagePoint reports by linking to them and passing in different parameter values. Getting Started You are Engineer BB. In the previous lab, you created a Template Excel report. In effect, that report accepts an oven as a parameter. Engineer CC has created a dashboard showing an overview of Line 1 with OEE values for Oven 1 and Oven 2. In the dashboard, Engineer CC has included drill-down links to a specific Excel report (this is the Excel report created in the previous lab) and passes in either Oven 1 or Oven 2 depending on which of the two links the dashboard viewer clicks. Once you have this working, Engineer CC and you intend to present this to Plant Manager AA so more users can access this dashboard and/or potentially create their own dashboards. Launching the Portal 1. Launch VantagePoint Portal (Start > All Programs > Rockwell Software > FactoryTalk VantagePoint > Portal). 2. In the navigation menu at the top, click Reports > MyEnterprise. 62 of 74

63 3. Note that under MyEnterprise > Public you see all the reports you have created so far (you may have to scroll down or close the folders above Public such as in the below graphic). In the real world, you would set security so users see only what they have access to in the VantagePoint model. You may click on these reports to view them. Viewing the Dashboard 1. Continuing on from the previous section, in the model browser, navigate to MyEnterprise.[BestForYou Foods Inc.].Los Angeles CA,Areas.Baking.Lines.Line 1. OEE Dashboard. Allen-Bradley 63 of 74

64 Linking to a Report and Passing in a Parameter Value 1. Click on the Details link for Oven 1. This link is configured to pass Oven 1 as the selected piece of equipment. 2. This should link to the report you created in the previous lab with Oven 1 already selected. 64 of 74

65 3. Close this window. 4. Now click on the Details link next to Oven 2. This link is configured to pass Oven 2 as the selected item. This will link to the same report, but instead showing data for Oven Close this window and VantagePoint Portal. Allen-Bradley 65 of 74

66 Integration of Alarm Information Lab: Leveraging FactoryTalk Alarms and Events In this lab the participant will add in several Alarm History Reports to the BestForYou Foods Inc. UPM. In our lab exercises so far, we started by looking at a high level KPI to determine how our manufacturing operation was performing. Upon investigating a drop in our KPI, we have developed several Ad Hoc diagnostic reports that helped us narrow down the scope of the potential root cause. We now want to augment the existing reports by tying in our controller based alarm information. Viewing FactoryTalk Alarm and Events (FTAE) Reports in VantagePoint In this lab, you are the Plant Manager (Plant Manager AA). The controls engineering team has just completed work on adding a series of device alarm instructions to the controller programs on Line 1. Your senior engineer (Engineer BB) has configure the FTAE Alarm server to log the alarm history information in a SQL database and has developed a series Alarm History Reports that you now need to integrate into the overall reporting solution. Getting Started 1. Launch the VantagePoint Portal (Start > All Programs > Rockwell Software > FactoryTalk VantagePoint > Portal). 2. Select BestForYou Foods from the Reports menu 3. Navigate to MyEnterprise.BestForYou Foods.Reports.Alarm Reports and select the report FTAE Alarm Frequency. 66 of 74

67 This is one of several reports that help evaluate alarm history information. The chart shows the top 10 most frequent alarms over the selected time period (default is last hour). The table on the lower right shows the detailed alarm events for the selected bar in the chart. Clicking on a different bar will result in updating the table with the detailed alarm events. Try clicking on different alarms (red bars) to verify. Allen-Bradley 67 of 74

68 4. In the report list, select FTAE Alarm Distribution. This chart gives you a perspective of how the top 10 alarms have contributed to the overall number of alarm events and alarm durations during the specified period. 5. Next, select FTAE Hourly Alarms. This report shows you the number of alarm events per hour over the selected time period (default is last 24 hours) both in a trend and a table format. Note that your actual display data may appear different than when the below graphic was made. 68 of 74

69 6. Next, select FTAE Alarm Duration. This report shows the top 10 alarm events based on duration (versus frequency). This information is shown as a bar chart and in tabular format. 7. Experiment with these and other Alarm Reports as desired. Close VantagePoint Portal when ready to continue with next section. Allen-Bradley 69 of 74

70 Lab: Creating Type Rules to Associate Reports with a Type There are two kinds of Type Rules in VantagePoint Content Type Rules and Container Type Rules. These pertain only to the way in which the model appears in the VantagePoint Portal. A Content Type Rule specifies that a set of reports is to be attached to any item in the model (when viewed in the Portal) of a given type. For example, we may want a Tank Summary report to automatically be attached to all Tank items in the model or we may want a Batch Details report to be attached to all Batch items in the models. A Container Type Rule specifies that all items of the given type are to be treated as a container node in the model when viewed in the Portal. Generally, all items in the model that are not folders or for which there are no Container Type Rules defined are not displayed in the Portal. We have already defined the Container Type Rules for our BestForYou Foods application. Creating the Content Type Rules 1. Launch VantagePoint Manager. 2. Navigate to System.Applications.Portal.Settings.ContentViewer.ContentTypes.RSSamples.Model.Line.ViewableCont ent. Notice that we already have content type rules defined for an Alarm Summary and an OEE Dashboard. We are going to add some additional Content Type reports to the RSSamples.Model.Line definition. 70 of 74

71 3. Right-click on ViewableContent below RSSamples.Model.Line and select New > Item. 4. Select Portal.ViewableReportContent. 5. Click Create. 6. For the Name and DisplayName fields, enter Hourly Alarm Counts. Click the browse button next to the Report field. Allen-Bradley 71 of 74

72 7. Navigate to MyEnterprise.BestForYou Foods - Reports.Alarm Reports and select FTAE Hourly Alarms. Click Assign. 8. Click Create to complete the operation. 72 of 74

73 9. Launch VantagePoint Portal. 10. From the menu, click on Reports > BestForYou Foods. 11. Notice that in our model, each item that is of type RSSamples.Model.Line now has an Hourly Alarm Counts report assigned to it (Baking - Lines 1 and 2, Filling - Lines 1 and 2, etc.). 12. Select the Hourly Alarm Count under the Line 2 node. 13. Close VatagePoint Portal and Manager This lab is complete Allen-Bradley 73 of 74

74 Publication XXXX-XX###X-EN-P Month Year 74 of 74 Copyright 2011 Rockwell Automation, Inc. All rights reserved.