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The Best of the Best: Wonderware Conference 2015 eBook
1. The Best of the Best: Wonderware Conference 2015
Schneider Electric
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Great Power.
Great Possibilities.
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03.Wonderware Delivers on Promises
04. Applying the Internet ofThings
06.Video: Pima CountyWastewater Reclamation Success Story
07.Video: Wonderware Operations Integration Solutions: Connectivity, Scalability, Uptime, IoT
08. 7Tips to Make the Right SCADA Choice
10. Schneider Electric ReleasesWonderware Alarm Adviser SP1
11. Improving Productivity at Nomacorc
13. Information Access and Mobility
15. Getting Intelligence fromYour Big Data
17.Video: Inside Campbell’s Global Quality Rollout
18. StructuringWorkflows to Improve Production
20. Optimizing Asset Performance
22.Video: F&N Dairies UsesWonderware Operations Management Solutions
23.WonderwareTakes Center Stage
Table of Contents
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AtSchneiderElectric’ssoftware-focusedconferencelastyear,Ravi
Gopinath,executivevicepresidentofthesoftwarebusiness,putforth
apledgeofgamechangersthatwouldresultfrommergingInven-
sys’ssoftwareofferingswithSchneiderElectric’sportfolio.They’ve
spentthepastyeardeliveringonthosepromises,transformingthe
industrialsoftwaremarketwithleadingtechnologiesandbuilding
astrongportfoliowithstrongpenetrationrates,saidTomComstock,
vicepresidentofmarketingforSchneiderElectricSoftware.
“We’realreadydeliveringvaluetoourcustomersacrossevery
importanttechnologyfrontierthatapplies,”Comstocksaid,point-
ingto11customerpresentationsattheWonderwareConference
takingplacethisweekinDallas.
Comstockemphasizedtechnologiesinanumberofareas,including
thecloud,mobility,situationalawareness,industrialBigData,asset
performancemanagement(APM)andsocial/collaboration/workflow.
SchneiderElectriccommittedlastyeartogrowingitsindustry
base,addedRobMcGreevy,vicepresidentofinformation,assetand
operationssoftwareforSchneiderElectricSoftware.“Ourcontinued
investmentinboththemanufacturingsectorandinfrastructure
doescontinue,”hesaid.“Butwe’realsofocusingoncreatingmore
verticalization.”Thatmeanscreatingmorepackagedsolutionsfor
specificindustries,makingiteasierforcustomerstoapply.
McGreevy’ssideofthebusinessisseeingafewkeytrends,he
said,includingcontinuedsignificantinvestmentaroundinforma-
tionaccessandmobility,withpervasivemobilitybeingrequiredby
alltypesofusers;enterpriseAPM,withmorerecentemphasison
predictivemaintenanceandthecompany’snewpredictiveanalytics
tool,AvantisPRiSM;andtransformingmanufacturingoperations.
Withregardtotransformingmanufacturingoperations,McGreevy
pointedtothesignificantincreaseinmergersandacquisitionswithin
thefoodandbeverageindustryinparticular.“There’sanecessityto
integratealltheseplantsandsitestogether,”hesaid.“Ifyou’redoing
consolidation,youhavetomarryERPwithMESinamuchmore
tighterwaythaneverbefore.ThatmeansmoreIT/OTconvergence.”
WithWonderwareDevelopmentStudioOnline,Schneider
Electrichasbeentakingitsengineeringtoolsandputtingthem
intothecloud,notedNormThorlakson,globalheadofSchneider
ElectricSoftware’sHMIandsupervisorysoftwarebusiness.
Easeofusehasbeenatthecoreofdevelopmentonnext-gener-
ationsupervisorysystems.“Weneedtomakeouroffersaccessible,
usableandattainablebymorepeople,”Thorlaksonsaid.“WhatRob
[McGreevy]isdoingforfoodandbev,we’realsogoingtobedoing
withwater,oilandgas,infrastructureandmining.”
ThereisalsoastrengthenedemphasisthisyearontheWonder-
warebrand,achangethatisbeingwelcomedbycustomersand
partnersinthisspace,whichComstockpointedtoaspartofthe
WonderwareteamandWonderware“stateofmind.”
TherenewedemphasisontheWonderwarebrandisnoaccident,
accordingtoPhilCouling,directorofHMI/supervisorysoftware
productmarketingforSchneiderElectric,whosaidthebrand
hadadmittedlybeendilutedbytheInvensysmessage.Butsince
InvensyswasacquiredbySchneiderElectriclastyear,“we’vebeen
gettingtheWonderwarebrandbackoutinfront,”hesaid.
Aspartofthat,they’rebringingbacktheWonderWorldTour,with
aNorthAmericanstopinOrlandoalreadyscheduledforOctober
2016. £
Wonderware Delivers on Promises
N E X T A R T I C L E
ApplyingtheInternetofThings
Emphasizingkeydevelopmenteffortsinmobility,industry
verticalization,easeofuseandmore,executivesfrom
SchneiderElectricSoftwaredetailadvancesintheproduct
portfolio.
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Whatcouldyoudodifferentlyifthecostofsensingandcommu-
nicationreachedzero?ThisisthequestionAndyRobinsonofAvid
SolutionsaskedatthestartofhissessionattheWonderware2015
ConferenceaddressingtheuseofWonderwareSystemPlatformin
InternetofThings(IoT)applications.Hisquestionisnotafanciful
what-ifproposition;itisafast-approachingrealityasinterestin
IoTdirectlyinfluencesthelevelofInternetconnectivitythroughout
industryand,therefore,thecoststoconnectsystemswithinaplant
andacrosstheglobe.
