Wonderware MES 2012 Quality Management

2. Wonderware MES 2012Quality Management Session Name: Wonderware MES Quality Management Session ID #: PBWW213 Presented by Jeff Barkehanai November 9, 2011 Invensys proprietary & confidential

3. Invensys Enterprise Control Offerings Corporate Systems Industry Solutions Services: Consulting, Project Execution, Learning, Operational Improvement, Maintenance & Support Partner Ecosystem Corporate Software Applications Invensys and Third Party Manufacturing / Production Operations Automation Invensys and Third Party Enterprise Control System IT Platform Integration and Collaboration Platform

4. Where The Offerings We Will Discuss Fit Within TheInFusion Enterprise Control System Execution Integration & Collaboration Platform Enterprise Asset Management Mobile Workforce Management Manufacturing Execution Systems Batch Performance Software Applications Enterprise Manufacturing Intelligence Asset Performance Performance Measurement and Reporting Enterprise Integration Visualization Quality Optimization Workflow Advanced Process Control Simulation / Optimization Design Operator Training Third-Party Offerings Open Device Integration Web Portal Control Automation Software Applications DCS PAC SCADA HMI Application Toolkit Safety Turbomachinery Control Safety Instrumented Systems General Purpose Safety Historian Measurement & Instrumentation Recorders Instrumentation Controllers

5. Quality in business context • Quality in business, engineering and manufacturing has a pragmatic interpretation as the non-inferiority or superiority of something. Quality is a perceptual, conditional and somewhat subjective attribute and may be understood differently by different people. • Consumers may focus on the specification quality of a product/service, or how it compares to competitors in the marketplace. Producers might measure the conformance quality, or degree to which the product/service was produced correctly. • Source Wikipedia - http://en.wikipedia.org/wiki/Quality_(business)

6. Quality (Management) • Deming defined Quality using these terms: "Costs go down and productivity goes up, as improvement of quality is accomplished by better management of design, engineering, testing and by improvement of processes. - Better quality at lower price has a chance to capture a market.- Cutting costs without improvement of quality is futile.“ • Sources:MESA - http://www.mesa.org/en/modelstrategicinitiatives/QQR.aspWikipedia - http://en.wikipedia.org/wiki/W._Edwards_Deming W.E. Deming – Pioneer in QM and TQM

7. Relevance of Manufacturing Execution Systems to Quality (Management) • Considering MES as an Software/IT based approach in Manufacturing Operations Management (MOM), it helps to: • Increase the level of automation in operations data and information management • Reduce errors and variation (waste), • Improve resources utilization (productivity, efficiency) • Facilitate continuous improvement Reduced errors and improvements,lower variation and tolerance Reduced waste, better resource utilization

8. Wonderware MES/Operations management • Production execution and resource management • From a Quality management perspective generic MES Functions contribute to: • quality planning, control, assurance and improvement Inventory Certifications Labor Management Procedure Steps Specifications / Parameters Download Production Events Tracking Data Collection Bill of Materials Work Order Execution

9. Wonderware MES/Performance management • Production equipment utilization and performance monitoring • OEE provides a high level KPI monitoring of asset utilization: • Computes quality as relative good/overall as one OEE equation factors OEE = availability* performance * quality • by equipment, Work Order, product and product class and shift/day/week… Overall Equipment Effectiveness (OEE) Equipment utilization – Downtime tracking Work Order Execution

11. Wonderware Quality Software • The presentation discusses the current and upcoming software products that manage operations quality initiatives within a company • Wonderware QI Analyst software – Existing SPC software • Wonderware MES/Quality Management – New upcoming functionality enhancing Wonderware MES software

12. QI Analyst

13. Overview • The Wonderware Quality Information Analyst (QI Analyst) offering focuses on Statistical Process Control (SPC) of process and product characteristics. • Results are immediately evaluated for control rule violations and alarms are indicated to the operator or others through Alarm controls in the HMI application, SPC Charts, or email. • The data can be recorded within the system or come from an external source.

