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Business Intelligence for Manufacturing

Help empower line workers, supervisors and

management to make better, more-timely

decisions to achieve greater throughput, with

higher quality, better asset utilization and at lower

cost with FactoryTalk® VantagePoint EMI rom

Rockwell Automation. FactoryTalk VantagePoint

EMI (Enterprise Manuacturing Intelligence)

connects to manuacturing data sources –

real-time, historical, relational and transactional

– to create a single virtual data resource thatcan access, aggregate, correlate and present

role-appropriate inormation to inormation

workers, supervisors and management with a web

browser. With FactoryTalk VantagePoint EMI, your

company can have better manuacturing insight

and greater IT agility, helping you to achieve your

most challenging manuacturing goals:

• Tighter Cost Control

• Optimal Production Performance

• Better Equipment Utilization

• Higher Product Quality

• More Ecient Supply Chain Management

FactoryTalk® VantagePoint EMI

is the gateway to data buried

in your manuacturing and

business systems. Users easily

confgure role-relevant reports,

dashboards and KPIs that

deliver deep, actionable

manuacturing insight.

Meeting Manuacturing Goals

Aligning manuacturing operations with business goals is a dynamicinormation problem. It requires real-time visibility into operations ordecision-makers throughout the supply chain: rom the plant oor, all theway up to top management.

Until now, the costs and inrastructure associated with attempts toachieve that visibility have allen primarily on corporate IT departments.Yet the data that uels real manuacturing insight is most oten generatedin the manuacturing systems themselves. What’s been needed is amanuacturing inormation system that can provide visibility and insightin a way that enables sound operational decision-making. FactoryTalk VantagePoint EMI does just that.

With its unique and powerul Unied Production Model, FactoryTalk VantagePoint EMI puts manuacturing data in the proper businesscontext, correlates seemingly disparate manuacturing and businessinormation, and aggregates inormation across multiple manuacturinglines and plants. Then it delivers relevant reports, dashboards and KPIsto users, supervisors and management through a simple web browser,empowering them with the inormation they need to help solvemanuacturing problems beore they impact the bottom line.

VantagePoint EMI

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Goal: Analyze Production, Reduce Cost

Engineering, maintenance, quality and operations wantto squeeze costs by analyzing and removing productionbottlenecks and other ineciencies. FactoryTalk VantagePoint EMI can integrate plant-oor inormationrom historians, control systems and HMI systems. Userscan nd, graph, analyze, report on and share inormationhelping to reduce costs and streamline production.

Goal: Maximize Equipment Perormance

Plant managers, engineering managers and maintenancemanagers want to maximize equipment perormance.FactoryTalk VantagePoint EMI can integrate assetinormation (Enterprise Asset Management, MaintenanceManagement, Condition-based Monitoring) withplant-oor inormation to provide meaningul insightinto equipment perormance and condition. Real-timeaccess to key equipment metrics, like OEE and downtime,empower users to drill down, analyze and resolveequipment problems.

Goal: Improve Product Quality

Production and quality managers seek to improve productquality. FactoryTalk VantagePoint EMI can integrate qualityinormation rom LIMS, SPC, and specication systemswith manuacturing runtime and historical data to providereal insight into product quality. Providing such qualitymetrics as deect, rework rates, and scrap, allows users todrill into and resolve quality problems.

Goal: Optimize Production Perormance

Plant and production managers strive to optimizeproduction perormance. FactoryTalk VantagePoint EMIcan integrate production inormation (schedule/cost romERP/MES) with asset, quality and plant-oor inormationto provide enterprise-wide insight into manuacturingperormance. Armed with FactoryTalk VantagePoint EMI KeyPerormance Indicators (KPI) and web reports, supervisors

and managers can make decisions that can incrementallyimprove overall production perormance.

Goal: More Ecient Supply Chain

Plant, production and supply chain managers try toimprove agility and responsiveness by optimizing supplychain management. FactoryTalk VantagePoint EMI canintegrate production inormation with vendor andcustomer inormation to provide insight into the supplychain. Production supervisors and managers leveragesupply chain data and perormance metrics, like percentageo perect delivery to improve supply chain management.

FactoryTalk VantagePoint EMI uses your

greatest hidden asset – manuacturing

data – to allow you to better align

the manuacturing process with your

business goals.

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VantagePoint EMI Composite Control Loop Report

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Users want reports across similar plants, production linesor equipment to be consistent across the organization,independent o their data sources. FactoryTalk VantagePoint EMI lets you model the business in aconsistent manner no matter what the underlying datasource to help standardize the way you report on andvisualize manuacturing.