HanuKommalapati,seniordirectorofprogrammanagementat
Microsoft,alsospokeattheconferenceaboutextendingindustry
capabilitieswiththeuseofIoT.Inhissession,heexplainedhow
technologieslikeWonderwareSystemPlatformandMicrosoft
Azurearemakingiteasyforindustrialcompaniestotestand
employIoTapplications.
Kommalapatibeganbysayingthedriverheseesbehindindus-
try’sinterestinIoTisnottheappealofthetechnologyitself,but
thefactthat“anybusinessthatknowsitselfcanbemoreproactive.
Businessesareseekinggreaterselfawareness,”hesaid.
IntermsofrealworldIoTapplications,Kommalapatisaidthat
companiestendtodeploytheseprojectsinaphasedapproach.“In
thefirststage,theyconnecttothecloudfortelemetry—tomoni-
torandtrackthedevicestateandcreatebasicrulestoimprove
operationalefficiency,”hesaid.“Thenextstageinvolvesbusiness
intelligence—analyzingandvisualizingthedatacollectedfrom
devicestodiscoverpatternsusingpredictiveanalyticsandopera-
tionalizingthoseinsightstoimproveprocessesinrealtime.”
JustasinterestinIoTischangingindustry,Kommalapati
explainedthatitisalsochangingMicrosoft.Toillustratethishe
highlightedthevariousversionsofWindows10IoT—whichrange
fromWindows10IoTCoreforsmalldevices,toWindows10Mobile
Enterprisefordevicesrangingfromsmartphonesandtabletsto
barcodereadersandotherhandheldmobiledevices,toWindows
10IoTEnterpriseforindustrialorcommercialdevicessuchasrobot-
icssystems,OEMmachinery,andmedicaldeviceequipment.
ShiftinghisfocustoMicosoft’sAzurecloudserviceandhowit
supportsthestagesofIoTimplementation,Kommalapatisaid
thatAzure’sEventHubssupportglobaldeviceconnectivityand
managementinthecloudusingahigh-scaletelemetryingestion
servicewithHTTP/AMQPprotocolsupport,whichpermitseach
EventHubtohandleupto1millionpublisherswith1GB/sec
ingressandmanage60+terabytesofdataaday.“Ifyourdevice
platformisnotcurrentlysupported,”addedKommalapti,“youcan
useafieldgatewayandevent-to-protocoladaptertotranslatethat
device’sdatatotheEventHub.”
Withthismuchdatagoingintothecloud,securityisanobvious
concern.KommalapatisaidthisiswhyMicrosoftisdevelopingthe
AzureIoTSuitewhichcansupporttheconnectionofmillionsof
devices,handletheirtelemetry,andprovidecommandandcontrol,
deviceregistryandidentification.HeaddedthattheAzureIoTSuite
Applying the Internet of Things
N E X T A R T I C L E
Video:PimaCountyWastewater
ReclamationSuccessStory
AsWonderwareandMicrosoftextendtheirproduct
capabilitiesforInternetofThingsapplications,launching
theseinitiativesacrossindustryaregettingeasierandeasier.
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willalsosupportMQTT(MessageQueueTelemetryTransport),
whichhappenstobeoneofAndyRobinson’spreferredmethodsof
usingWonderware’sSystemPlatforminIoTapplications.
RobinsonexplainedthathelikesMQTTbecauseofitslightdata
use(headersareonly7bytes),useofTLSandlackofanincoming
connectiontoclientforsecurity,itsthreelevelsofqualityofservice,
plusthefactthatitisanacceptedOASISstandard.Inhissessionhe
alsopointedoutthatMQTT,comparedtoHTTP,is93xfaster,uses
12xlessbatterypowertosenddata,uses171xlessbatterypower
toreceivedata,anduses8xlessnetworkoverhead.
MovingbeyondtheinitialIoTimplementationstageofdevice
connectivity,KommalapatitouchedonhowMicrosoft’sAzure
StreamAnalytics,HDInsightandMachineLearningleverage
Hadoopforstoringandanalyzingdataacrosshundredsoreven
thousandsofnodes.Forpresentationofthesesystems’dataand
businessconnectivitytoit,hehighlightedtheroleofMicrosoft
DynamicsandBizTalkservices.
ConsideringallthatKommalapatiandRobinsondiscussedin
theirpresentations,thecloselinksbetweenWonderwareand
Microsoft,andtheongoingIoT-relatedadvancesmadebythe
twocompanies,forcompanieslookingtoemployIoTsolutionsto
improvetheiroperations,thenecessarytoolsarenowavailable
andbecomingeasiertouse. £
AndyRobinsonofAvidSolutionspreviewshissession
scheduledforWednesdayat9:30am(WaterfordA/B)
inthisvideowherehediscussesunderstandingcore
InternetofThingsconceptsandhowtointegrate
themintotheWonderwareSystemPlatform. £
N E X T A R T I C L E
Video:PimaCountyWastewater
ReclamationSuccessStory
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UsingahighperformanceHMISCADAsolutionbasedonSituationalAwarenessandamobileworkforceand
decisionsupportsystem,thePimaCountyRegionalWastewaterReclamationDepartmentprovidesmanagement
andmaintenanceofthecounty’ssanitarysewersystem. £
Video: Pima County Wastewater Reclamation
Success Story
Situational Awareness--Complexity Made Simple
Make decisions at the speed of your process. Better HMI designs
provide true“Situational Awareness,”which leads to greater operator
effectiveness and fewer shutdowns. Properly designed HMI
applications help optimize both the business value and the safety of
your system.