14. What is it? • Wonderware QI Analyst Software • Version 8.0 SP2 released in May 2011 • Licensed by seat or concurrent user • Components Delivered • Standalone Configuration Module • QI Controller • Standalone Workstation • QI Workstation • Control Rule Violation Monitor • QI Chart Service • ActiveX Controls • SPC Chart • Chart Service Viewer

15. What is new? • Support of latest OS (Win 7 SP1 / Win 2008 R2 SP1) • Support of latest DBMS (SQL Server / Oracle) • Rollup of hotfixes since December 2008 release + over 50 customer reported issues

16. Roadmap for QI Analyst • Mature Product • Will continue as a supported product for many years • Hotfixes are still available for the product • No new features are being added to the product • Next Release • Will be considered for 2013 • Rollup of hotfixes • New OS / DBMS / System Platform support

17. SPC Charting, Monitoring & Analysis • Configurable Multi-charts • Standard Charts • Variable Charts • X-bar & Range or Sigma • X-Individual & Moving Range • Moving Average & Range or Sigma • Cusum of Means or Individuals • EWMA of Means or Individuals • Attribute Charts • p, np, c, u, DPMO • Special Charts & Analysis Tools • Run, Histogram, Scatterplot • Paretos of Nonconformities, Causes, Actions or Rule Violations

18. Process Databases Chart Service and Viewer • Windows Service • ChartService Viewer • Provides green light/red light chart status indicators • Click on light indicator to view real-time SPC chart and alarm violations • Allows at a glance monitoring of a large number of critical process parameters • Viewer can be embedded in InTouch HMI or any ActiveX container application

20. Wonderware MES SoftwareQuality Management

21. Overview • The Wonderware MES Quality Management (MES QM) offering focuses on the processes and procedures for identifying, measuring, and controlling the manufacturing process. • For the MES QM implementation to be successful, the manufacturer must have a corporate quality initiative that is supported by management with policies in place that describe the desired outcome of the system. • The MES QM offering does not address the corporate quality policies, the documentation of the procedures, or the process improvement ideas. The software supports the quality initiative by managing the data, enforcing procedures, and providing SPC analysis of the results.

22. OperationsManagement PerformanceManagement Quality Management What is it? Wonderware MES software • Wonderware MES Software 2012 • Version 4.5 • Granular, scalable Manufacturing Execution System • Highly configurable standard software • Build on ArchestrA System Platform infrastructure • Flexible License offerings for combined/standalone use: • Operations Management • Performance Management • Quality Management

23. Wonderware MES 2012 granular capabilities Performance capabilities Operations capabilities Quality capabilities Equipment Utilization and Downtime Quality Specifications Sample Plan definition Overall Equipment Effectiveness (OEE) Sample Plan Execution Inventory Statistical Process Control (SPC) Procedure Steps Product Specifications / Parameters Certifications Production Events Tracking Labor Management Data Collection Bill of Materials Work Order Execution

24. Wonderware Quality Software Benefits • Tie quality operations into production for tighter control • Identify out-of-scope trends and conditions more quickly • Root cause analysis, SPC tools • Minimize waste, enable corrective and preventive actions—better customer experience, end user satisfaction • F&B companies: brand management • Functionality • Specification Management • Sample Plan Management • Sample Plan Execution • Statistical Process Control • Web-based ArchestrA Reports • Integration with External Systems (ERP, PLM) • Integration with Invensys products and Platform (InTouch, MES, Workflow, Intelligence)

25. Why? • Wonderware Manufacturing Execution Systems Customers • Requests for Quality Management Functionality in Wonderware MES software • Integration with SPC Solutions • Managing Sample Generation • Better Data Logging

