Proficy Plant Intelligence Solution Plant Performance Analysis

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Proficy Plant Intelligence SolutionPlant
Performance Analysis Execution Software
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Plant Performance Analysis and Execution Software

• A suite of powerful Plant Intelligence
  application modules that allow manufactures to
  make business sense out of plant and
  manufacturing data.

• Efficiency Management for improving your
  throughput through overall equipment
  effectiveness (OEE) measures
• Reduction in downtime, machine effectiveness,
  waste, reject
• Quality Management for improving the quality of
  your products and process
• More consistent operations
• Lower waste, rejects and recall rates
• Production Management for insight into how
  products flow through the plant
• Produce product genealogy reports,
• Better scheduling and lower inventory levels
• Reporting for leveraging the value of all modules
• Web-based for real-time decisions
• Pre-canned reports and fully configurable

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Plant Performance Analysis and Execution Software

• Value of Proficy
• Enables production managers to make dramatic
  improvements in plant profitability and
  efficiency.
• Enables managers to digitize plant operations
  into a virtual plant that provides
  unprecedented levels of analysis, reporting and
  insight throughout your operations
• Highly unique and differentiated
• Focused on Improving
• Better utilize plant assets (people, equipment,
  materials) getting more for less
• Increase product quality right the first time
• Improve production operations - Collaboration for
  more agility
• Ensuring corporate accountability meet
  regulatory and customer requirements
• Full integrated in to GEF solution.

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Integration with the Plant Intelligence Solution
Proficy is fully-integrated into the other
modules for a seamless user experience and lower
TCO.

• infoAgent and Proficy
• All Proficy data can be exposed to infoAgent
  can use infoAgent native components to render and
  analyze the information along with other data
  sources.
• Proficy Published web reports can be viewed from
  within infoAgent
• Proficy and iHistorian
• iHistorian feeds the Proficy system and is the
  primary data source
• All iHistorian functions are supported including
  tag browsing
• Reporting Add-ins are integrated in to Excel
• Proficy and HMI Solutions
• Proficy Web Reports Hosted in HMI for report
  viewing
• Down Time and AutoLog Controls in HMI Screens

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GE Fanucs Plant Intelligence Solution

• Make Business Sense out of Plant Data in
  Real-time
• Collect plant data into a secure, central
  repository
• Digitize plant operations in a virtual plant
• Transform plant data into meaningful information
  using business rules and analyses
• Provide web-based visibility for real-time
  decision-making
• Feedback information to operations, the business,
  customers and suppliers for continuous process
  improvement

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Plant Intelligence Solution

• Key advantages of our solution
• Integrated, Comprehensive Solution
• No comparable solution in the market today!!
• Unique Historian-based Approach
• Information based on your actual plant data
• Open Product Architecture
• Add only whats needed instead of all or
  nothing approach
• Flexible and Easy to Configure
• Configurable application modules to meet
  different needs
• Secure and Audited
• 21 CFR Part 11 Compliant
• Comprehensive Integrated Reports and Analytics
• Web-based for real-time decisions

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Plant Performance Analysis and Execution Software
Proficy supports every stage in the Production
Process from Scheduled Execution to Finished
Goods.
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Plant Performance Analysis and Execution Software
A full breadth of Application-specific Modules
designed to support your production team.
Production
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Proficy Architecture
Reporting
Analysis
Quality
Efficiency
Production
Product Management
Event History
Plant Model
Plant Historian
Plant Floor Data
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Efficiency

• Efficiency - Complete Picture Of Plant
  Performance
• Provide historical production counts by hour,
  shift, and day
• Provides insight into overall equipment
  effectiveness (OEE)
• Enables throughput improvements without
  additional equipment expenditures.
• Shows comprehensive views of equipment including
• Uptime, Downtime, Efficiency
• Scrap, Waste production, Yield
• Tracks overall equipment efficiency and reasons
  for downtime / waste
• Provides Comprehensive analytical and reporting
  Capabilities
• Comprehensive web based analysis and
  visualization
• Powerful extensions to Microsoft Excel
• Report scheduling and viewing capabilities
• Detailed Production data for long term analysis

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Value of Efficiency Focusing on how well we
operate or produce

• Improve operating efficiencies
• Assets, Labor, Schedule, Products
• Root cause analysis to reduce and prevent
  downtime
• Process and production optimization and
  de-bottlenecking
• Maximize use of production schedule and resources
• Minimize downtime
• Reduced costs and/or increased production
• Products, Assets
• Reduced waste
• Reduced setup / transition time
• Increase asset utilization

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Quality

• Quality - Increase quality through enhanced
  real-time visibility
• Enables quality improvement initiatives without
  additional equipment expenditures.
• Secure Audited Product Specification Management
  Quality Conformance
• Capture and summarize manufacturing and quality
  data in the context of production events such as
  batch, lot, item, roll, serial no., time period
• Automatically or Manually Capture Quality
  Information
• Reason Codes, Research Notes
• Recipe, Batch and Production Information
• Generates Quality Alarms and Out of Spec
  conditions
• Pre-Integrated With Production Management
  Processes and Controls
• Provides Comprehensive Analytical and Reporting
  Capabilities
• Comprehensive web analysis and visualization -
  Trending, SPC Charting
• Powerful extensions to Microsoft Excel
• Report scheduling and viewing capabilities
• Detailed Quality data for long term analysis