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N E X T A R T I C L E
Video: WonderwareOperationsIntegration
Solutions:Connectivity,Scalability,Uptime,IoT
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AnewreleaseofWonderwareOperationsIntegrationSolutions,the
nextgenerationofdeviceintegration,greatlyexpandstheconnectiv-
ityspectrumbothdowntothedatalayeraswellasuptothebusiness
andERPlayerswhichwillsupportanindustrywide,global,IoTand
Cloud-readycommunicationstrategy. £
Video: Wonderware Operations Integration Solutions:
Connectivity, Scalability, Uptime, IoT
N E X T A R T I C L E
7TipstoMaketheRightSCADAChoice
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NotallSCADAsystemsarecreatedequal.Asthebrainofyour
automatedoperations,therightSCADAsystemcaneasecommuni-
cationwithRTUsandPLCs,todayandtomorrow.
InasessionTuesdaymorningatSchneiderElectric’s2015Won-
derwareConferenceinDallas,JohnKrajewskiwilldiscusshowto
takeadvantageofthelatesttechnologyandtrendsforHMI/SCADA
(HMISCADA-02,Sept.22,9:30a.m.).
Assomewhatofapreview,herearesevenguidelinesfrom
SchneiderElectrictohelpyoumaketherightSCADAchoice.
1.Itshouldcommunicateeasilywithyourexistinghard-
ware.ManySCADAsystemsofferonlyOPCconnectivity.Butgiven
thatthevastmajorityofindustrialoperationsuseamixofold
andnewhardwarefromseveraldifferentvendors,itwouldn’tbe
surprisingtofindthatyourolderequipmentdoesn’tsupportOPC.
Ifyoudon’tensurethattheSCADApackageoffersavarietyofna-
tivedrivers,youcouldenduphavingtofindthenecessarydrivers
yourselfforyourlegacysystems,orbuyanexpensiveOPCwrapper.
2.Itshouldsupportyourneedsfortodayandinthefu-
ture.UnlimitedI/Olicensingcanhelpyouscaleforfutureproduc-
tiongrowth,aslongasyourindustrialsystemisbuilttohandleit.
MakesuretheSCADAsystemhasbeenthoroughlytestedtohandle
7 Tips to Make the Right SCADA Choice
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SchneiderElectricReleasesWonderware
AlarmAdviserSP1
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alargenumberofI/Opointstoavoidslowresponsetimesandother
problemscausedbyaSCADAsystemnotdesignedforsuchuse.
3.SCADAsoftwareshouldbealow-riskinvestment.Soft-
warethat’salow-riskinvestmentdoesnotmeansimplysoftware
thisislower-priced.TheinitialcostofyourSCADAhardwareisjusta
smallpercentageofthelifetimecostoftheequipment,andhaving
throwawaysoftwaredoesnotfurtherthatinvestment.Besureto
selectaSCADAsystemwithlargegraphiclibraries,customizable
reports,andafamiliarprogramminglanguage.
4.Supportmustbeavailablewhenandwhereyouneed
it.IfaSCADAsystemgoesdown,theconsequencescanbeserious,
rangingfromlostdatathatcanaffectregulatorycompliancetoun-
scheduleddowntimethatimpactscustomers.It’simportanttopick
aSCADAvendorthatwillprovidesupportwhenandwhereyouneed
it.Youwillalsowanttomakesurethere’salargenetworkofsystem
integratorscertifiedtoprovideregulartrainingandcoursework.
5.YourSCADAsuppliermustcontinuetobeinbusiness.
WithsuchanimportantinvestmentasaSCADAsystem,youwant
asupplierthatwillbeinbusinessforaslongasyouare.Another
considerationistheprovider’sexperienceinyourindustry.You
don’tjustneedsomeonetoinstallthesystem;youneedsomeone
whounderstandsyourindustry’sparticularneeds.
6.Upgradesshouldbesimple.SCADAsystemsmustbeable
toadapttochangingrequirementsandtechnologies,andback-
wardscompatibilityiskey.Makesureyourvendoroffersalong
historyof100percentbackwardscompatibilitytomakeupgrades
easyandprecludeyoufromhavinganorphanedsolution.
7.Securityiscritical.Therehavebeenmanyinstancesof
SCADAsystemsbeingcomprisedbyintrusions,eitherfromthe
Internetorinternalsources.Withthemission-criticalnatureofa
SCADAsystem,protectingitfromunauthorizedusersandhack-
ersisvital.Thevendor’scommitmenttosecurityisabigfactorin
safeguardingyoursystem.
FormoredetailsabouthowbesttomeetyourSCADArequire-
ments,read“7TipsforSelectingtheRightSCADASystemforYour
Needs.” £
New Series ofWonderware Industrial Computers,
InTouch Panel PC Compact Series D
New series of Wonderware Industrial Computers scales from small
footprint machine level HMI software to a whole plant supervisory
visualization solution with InTouch to enable a consistent plant
intelligence software solution across a broad spectrum of industrial
applications.