26. What is New? New Functionality Delivered for Quality Management • Specification Management – definition of product and process specifications in the context of items, equipment, and operations • Sample Plan Definition – what characteristics to collect and when to collect them (e.g. time based, event based, etc.) • Sample Plan Execution – execute sample plans, collect data (manual, auto, or combination), and show status • SPC • Configurable Control Limits and Control Rules • SPC charts • Immediate Analysis and Feedback of Control Rule Violations

27. New Software Components • Components Delivered for Quality Management • MES Client Configuration Module • Sample Viewer (data grid) .NET Control • SPC Chart .NET Control • Sample Recording Object (System Platform Object) • Reporting Content

28. Characteristics • Products are manufactured with specific characteristics • Characteristics often have Specification Limits • When a consumer purchases a product with a stated weight, there are laws that dictate the allowable deviation from the stated weight on the packaging. • When producers purchase chemical reagents, they require a target percentage of active ingredient with upper and lower tolerances around the target. • When packaging a product, the manufacturer wants to ensure there are no visible defects on the packaging and that all the text is readable. • A manufacturer often tracks thousands of characteristics • Quality Manager needs a system to simplify this process

29. Sampling Strategies • Testing can be costly and/or destructive • Every unit shipped cannot be tested • Sampling strategies are used to test a subset • Sampling • Simple • Every two hours test 10 products • Every 30 units test 2 units • Complex • Conditional logic of whether the last sample taken was good or bad and then sample more frequently • The number of products tested must also be optimized

30. Production Scenario • Operator Interface • View into upcoming samples for the shift • View of current samples with Expiration / Warning / Requested times • Recording Data • Recording of when the sample was taken from the line • Manual / Semi-Automatic / Automatic data entry • Record who recorded the result, what equipment was used, and when • Immediate indication of control rule violations as results are recorded • Process Updates • Equipment downtime reflected in when next sample is required • Additional samples for specific events

31. Sampling Frequencies • Manufacturers Use Various Sampling Frequencies • Time • Calendar sampling based on duration or time of day/week/shift • Machine run time • Count • Items Produced • Lots or Batches • Event • Change in Item/Lot Produced or Consumed • Equipment State Change

32. Sample Execution • History and Context of a Sample • Sample Request and Expiration times • Operator Indicates a Sample is Pulled • Time for Each Result • User Recording the Result • Never Delete or Update a Result • Mark a Result as Superseded

33. SPC Analysis • As samples are taken, the results need to be stored and analyzed. • In-Line / At-Line / Off-Line • Results Analyzed when Data Collected • statistical process control (SPC) • Configured control rules are evaluated • Violations returned including Severity of Characteristic • Missed Samples can be Monitored • Based on Results • Notify Operator • Place Lots on Hold • Retest

34. Specification Management Sample Plan Definition Management Quality Report Management Wonderware MES Quality Mgmt Sample Plan Execution Management Statistical Process Control Lot Disposition Management Features at a Glance • Item and item class definition • Entity & entity class definition • Variable/Attribute definition • Severity • Control Limits • Specification definition • Import specifications from external source (ERP/PLM) • Quality summary • Measurement statistics • Measurement details • Sample plan definition • Sample Naming scheme • Sample plan frequency definition • Time • Count • Event • Import sample plan from external source (ERP/PLM) • Standard run rule selection • SPC Charts (X-Individual, X-Bar-R, Moving X, p, np, c, u, DPMO) • Run rule violation trigger • Additional operator data collection (comments/ causes ) • View / Record sample details • Sample collection notification • Additional sample request generation • Automatic sample collection • Change lot status* • Change routing* *These items are targeted for the second phase of the project

35. Demonstration

36. MES Client ConfigurationQuality Management Module • New Quality Management Module • Enabled through licensing • Contains all QM Specific Editors

37. MES Client ConfigurationSample Plan Frequency Class • Sample Plan Frequency class Editor • Enter Name and Description • Optional Size multiplier and Disable flag • Optional Warning and Expiration time interval • Optional Spare Fields • Frequency Type Options • Shift (Offset from start / end, time interval, and number of times) • Calendar Time (time interval) – Can have fixed time of day / minute • Entity Run Time (time interval – will use utilization data 1st else job data) • Entity Production (what to count and how many) • Data Change (item prod / cons, fg / rm lot, utilization, job info, inventory receipt, new spec, or step action)

