Process Automation Integration

2. Process Automation Integration Utilizing ABB’s 800xA and OPC

3. The Integrated Plant System Delivery Confirmation Rescheduling B2B / B2E Customerorder Inventory Maintenance Purchase order Scheduling Customer - Supplier Internet ERP / EAM Analysis and Optimization AIP Material refill Alarm or Incident Production data Plant status Automation equipment / Production

4. IFS Maintenance Aspect System AIP/800xA as an Integration Platform Fault Report Active WO Object Info OEE Aspect System Aspect Integrator Platform / 800xA Aspect System Process Portal Asset Optimization

5. Asset Cost Reduction • Information Availability • Seamless navigation between different information systems Work order history Business performance Active work orders Equipment data sheet Equipment cost analysis Electrical diagram OEE P&I Diagram

6. LU LU LU 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 Database

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.

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 PDAevent Operator input Direct input Monitoring PM / WO Event Asset Monitors Detection Collecting data from field devices PM Event Alarms / Events IFS WO/ PM module Parameters Operational hours, etc. Predictive maintenance

9. Maximum performance Real performance (OEE) Maintenance, Engineering and Procurement costs $ Time Overall Equipment Efficiency • It’s all about how to increase profit through cost reduction activities as well as real performance enhancements! Lost profit

10. How is production capacity used? Total available time Planned stop time Planned stop time Planned production time A Unplanned stop time Available operating time P Reduced speed Net operating time Q Quality losses Value adding operating time

11. OEE Database Overall Equipment Efficiency– Without automation integration Manual OEE Data acquisition leads to poor quality of the OEE index! Availability Manual registration- If remembered! Performance An event occurs:- Start/Stop - Speed change - Quality loss Yield (Quality rate) OEE index = Availability x Performance x Yield

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 processequipment Start / Stop - events OEE Webportlet OEE Database Speed change - events Quality losses

13. Level 1: Connectivity DemoIntegrated Plant System

14. Asset Information –Demands, Spare parts, Inventory

18. Work Order Planning

21. Document Management

25. Fault Reporting

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