N E X T A R T I C L E
SchneiderElectricReleasesWonderware
AlarmAdviserSP1
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NewalarmanalysissoftwareforindustrialapplicationsfromSchneider
ElectrichelpsanalyzethemostimportantSCADAandHMIalarms,eliminate
nuisancealarms,andimproveoperatorawareness. £
Schneider Electric Releases Wonderware
Alarm Adviser SP1
N E X T A R T I C L E
ImprovingProductivityatNomacorc
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Manufacturingexecutionsystems(knownbytheacronymsMES
andMOM—formanufacturingoperationsmanagement)are
amongthefastestgrowingtechnologiesinindustrytoday,accord-
ingtoARCAdvisoryGroup.Thereasonforsuchhighlevelsofinter-
estinthesetechnologiesliesinthevaluetheyprovideintermsof
creatingareal-timeoperationsinfrastructureforbetteroperations
visibility,productivityandthroughput,qualitymanagement,and
real-timeassetutilization—allofwhichcanleadtoadditional
profitsforthecompaniesthatusethem.Inaddition,ARCreports
thatusersclaimthereturnoninvestmentofMES/MOMsolutionsis
oftenachievedwithinsixtoninemonths.
Sowhathappenswhenyoualreadyhavesuchsystemsinplace
butknowthereisroomforimprovementinyouroperations?That’s
thescenarioChrisMonchinskiofAutomatedControlConcepts
describedduringhispresentationattheWonderware2015Confer-
ence.HeexplainedthatNomacorc—theleadingproducerofsyn-
theticwinebottlecorks—wasalreadyasavvyWonderwareuser
whenAutomatedControlConceptswascontactedtohelpthem
extendtheircurrentsystemsbeyondproductionmonitoring.“They
wantedmorethanmonitoring,”Monchinskisaid.“Theywanted
tomodifyoperatorbehavioranddrivecontinuousperformance.
Theyneededdatatomaintainaccuracyanduptime.Buttheyalso
wantedthesystemtobemodulartosimplifymaintenance.”
Nomacorc was already usingWonderware System Platform,
MES and QI analyst to monitor its production operations, which
produce more than 7 million synthetic corks a day. Nomacorc’s
products are constructed by combining two layers of extrusion
on top of each other to create a breathable synthetic cork for
wine bottles.The company’s product has been a boon to the
wine industry because cork is an organic product that can be
contaminated and/or react adversely with wine. Prior to the
introduction of synthetic corks, it’s estimated that 10-15 percent
of all wines were contaminated with cork taint.
MonchinskiexplainedthatNomacorcoperationsaremake-to-
order,“sotheytrackproductionperformanceandqualityclosely.
Improving Productivity at Nomacorc
Nomacorc,amanufacturerofsyntheticcorksforwine
bottles,andalong-timeWonderwareuser,soughtto
upgradeitsproductionsystemsbeyondforoperatorbehavior
modificationandcontinuousimprovement.
Nomacorc Improves Productivity with
Multi-site, Multi-countryWonderware
MES/Performance Deployment
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Thecompany’sgoalsforitsnext-generation
productionsystemincludedhaving:arepository
forprocess,alarmandOEE(overallequipment
effectiveness)data;acommonformatforallHMI
systemswithsupportformultiplelanguages(as
thecompanyhasplantsindifferentcountries);
acommonunderlyingframeworktosupport
commoncommunicationtoallPLCsandHMIs,al-
lowingforthesesystemstosenddatatobusiness
systems;andnewalarmingcommunications.
Todeliveronthesegoals,Monchinskisaid
theprojectstartedbyusingWondwareSystem
Platform’sBaseTemplateLibrarytoreplacethe
custombindscriptingapproachtodataobjects
intheproductionsystems.Adataconcentrator
approachwasusedtodevelopUDTsfordata
transfersthatwouldmatchNomacorc’sstandard
objectfootprints.Thiswaskeytoconnecting
Nomacorc’sblendersystem,whichusespropri-
etaryModbus/TCPand,therefore,hasonlyone
dataconnectionport.
•Otherkeydevelopmentstepsintheproject
included:
•ConfiguringtheInTouchHMIwithall-new
graphics,butaddingsecurityattributesto
ensurethatoperatorsdidnotmakeunwant-
edchangestothenewgraphics.
•ConnectingshifttrackingtoMESforbetter
shiftmanagementandOEEreporting.
•AdoptinguseoftheISA95modeltomapall
reasonsfordowntimeandscrapforim-
provedequipmentschedulingandefficiency.
•Trackingproductionofgoodandbadprod-
uctsbyusingthePLCtototalproductiondata
andtriggerthesystemtologit.
•Integrating Microsoft Dynamics ERP to the
production system with scripts and triggers
to determine necessary web services calls
between the systems.With this connection,
schedules and order statuses are integrated
between the ERP andWonderware MES/
Performance.
Asaresultoftheseupgrades,Nomacorc
operatorscannow:
•Get real-time feedback on automatic and
manual scrap conditions;
•SetOEEtargetsonthedashboard;and
•Drilldownintodashboardobjectstoget
Paretodetails.