38. MES Client ConfigurationSample Plan Frequency Class

39. MES Client ConfigurationSample Plan Class • Sample Plan class Editor • Enter Name and Description • Verified write flag • Runtime Sample naming convention and numbering reset option • Optional Spare Fields • Assignment of Sample Plan Frequencies to a Sample Plan • Must have at least one • May only have one of each type except data change type

40. MES Client ConfigurationSample Plan Class

41. MES Client ConfigurationSample Plan Class • Sample naming options • Sample Plan Name • Entity Name • Work Order, Operation, and/or Sequence No. • Segment Requirement / Segment Response • QM Specification name • Sample Plan Frequency name • Date Fields • Incremental number (Reset option for when to start numbering at 1 again) • Literal characters (fixed) • Example: SamplePlanNameYYYYMMDD##

42. MES Client ConfigurationSample Plan and Frequencies Bottle Production Sample Plan Frequencies Labeling Every 50 Inspect Shift Schedule Label Runtime Bottle Lot Change Job Change Every 500 Lab Test Bottle Runtime

43. MES Client ConfigurationCharacteristic Class • Characteristic class Editor • Variables – Results Expressed as Floating Point Number • Attributes – Results Expressed as Integer or pass/fail • Common Fields • Enter Name, Description, and Characteristic Type • Unit of Measure and Display Decimals • Filter analysis data by entity, item, job, or S95 data • Severity (Unused, Not Monitored, Non-Key, Key, or Critical) • Optional SPC Run Rule exclusions • Optional Spare Fields

44. MES Client ConfigurationCharacteristic Class

45. MES Client ConfigurationCharacteristic Class

46. MES Client ConfigurationCharacteristic Class - Variable • Common Fields – but based on selection of Variable • SPC Rule Violation Chart Type (X-Individual-Moving Range, X-Bar-Range, X-Bar-Sigma, Moving Avg – Moving Range, or Moving Avg – Moving Sigma) • Automatic data collection (and delay between measurements) • Sample Size (normal, minimum, and maximum) • Also used to indicate individuals vs. grouped data • How to obtain control limits (calculated, standards, preset) • If calculated, then number of samples to use • Variable Specific Fields • Sigma estimate options • Histogram and Goodness of Fit settings • Number of Samples for Moving Average

47. MES Client ConfigurationCharacteristic Class - Attribute • Common Fields – but based on selection of Attribute • SPC Rule Violation Chart Type • Binary Attribute (p or np) • Counted Attribute (c, u, or DPMO) • Automatic data collection • Fixed Sample Size OR Variable Sample Size (minimum and maximum) • For Variable, if it is copied from previous value or not • How to obtain control limits (calculated, standards, preset) • If calculated, then number of samples to use • Counted Attribute Specific Fields • Number of Defect Opportunities OR • Text Value Associated with Integer (List Variable)

48. MES Client ConfigurationQM Specification Class • QM Specifications class Editor • Enter Name, Description, and Version number • At least One (1) of the following context fields • Entity / Entity Class • Item / Item Class / Parent Item Class • Process and Operation • Default Sample Plan • Default Number of Samples per page for SPC chart • Optional Start effectivity date and end effectivity date • Optional SPC Run Rules to use • Optional Spare Fields

49. MES Client ConfigurationQM Specification Class

50. MES Client ConfigurationQM Specification Class • Assigning Characteristics • Enter Required Target • Optional Upper and/or Lower Specification Limits • May be multiplier of Target (Percent or fixed value) • Optional Reasonable Limits • May be Absolute or Multiplier of Specification Limit • Override for Sample Plan • Override for Severity • Override for Sample Size • Override for Control Limits • Override for Chart Type • Override for Automatic Collection