Flexible The Unied Production Model can be based on industrystandards like ISA 95, or it can be developed rom theground up to ensure a high delity representationo any environment. The model can also be createdautomatically rom conguration data inexternal systems. (E.g. Logix congurationles)

The model can then be extended andadapted as business priorities andinormation requirements change, andenriched as reports, dashboards, trends andKPIs are stored back into the UPM.

... and Delivers IT AGILITY

FederatedInormation systems evolve to addressreal world problems in manuacturing.Companies end up with a variety o diferentand sometimes incompatible systems. Itmay seem tempting to standardize, andto consolidate data into a single system,but the costs o such projects are high andimplementation times are long.

FactoryTalk VantagePoint EMI’s ederated solution leavesthe data in source systems, suraces the data as needed,and warehouses the data when appropriate to allowcompanies to ully leverage their existing inormationassets, and to avoid the capital outlays associated witha ‘rip and replace’ approach.

ReusableDeeper insight drives new business requirements andpriorities that drive the need or new inormation, newanalysis and new reports. FactoryTalk VantagePoint EMIallows creators o reports and other content to work

directly against the Unied Production Model, eliminatingthe complexity o managing interaces to multiple datasources and promoting the reuse o content.

The systems that contain manuacturing data areconstantly changing as they are recongured, upgradedand replaced. Business intelligence solutions need toaccommodate these changes. By separating reports andcontent rom their data sources via the UPM, engineeringeforts are minimized when data sources are modied.

ProgrammableBusiness intelligence sotware should serve as a platormor urther integration eforts, and as an environment orthe development o custom manuacturing applications.FactoryTalk VantagePoint EMI provides extensibility viaa unique combination o web services, an object modeland a relational interace. First, FactoryTalk VantagePointEMI’s service oriented architecture (SOA) exposes allunctionality as web services. Second, programmers candirectly access the Unied Production Model rom within

any .net programming environment on any workstationon the network. Finally, users can access data directlyrom the underlying SQL Server database.

Increased Functionality or BetterDecision Making

FactoryTalk VantagePoint EMI connects to manuacturingand business data sources, and helps users to organize,analyze, secure and present inormation to drive bettermanuacturing decisions.

IntegrationFactoryTalk VantagePoint EMI eatures premierconnectivity to Rockwell Automation products includingthe Logix amily, FactoryTalk products, ProductionCentreand Pavilion Technologies. Comprehensive connectivityoptions are also available to integrate with databases, ERPsystems, manuacturing and business applications, and3rd party historians, HMI systems and control systems.A developer toolkit is available to create new connectorsto other systems.

VantagePoint EMI Composite Reporting

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AnalysisData can be urther processed and analyzed withFactoryTalk VantagePoint EMI’s Analysis Services. Timeseries data can be synchronized, sampled and aggregated.Data can also be ltered, sorted, and subjected to customaggregations and calculations. Scorecards and KPIs canbe calculated and the results can be stored in the UniedProduction Model. In addition, manual data can also becollected, processed and stored in the model.

SecurityMultiple security roles can be dened, and administratorscan assign Microsot Windows® users and MicrosotWindows groups to these roles to give them appropriateaccess to the system. Every item in the Unied ProductionModel has a set o permissions that speciy each role’sability to read, write and execute operations on it.

PresentationReports, dashboards, trends and KPIs are presented inthe FactoryTalk VantagePoint EMI portal or in other portal

environments. Users are authenticated at the portal,and see only role specic portal pages and content.All content is available in a browser, and no clientinstallation is required.

Microsot Excel is utilized as the report creation tool, andnon-programmers with Excel skills can pull data rom theUnied Production Model into Excel,process and ormat the data, andshare their reports in the portal.

A dashboard builder allows usersto build Flash dashboards and KPIsthat are dynamically calculated

and updated rom the UniedProduction Model.

Users can trend and plot real-timeand historical data rom multipletime periods using the Trend andXY tools, and can use cursors,statistics, zooming, panning, stackingand scaling eatures to analyzemanuacturing operations.

ExtensibilitySolution templates that provide

advanced aggregation and onlineanalytic processing capabilities,scheduled and event driven analysisand reporting, and notication andworkow capabilities are availablerom Rockwell Automation via theKnowledgebase.

FactoryTalk VantagePoint EMI scales rom

a single data source and a handul o

users to hundreds o data sources multiple

locations and thousands o users.

Composite manuacturing applications can build onthese templates, and interact directly with the UniedProduction Model, reading data rom the model, savingdata to the model, and extending the model bycreating new connectors, classes and instances. Thisallows developers to quickly ocus on how best to processand present inormation, rather than spending timeworking out how to access and manage inormation romdiverse sources.