Inaddition,Nomacorc’sQlikviewappisableto
co-existwiththenewsystemandnowincludes
ERP,MESandprocessdata.Thisis“asourceof
truthforNomacorc,”saidMonchinski,“becauseit
allowsthemtobreakdowndatabyreasoncode
andtestandverifythedata.Theycanevenadd
commentsintoitnow.” £
Get OEE at the Speed ofYour Process
Wonderware MES brings you actionable line
performance information. Visualize, analyze Overall
Equipment Effectiveness in real time—increase asset
utilization, throughput, and quality—in the blink of an
eye. Download an ARC White Paper to see how OEE
brings you profitable operations.
N E X T A R T I C L E
InformationAccessandMobility
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Havingaccesstoinformationinyourproductionsystemsmeans
youcaninfluenceoutcomes,saidSaadiKermani,productmanager,
WonderwareInformationManagement,inhissessiononmobility
technologyatthe2015WonderwareConference.“Everyoneneeds
accesstoinformation—that’salwaysbeenthebusinessissue.
What’schangingisthecontextinwhichthatinformationisneeded
becausethepaceofbusinessisgettingfasterandwe’reexpected
todomorewithless,”headded.
“Anotherfactorthat’schangingacrossindustry
ispeople,”saidKermani,andbythathemeantthe
Millennialsinparticular.Thekeydifferencesinthe
Millennialworkforce,accordingtoKermani,isthat
theMillennialswilltypicallyonlyspendayear
ortwointheircurrentjobbeforemovingonand
theywillbringwiththemtheirkeyjobtool—a
smartphoneand/ortablet.“Theyonlywantto
knowwhattheirjobisandwhere’stheirapptodo
itwith,”hesaid.“SmartGlancefitsthismodel.”
SmartGlanceisWonderware’smobiledown-
loadableappthatprovidesaccesstoplantdata—
suchasprocessoroperationaldata,metrics,key
performanceindicators(KPIs)andreports—on
mobiledevicesregardlessofthedevice’splatform,
i.e.,Android,iOS,Windows,etc.Kermaninoted
thatSmartGlanceisnotabout“generatingnew
data,butaboutgettingtherightdatatotherightpeoplewhen
theyneedit.Withthisinformationinhand,userscandoanalysisof
thedataandtakeactionbycontactingpeoplewhohaveresponsi-
bilityforitintheplant,”Kermanisaid.
“SmartGlancehelpsyoumonitoryourequipmentagainst
productiongoals,suchasOEE(overallequipmenteffectiveness),”
Kermaniadded.“Italertsyoutopotentialprocessorequipmentis-
suesandreducesthetimeandefforttoaddressthemwithremote
visibilityacrossteams.”
AskedaboutthesecurityofSmartGlance,Kermaniexplained
thatSmartGlanceaccessesplantdataviatheMobileReporting
Connector,whichaccessesthedataviaasingleoutboundencrypt-
edport.“NodatagoesintoyoursystemviaSmartGlance,”hesaid.
TheMobileReportingConnector(MRC)forSmartGlanceisusedto
createusersandgroupsofusers(suchasquality,production,field
engineers,etc.)whocanreceivespecified,relevantsystemdatavia
SmartGlanceatestablishedfrequencies.
TheMRCenablesthe“connectionofmultiplehistorians,cre-
ationofreports,andtaginsertionswithnoSQLserverknowledge
required,”Kermanisaid.“YoucanalsouseMRCtogivenicknames
totags,sincetagnamescanbelong.”
Information Access and Mobility
N E X T A R T I C L E
GettingIntelligencefromYourBigData
Aconfluenceoftrendsaroundthecloud,mobiletechnologiesandachanging
workforceisimpactinghowindustryaccessesproductiondatafordecision
makingandplanning.
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Inreferencetotiming,Kermaninotedthatsendingupdatesevery30
secondsisasfastasdatacanbepushedwithSmartGlance.“Ifyouneeddata
morefrequently,InTouchAccessAnywhereisthepreferredsolution,”hesaid.
KermanialsopointedoutthesimplelicensingstructureforSmartGlance.
“There’sonlyonequestionforSmartGlancewhenitcomestolicensing,”he
said,“andthatis:Howmanypeoplewilluseit?That’sit.Withthatyouget
unlimitedtags,reports,anddevices.Justpaypernumberofusersonan
annualsubscriptionbasis.”
Highlightingthestand-aloneapplicabilityofSmartGlance,Kermaninoteda
usecaseintheoilandgasindustrywhereacompanyisapplyingSmartGlance
topullOSISoftPISystemhistoriandatatomakeitavailabletoworkersaround
thecompany’ssitesandinthefield.“They’reabletodothiswithSmartGlance
onitsown.TheyhavenootherWonderwaresoftwarecurrentlyinstalled,”he
added. £
N E X T A R T I C L E
GettingIntelligencefromYourBigData
Wonderware Online: high availability and business continuity
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OneofthebiggestproblemswithBigDataissimplythatit’sbig.
Wherethisisareallybigdealisgettingahandleonhowtoputit
alltowork.Withsomuchdatacomingfromarangeofdisparate
sources,itcanbedifficulttocreatethenecessarycontexttomake
businessdecisionsbasedonreal-timeoperationsmetrics.
WonderwareIntelligencetacklesthatbyhelpingmanufactur-
erscollectdatafrommanydifferentplaces—whetherhistorians,
ERPsystems,qualitysystemsorothersources—andputitinto
contexttopresentkeyperformanceindicators(KPIs)inintuitive
dashboards.
