Unleash the Power of Data Collection

1. Unleash the Power of Data Collection Ron IannaconeFactory Intelligence Network LLCMay 7, 2003 423 Commerce LaneSuite 6 W. Berlin, NJ 08091Phone: 888-405-4017Fax: 856-767-4638 www.FactoryIntelligence.com

2. Unleash the Power of Data Collection

3. What is Data Collection? • What data collection is NOT! • PLC – PLCs execute programs and are not designed for long-term data storage • HMI – Designed to provide operator interface • Chart recorders – limited in # of points and duration of storage • Meters, Counters, Instruments – limited # of points and duration of storage • Pad & Pencil • Asking what happened after the fact

4. What is Data Collection? • What data collection IS! • Continuously monitor many data points • Long-term storage of data • Information easy to retrieve and use • Some examples of data collection • WonderWare InSQL, OSI Soft’s Pi, Rockwell, GE, Genesis etc. • FIN

5. Why Data Collection? • Why do I need data collection? • Knowledge is power! • Stuff fails • If it rotates, it will break • Production equipment is more complex than ever • More work – fewer people • Accurate information helps you do your job better • Data is the information that supports decisions • Talented personnel + reliable data is the key to reducing downtime • Continuous monitoring means you don’t miss an event

6. Unleash the Power of Data Collection • Data collection software stores information so you don’t have to! • Access data easily - only when you need it • Monitor key conditions regularly Avoid information overload!

7. Data Collection & Downtime How can data collection reduce downtime? • It’s 4:00 AM and you walk into the plant and ask, “What was the line speed before it went down?” “In God we trust… all others must use data.” - W. Edwards Deming • With data collection you can: • Analyze conditions before an event occurred (1 sec., min., hr., day) • Trend multiple points simultaneously (speeds, temps, switches etc.) • View historical data from your plant and others around the world. • Reduce the time required to assess causes and provide solutions!

8. Roll 1 Speed Measurement Fault @ 1:02 AM 8-25-02 Roll 1 Speed Example 1

9. Roll 1 Speed Measurement Fault @ 3:02 PM 8-25-02 Roll 1 Speed Oscillations Roll 1 Speed After Tuning Example 1

10. Roll 1 Motor Temperature 4-2-03 Example 1

11. Example 2 Roll Temperature Hitting Gap Open PB Hitting Gap Close PB

12. Gap Position Gap Position Changing Example 3 Gap Close PB

13. Example 4

14. Preventative & ProactiveMaintenance Data collection plays a vital role • Monitor critical bearing, & motor temperatures • Detect control loops and other equip. performance • Analyze motor current, speed, & faults • Watch plant air and/or hydraulic pressures as well as other process parameters

15. Reasons forData Collection • Reduce downtime • Detect performance/process degradation • Focus maintenance only on equipment needing service • Schedule shutdowns based on data • Correlate product quality with equipment condition

16. F.A.Q.’s Is data collection expensive? • No! It doesn’t have to be ! Our product FIN is affordable How do I collect the data? Won’t I have to rewire my equipment? • Most of the data you may need may already be in your existing PLCs I have many different PLCs. Some equipment doesn’t have a PLC ! • FIN can talk with virtually any PLC. FIN handles non PLC based equip. with Ethernet I/O modules. It can collect data from scales, temperature or process controllers, even HMI packages like Wonderware, etc. We’re too busy to configure the system, will we need an integrator? • FIN is one of the only data collection packages that comes fully configured and works out of the box. Our engineers even do a plant audit to determine your needs.

17. Additional Information Thank You for Your Time! Visit Us at Booth 416 toSee FIN in Action