Examples o composite manuacturing applicationsbuilt with FactoryTalk VantagePoint EMI include energy

management applications, oil and gas asset managementapplications, batch analysis and reporting applicationsand down time reporting applications.

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FactoryTalk VantagePoint EMI

provides a oundation or your

manuacturing strategy that

builds additional breadth and

unctionality on your current

systems as you need it, and where you need it.

VantagePoint EMI Dashboard Report

VantagePoint EMI Control Loop Report

VantagePoint EMI Multi Tag Excel Report

VantagePoint EMI Stacked Equipment Trend

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Case Studies

FactoryTalk VantagePoint EMI...

Proven Business Intelligence for Manufacturing

Hexion Specialty Chemicals is the world’s largest producero thermosetting resins and ormaldehyde used or buildingproducts. With numerous acquisitions, Hexion inherited plantswith completely diferent control systems and historians (includingOSI PI, Wonderware InSQL, GE Procy and Delta V), but needed asingle analysis and reporting solution that could integrate all thesedisparate systems. Ater considerable research, Hexion selectedFactoryTalk VantagePoint EMI.

With FactoryTalk VantagePoint EMI, Hexion was able to aggregatedata from all of the company’s disparate control and historiansystems, providing analysis and reporting that can be shared in aportal and accessible to users via a web browser. They were ableto build a standard, reusable set o reports, dashboards and KPIsand provide access to them at the various levels throughout the

enterprise. This capability provided a clear growth path to linkplant operations to enterprise computing applications so corporatestaf can use plant data or better business decision making.

FactoryTalk VantagePoint EMI...

Integrates All Disparate Systems

Arkansas Steel Associates LLC is a leading producer of railroad tieplates for the U.S., Canada and Mexico with growing service torailroads in the rest of the world. After the company’s acquisitionin 1989, they went through accelerated growth and modernizationthroughout their operations. In addition to plant upgrades,Arkansas Steel also made major improvements to both plantcontrol systems and enterprise computing applications. Theyupgraded the human-machine interace (HMI) systems and addedWonderware InSQL Server databases for collecting all process datarom the urnace and caster systems.

With FactoryTalk VantagePoint EMI in place, production managershad new tools to help achieve on-track production orders. Researchand development labs could now monitor product quality andtest new resin ormulations remotely; and shipping and inventorycould be monitored easily, based on simple tank levels. Process

engineers could monitor overall equipment eciency (OEE) andcould drill down to resolve problems or optimize batch productionphases. Site engineers even had visibility now to track energyconsumption.

By adding FactoryTalk VantagePoint EMI to their reporting andlaboratory information management system (LIMS), ArkansasSteel was able to integrate all their systems including their controlsystems, historians, HMI systems, MES tracking and enterpriseapplications. VantagePoint EMI’s Unied Production Model allowsor creation o a logical model o all plant operations deliveringinormation to operators via dashboards in the VantagePointportal.

Arkansas Steel’s caster dashboard provides an instant status overview.

Hexion Specialty Chemicals plant overviews now share a common look and feel.

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Find out more About FactoryTalk®VantagePoint EMI and all o RockwellAutomation’s ManuacturingIntelligence Sotware Solutions

Join us or our live Discover Webcast series eaturing ourlatest FactoryTalk products. Each 60-minute live presentationwill show you how our solutions can help you harness

the power o your manuacturing inormation. The latestschedule o webcasts and registration inormationcan be ound at:http://discover.rockwellautomation.com/go/webcasts

There is also an extensive library o video presentationsand demos available or FactoryTalk VantagePoint andVantagePoint EMI, including more detailed presentations on:

• Trend: Ad hoc trending using signals rom a variety o data sources (26:03)

• Alarm & Event History: Using VantagePoint to reportagainst the FactoryTalk Alarm & Event History (5:16)

• Historian:VantagePoint as the premier client orFactoryTalk Historian SE (and, yes soon, ME) (3:18)

• Calculation Tags: Using VantagePoint’s powerulcalculation engine to create Calculation Tags (11:22)

• Composite Reports: Creating composite reports (multiplereport objects in a single portal page) in VantagePoint(13:53)

• Portal: Creating and using reports in theVantagePoint Portal (14:28)

• Live Data: Connecting to FactoryTalk Live Data sourceswith VantagePoint (11:36)

They can all be accessed though ourDiscover Rockwell Sotware portal at:http://discover.rockwellautomation.com/mi

Publication FTALK-PP034A-EN-P – November 2009

FactoryTalk and VantagePoint are trademarks o Rockwell Automation, Inc.All trademarks and registered trademarks are property o their respective companies.

Copyright ©2009 Rockwell Automation, Inc. All Rights Rese rved. Printed in USA.

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