“AcustomermayneedKPIswherebitsofthatdataneeds
tocometogether,getrationalizedandaccumulated,”said
MaryanneSteidinger,directorofproductmarketingforasset,
operationsandinformationsoftwareatSchneiderElectric.“Intel-
ligenceaccessesthesourcedataandputsitintocontext.”
AttheWonderware2015ConferencethisweekinDallas,
SchneiderElectricSoftwarereleasedthelatestversionofits
enterprisemanufacturingintelligencesoftware,Wonderware
Intelligence2014R2.
Getting Intelligence from Your Big Data
N E X T A R T I C L E
Video:InsideCampbell’sGlobalQuality
Rollout
SchneiderElectric’slatestiterationofitsWonderware
Intelligencesoftwarehelpscustomersmakefaster,more
advancedqueriesontheirindustrialBigData.
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The newest version collects, calculates and contextualizes
data and metrics from multiple sources across the manufactur-
ing operation, puts it into a centralized storage and updates it
all in near real time. Optimized for retrieval, the information can
be used to monitor KPIs via customizable dashboards, as well as
for drill-down analysis and insights into operating and overall
business performance.
TheimprovementsaddressedinthenewestversionofIntel-
ligenceinclude:
•Theabilitytousestoredprocedurestoincreasethespeedof
queries.
•Theabilitytodynamicallyusestartandendtimesformore
precisequeries.
•StreamlinedadministratorrightsfortheIntelligenceservice.
Where Intelligence previously operated on a first-in-first-
out (FIFO) basis, it now accesses the most recent information
first, which improves the query time and overall performance,
Steidinger explained.
Intelligenceenablescustomerstoreallyunderstandthe
importantaspectsoftheirmanufacturingoperations—like
quality,throughput,variance,productivity,etc.—byrolling
itallintoadashboardpersonalizedforvariousenterpriseand
plantroles.
“WonderwareIntelligenceisaneasy-to-use,non-disruptive
solutionthatimproveshowourcustomersvisualizeandanalyze
industrialBigData,”saidGraemeWelton,directorofAdvansys(Pty)
Ltd.,aSouthAfricancompanythatprovidesspecializedindustrial
automation,manufacturingsystemsandbusinessintelligence
consultingandprojectimplementationservices.“Itallowsour
customerstobuildtheirowninteractivedashboardsthatcancap-
ture,visualizeandanalyzekeyperformanceindicatorsandother
operatingdata.Notonlyisitmoreuser-friendly,ithasbetterquery
cycletimes,it’sfasterandithassimpleradministrationrights.It’s
aninnovativetoolthatcontinuestodrivequalityandvalue.”
Thoughthedashboardsarepersonalizedtoputtherightdata
intothehandsoftherightperson,theynonethelessprovide
everyoneintheoperationthesameversionofthetruthdrawn
fromasingledatawarehouse.Theinteractiveandvisualnatureof
thedashboardssignificantlyincreasesthespeedandconfidence
oftheusers’decision-making,whichallowsthemtoimprovetheir
productivity,reduceoperatingcostsandincreaseprofitability.
“Bynothavingtomanuallycollect,calculateandstoredata,and
thenhavingeasyaccesstoandtherightcontextforthatdata,users
areabletoimprovetheirprocessesandoptimizetheirenergycon-
sumption,oftenprovidingareturnoninvestmentwithinweeksof
implementation,”saidChristian-MarcPouyez,Intelligencesoftware
productmanagerforSchneiderElectricSoftware.“Forexample,its
easyaccesstooperatingperformancedataallowsuserstocompare
trendssotheycanidentifytherootcauseofsomeunscheduled
downtimeorotherincident.Preventivemeasurescanthenbeem-
ployedtoeliminatefutureincidence,whichmeansbetteroverall
performance.Infact,somecustomershaveseentheirproductivity
increasebymorethan20percent,whiletheirmanufacturingand
productionscosts,includingtheirenergyusage,havedropped
morethan10percent.” £
How New Belgium Brewing Reduced
Downtime and Increased Efficiency with
Wonderware MES
After discovering its bottling line was only producing at
50 percent of capacity, New Belgium Brewing applied
Wonderware MES to address the problem and generated
additional production benefits in the process.
N E X T A R T I C L E
Video:InsideCampbell’sGlobalQuality
Rollout
17. NEXT ➔NEXT ➔
The Best of the Best: Wonderware Conference 2015
Schneider Electric
Wonderware
17 / 23
Campbell’sis18monthsintoaglobalqualitysolutionrolloutthat
willprovidestandardizedstatisticalprocesscontrolmethodologies
forthecompany’sproductionlines.MichaelKershawandBarry
DickersonfromsystemintegratorsCrossmullerTechnologyand
CallistoIntegrationdescribethejourney. £
Video: Inside Campbell’s Global Quality Rollout
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N E X T A R T I C L E
StructuringWorkflowstoImprove
Production
18. NEXT ➔
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Schneider Electric
Wonderware
18 / 23
Nomatterhowtechnologicallyadvancedyour
processesmaybe,yourcompany’sabilitytoproduceis
onlyasgoodasitsworkflowprocesses.Withoutgood
workflowprocedures—andsupportingtechnology
toensuretheseproceduresarefollowed—yourriskof
downtime,decreasedthroughputandlossofrevenues
isgreatlyincreased.