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Value of Quality

• Increase quality production from enhanced
  real-time visibility
• Reduce rejects / downgrades
• Reduce customer complaints / returns
• Avoidance of major quality event
• Avoidance of product recall
• Lower cost of quality
• Data collection time reduction
• Complaint / Quality research time reduction
• Product / process optimization
• Better Products, Less time, less rework
• Faster product time to market
• Faster NPI, Higher Success rates

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Production Management

• Production Management improve execution,
  tracking and genealogy
• Provides insight into how products flow through
  the plant by tracking production against
  specifications, equipment and schedules.
• Enables up and downstream traceability
• Allows in-process scheduling changes to reduce
  WIP and overall inventory
• Provides Comprehensive Product Genealogy
  Reporting and Analysis
• Comprehensive web analysis and visualization -
  Trending, Genealogy view
• Powerful extensions to Microsoft Excel
• Report scheduling and viewing capabilities
• Detailed Tracking data for long term analysis
• Birth History
• Traceability overall Genealogy

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Production Management Focusing on improving
production execution

• Increase Schedule execution and accuracy from
  integrated product, quality and production
  tracking systems
• Reduction of overruns / shortages
• Reduced inventory costs (raw materials, WIP,
  finished goods)
• Faster, more accurate product changeovers
• Detailed, easily accessible tracking and
  genealogy information
• Limit the scope of recalls
• and quarantines
• Automated recall /
• quarantine
• Quick response to
• customer issues
• Production / Process optimization
• Timely and Precise Material Staging
• Use Real-Time Alarms To Trigger Order
  Re-Optimization

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Plant Wide Reporting

• Reporting Options - different choices to meet
  different needs
• Right tool for the right job!
• Excel Add-in
• Flexibility Add-in based reports for ad-hoc
  customized reporting
• Free-Form Analysis, Highly Customizable
• Menu Based
• Standard Templates
• Standard Reports / Examples
• Published Web Reports
• Published web formatted reports
• HTML and other Published forms (PDF, XML, TXT)
• Web Analysis
• Rigid Application Analysis
• Free Form Interactive Analysis

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Manufacturer Chemicals / Chemical Consignment

• Customer Goals
• Chemical Consignment
• Move to Vendor Managed Inventory
• Inventory Consumption information via Internet
  Access
• Transfer of Ownership - no Longer Upon Delivery
• Pay on an As Used Basis
• Approach
• Evaluated in-house custom solutions, Chose
  Proficy
• Installed Proficy on existing infrastructure
• Inventory, Consumption and Delivery information
  managed through Proficy
• Accomplishments
• 80 Reduction in Man-hours
• Eliminated Order Placement for Chemicals
• No Longer Release Trucks - Paperless
• Less Paper Work
• Invoicing is Eliminated
• Eliminates Carrying Cost of Inventory

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One of the Worlds Largest Breweries

• Customer Goals
• Increase efficiency of production packaging
  facilities
• Increase overall production, throughput
• Reduce waste due to overruns and under runs
• FDA Compliance
• Approach
• Evaluated Competitors, In-House custom approaches
• Purchased Proficy Solution
• Installed on existing infrastructure
• Accomplishments
• Dramatic increase in overall line efficiency
• 5 increase in overall productivity
• 90 decrease in rejects and packaging errors
  (waste)
• Fewer finished product holds
• Increased communication and information sharing
  amongst production teams

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Leading CPG Manufacturer

• Customer Goals
• Increase Reliability Tracking
• Regulated and non-regulated products
• Simplify overall quality work process for all
  products
• Standardize on one way to report on data across
  all plants
• Approach
• In-house solutions, existing vendor applications
  were not meeting needs
• Chose Proficy after lengthy vendor evaluation
• Implemented multiple modules across multiple
  facilities including linkage to SAP
• Accomplishments
• Extended timeline / reduced capital expenditures
  through increased production
• Standard approach to recipe and specifications
  lead to Quicker NPI and higher overall quality of
  products
• Cross Plant production caparisons enable large
  scale optimization and best practices

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Major Food Manufacturer

• Customer Goals
• Increase quality and enable full product
  traceability / genealogy
• Gain insight into actual production costs by line
  and product
• Bridge complex product genealogy across multiple
  systems
• Multiple Vendors, Applications, Databases
• Approach
• Leveraged existing installed infrastructure
  (Historian, Control and Batch Systems)
• Implemented Proficy Genealogy and linked to
  existing batching systems and utilities data for
  actual costing
• Tied to SAP for process Orders reporting
  consumption and energy usage
• Accomplishments
• Complete product genealogy across all aspects of
  the food production process (raw material through
  finished product)
• Closed loop with SAP process orders through to
  production and consumption information
• Energy Genealogy showing actual cost of
  products as produced allowed for improvements

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GE Fanuc Hardware, Software and Professional
Services
Americas Business Locations

• A Business of GE Industrial Systems
• Global Presence GE Fanuc Business Offices in
  the UK, Luxembourg, France, Germany, Italy,
  Japan, China, and Australia
• Focused on Target Vertical Industries, including
  Life Sciences
• Broad Portfolio of Award Winning Products and
  Services
• Six Sigma Methodology a Proven Advantage for
  Customers

World Headquarters Charlottesville, Va
Technology, Business, and Customer care
center Foxborough, Mass
Technology and Professional Services Center,
Albany, NY
Technology and Customer Care Center, Edmonton,
Canada
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