AttheWonderwarebySchneiderElectric2015
Conference,KeithChambersandJuanCarlosGarciaof
SchneiderElectricexplainedhowcoordinatedwork-
flowsareaninherentpartofasuccessfulmanufactur-
ingoperation.Intheirpresentation,theyshowedhow
Wonderware’sindustrialworkflowsoftware,basedon
SkeltaBPM,supportsplantfloorcollaboration,escala-
tionmanagementandexceptionhandling.
“Thissoftware,whichprovidesfullyintegrated
workflowdefinitions,formsandanalytics,isusedto
coordinatehowpeoplecanworktogetheroptimally,”
saidChambers.“WhileInTouch(humanmachine
interfacesoftware)collectsandvisualizesdata,
Workflowusesthisdatatocoordinateactionsacross
production,maintenance,quality,warehouse/logis-
tics,andenvironmentalhealthandsafetyoperations.”
TheWorkfloweditorallowsforthecreationand
editingofworkflowsspecifictoyouroperationsthat
arethenassignedtoanobjectintheArchestrAdevel-
opmentenvironment.Eventsandscriptswithinthe
objectcantriggerworkflowsinInTouchoronSkelta
devices.“Workflowscanincludeformsfortask-based
userinteractionsandcollaboration,”saidChambers,
“andtheycanbeintegrateddirectlyintoWonderware
MES,InBatch,andAvantisEnterpriseAssetManage-
mentaswellasOfficeandSharePoint2013.”
Some of the operations examples Chambers
highlighted as ideal applications forWorkflow
software across industry include the release of
new recipes or formulas to the production floor,
approving the release of a new product, execut-
Structuring Workflows to Improve Production
Usingworkflowsoftwareforerrorproofingofoperatoractions,compliancewith
standardoperatingproceduresforproduction,environmentalhealthandsafety
directives,andreducedregulatoryrisk.
N E X T A R T I C L E
OptimizingAssetPerformance
19. NEXT ➔
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Schneider Electric
Wonderware
19 / 23
ing maintenance work orders, starting up
or shutting down a process, managing
demand/supply activities such as kanban,
and responding to alarms.
ThebenefitsofusingWorkflowsoftware,
accordingtoChambers,includeerror
proofingofoperatoractionsandresponses,
compliancewithstandardoperating
proceduresforproduction,precisefollowing
ofenvironmentalhealthandsafetydirec-
tives,improvedtransparencyintooperator
actionsandreducedregulatoryrisk.
Forarealworldexampleofhoweffective
goodworkflowprocedurescanbe,consider
thesuccessFujirebioDiagnosticsInc.hasex-
periencedsinceinstallingtheWonderware
Workflowsoftware.FujirebioDiagnostics
isanFDA-regulatedsupplierofbiomarkers
(bloodtests)foroncologicalpurposesthat
helpphysicians,laboratoryprofessionals,
andpatientsbettermanagedisease.The
company’s160,000-sq.-ft.facilityproduces
about75milliontestsannually.
ThoughFujirebiohasbeenaleaderin
itsfieldfortwodecades,thecompany
achievedamajormilestonein2013whenit
replaceditsmanual,paper-basedprocessof
periodicallyrecordingtemperaturereadings
forspecificgoodmanufacturingprocesses
(GMP)-relatedequipmentwithanew
computerizedsystem.Byautomatingthis
manualprocess,Fujirebiocreatedamajor
opportunitytosavetimeandpaperand
retaincompliancebyautomatingtheac-
quisitionofequipmentdataandgenerating
electronicreportsforreviewandapproval.
The company’s project to address this
was called the Electronic Initiative and the
first phase involved the implementation of
what it called the Equipment Monitoring
System or EMS.The software used in the
Equipment Monitoring System is theWon-
derware System Platform with theWon-
derwareWorkflow. Prior to implementa-
tion of the EMS, workers typically spent
up to 15 hours reviewing GMP packs. After
installation, workers only spend minutes
on the data because they are reviewing by
exception and not having to worry about
missing key items. In total, the company
estimates they are saving about 1100
man-hours per year by using the EMS.The
software also enables Fujirebio to comply
with 21 CFR 11 regulations for electronic
records and electronic signatures.
Looking ahead, the EMS provides
Fujirebio with an infrastructure for other
electronic data capture projects such as
MES/MOM, process automation and ERP
integration. £
Fujirebio Diagnostics, Inc. -
aWonderwareWorkflow success story
N E X T A R T I C L E
OptimizingAssetPerformance
20. NEXT ➔
Sponsored by
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Schneider Electric
Wonderware
20 / 23
AlthoughtheInternetofThingshasonlymore
recentlybecomea“thing,”anybodyinindustry
wellknowsthatmanufacturingoperationshave
beengatheringreamsofdatafordecades.But
trulytakingholdofthecapabilitiesthatdatahas
toofferiswhathasbecomeanever-nearerreal-
ityasconnectivityandanalyticsimprove.
Predictiveanalyticsandtheirabilitytoenable
predictiveratherthanreactivemaintenanceisa
biggamechangerformanufacturers.Schneider
Electrichasbeenputtingalotofemphasison
optimizingtheenterpriseassetperformance
management(APM),anditsAvantisPRiSMis
thelatestadditiontothateffort,capturingall
thehigh-fidelityprocessdatatodiagnoseasset
health,notedRobMcGreevy,vicepresidentof
information,assetandoperationssoftwarefor
SchneiderElectricSoftware.
Avantis PRiSM predictive analytics monitor
the real-time health and performance of criti-
cal assets to predict equipment failure or decay
points.The capabilities provided by artificial
intelligence, advanced pattern recognition and
sophisticated data mining can reduce mainte-
nance costs and increase availability, reliability
and capacity.
In aTuesday morning session at theWonder-
ware Conference, titled,“Past, Present, Predict,
Prevent”(OPS/INFO-03, Sept. 22, 10:45 a.m.),
Keith Chambers, Sean Gregorson and Paul
Shelton will explain how Avantis PRiSM can
help you achieve greater reliability and perfor-
mance from your production assets.
Avantis PRiSM can provide early warning
notification and diagnosis of equipment issues
days, weeks or months before failure—
Optimizing Asset Performance
N E X T A R T I C L E
Video:FNDairiesUsesWonderware
OperationsManagementSolutions
AvantisPRiSMpredictiveanalyticsisthelatesttoolinSchneiderElectric’sarsenalgearedtoward
improvingthehealthandperformanceofcriticalassets.
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Bridging the Gap in the Batch Market
Recipe management plays an important role in the
success of batch manufacturing. However, a huge
gap exists between the simpler HMI/SCADA recipe
management solutions offered and full blown batch
management and control packages. This white paper
from ARC Advisory Group discusses how Wonderware
Recipe Manager Plus software can fill that gap.
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Schneider Electric
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21 / 23
warnings that could go unnoticed by traditional maintenance
practices.
“Thevalueproponthisissuperhigh,”McGreevysaid,speaking
toindustrymediaandanalystsduringabriefingatSchneiderElec-
tric’s2015WonderwareConference.“93percentofourcustomers
havereportedequipmentfailures.”
Inonecase,forexample,autilitywasexperiencingsporadic
issueswithasteammodelturbine;theconditionescalatedand
eventuallyresultedintheshutdownoftheunitforcorrective
action.Butuponcompletionofthemaintenance,asimilarcycleof
sporadicissuesbeganagain,inadditiontonewproblems.
Analyzing the unit’s raw historical data with Avantis PRiSM,
it was clear that such a tool, had it been in place, could have
provided early warning that turbine thermal expansion issues
were developing and becoming chronic over the year.Through a
modeling exercise, the tool was able to detect the fault pat-
terns with early warnings six months prior to failure.The model
showed that the bearing vibrations were a symptom while
thermal expansion issues were the primary cause of the prob-
lem. Proactive remedial maintenance would have corrected the
thermal expansion problem before it led to bearing vibration
issues and the shutdown of the unit.
Notonlywouldsignificantmaintenancecostshavebeenavoid-
ed,buttheutilitywouldhaveincreasedsalesthroughincreased
unitavailability.Estimatedsavingsinthiscaseareinthemillionsof
dollars—aresultof35daysofavoideddowntimeandassociated
repaircosts. £
N E X T A R T I C L E
Video:FNDairiesUsesWonderware
OperationsManagementSolutions
22. NEXT ➔
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Schneider Electric
Wonderware
22 / 23
FNDairies/Thailandneededplanttobusinessconnectivityto
enableproducttraceability,ensureproductquality,streamlinepro-
ductionandboostoverallcustomersatisfactionfortheirCarnation,
TeapotandBearbrandproducts. £
Video: FN Dairies Uses Wonderware Operations
Management Solutions
N E X T A R T I C L E
WonderwareTakesCenterStage
23. CLOSE ✕
The Best of the Best: Wonderware Conference 2015
Schneider Electric
Wonderware
Atthe2015WonderwareConferenceinDallas,
SchneiderElectricshowedastrengthenedem-
phasisofitsWonderwarebrand.Schneiderhas
spentthepastyeardeliveringonthepromises
madebyRaviGopinath,executivevicepresident
ofSchneiderElectricSoftware,afterthecompany’s
acquisitionofInvensys,buildingastrongsoftware
portfoliowithstrongpenetrationrates.Thiswas
themessagedeliveredattheconference’sopening
generalsessionbyTomComstock,vicepresident
ofmarketingforSchneiderElectricSoftware,
andbackedupbypresenters—includingseveral
customers—throughouttheweek.
InhisclosingkeynotebeforefootballgreatTerry
Bradshawtookthestage,Gopinathemphasized
thattheintegrationofInvensyswithinSchneider
Electricoverthepastyearandahalfhasgone“ex-
ceedinglywell”asthecompanyworkstoharmonize
andconvergethevariousSCADAplatforms.Making
referencetoaproposedmergerofSchneider’s
softwarebusinesswithAveva,Gopinathreassured
conferenceattendeesofSchneider’scontinued
commitmenttosoftware,notingtherenewedabil-
ityto“starttofullymonetizetheintrinsicvalueof
thesoftwarebusiness.”
AsasignoftherestrengtheningoftheWonder-
warebrand,Comstockalsoannouncedareturnto
theWonderWorldTour.Markyourcalendarnow
fortheNorthAmericanstop,takingplaceOct.3-6,
2016,inOrlando,Fla.
FormoreinformationonWonderwaresolutions
pleasevisit:http://software.schneider-electric.com
Get in touch! Contact us or subscribe to our
mailing list. £
Wonderware Takes Center Stage
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23 / 23