Rockwell Automation Discrete Machine Performance Solution User manual

User’s Guide
Doc ID BWDMPS-UM001A-EN-E
Discrete Machine
Performance Solution
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Contacting
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Warranty This Rockwell Software product is warranted in accord with the product license. The product’s
performance will be affected by system configuration, the application being performed, operator
control, and other related factors.
This product’s implementation may vary among users.
This manual is as up-to-date as possible at the time of printing; however, the accompanying
software may have changed since that time. Rockwell Software reserves the right to change any
information contained in this manual or the software at anytime without prior notice.
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procedure, or process described, nor to provide directions for meeting every possible contingency
during installation, operation, or maintenance.
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1•Welcome to the Discrete Machine Performance Solution 1
Chapter objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
What is the Discrete Machine Performance Solution? . . . . . . . . . . . . . . . . . . . . . . . . . 1
Features and benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Intended audience. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
System installer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
System configurator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Line operator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Report user . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Where can I go for help? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Get Discrete MPS training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Get phone support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Get web support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Get on-site support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Get consulting services. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Contact us . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2•Discrete MPS Hardware Installation 7
Chapter objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Top and side view. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Before unpacking the computer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Packing list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Shipping/transporting the computer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
European Union Directive compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Environmental considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Mounting hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Tools required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Mounting dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Mounting clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Mounting clearances for the Integrated Display Computer . . . . . . . . . . . . . . . . . 13
Panel cutout dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Panel mounting guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Installing computer in panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Connecting a keyboard and pointing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Connecting AC power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Connecting to a network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Contents
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DISCRETE MACHINE PERFORMANCE SOLUTION USER’SGUIDE
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• • • • •
3•Initial Operation and Setup 19
Chapter objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Operating guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Operator access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Boot-up sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Initial configuration steps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Using a touchscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Touchscreen serial port usage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Driver software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Resistive touchscreen technology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Calibrating the touchscreen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4•Collecting Performance Data 23
Chapter objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
What is the OEE rating?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
User-defined summarization criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Configuring a workcell availability calendar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Step 1 • Define time patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Step 2 • Configure Composite Time Patterns. . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Step 3 • Schedule exceptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5•Discrete MPS Configurator Application 35
Chapter objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Exploring the user interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
The Configuration Explorer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
The Configuration Work Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
The Configuration Status Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Main screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
General settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Workcells . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Efficiency Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Part Counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Ideal Cycle Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Availability Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Running status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Digital Events. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Multistate Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Breakdown Justification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Manual Justification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Automatic Justification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
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CONTENTS
v
• • • • •
Process Variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Summarization events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Strings Localization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Generating the application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Workcell Description changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
6•Discrete MPS Operator Interface 57
Chapter objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Exploring the Operator Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Graphical Keyboards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Main overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Login . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Workcell menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Performance analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Digital Event . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Multistate Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Process Variable trends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Summarization Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Breakdown justification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
7•Discrete MPS Reporting 71
Chapter objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Available reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Accessing reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Report display options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
General toolbar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Filter toolbar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Time Selection toolbar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Time Selection Tools toolbar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Managing report login accounts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Report samples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Performance Analysis OEE Details by Workcell. . . . . . . . . . . . . . . . . . . . . . . . . 79
Performance Analysis OEE Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Performance Analysis OEE Trend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Performance Analysis Production . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Performance Analysis Production by Shift (text). . . . . . . . . . . . . . . . . . . . . . . . . 83
Performance Analysis Production by Shift (bar chart). . . . . . . . . . . . . . . . . . . . . 84
Digital Events Total Duration (bar chart). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Digital Events Total Duration (pie chart) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
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• • • • •
Digital Events Number of Occurrences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Digital Events Detailed List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Analog Events Total Duration by Day (text) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Analog Events Total Duration by Day (bar chart) . . . . . . . . . . . . . . . . . . . . . . . . 90
Analog Events Total Duration by Summarization Event . . . . . . . . . . . . . . . . . . . 91
Counters Total by Month (text) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Counters Total by Month (bar chart) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Breakdowns Total Duration (pie chart) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Breakdowns Total Duration by Summarization Event. . . . . . . . . . . . . . . . . . . . . 95
Process Variables Trend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
A•System Troubleshooting 97
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
VersaView Integrated Display Computer problems . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Computer interface problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Index 99
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1
1
1 • Welcome
Welcome to the Discrete Machine
Performance Solution
Chapter objectives
This chapter provides an overview of the Discrete Machine Performance Solution, the
intended audience for this document, and sources of assistance for this product.
What is the Discrete Machine Performance Solution?
Companies in the discrete and repetitive manufacturing industries are being challenged by
management to maximize production from existing lines, to meet required cycle-times
and delivery dates for each product, and to reduce costs. To meet this challenge,
production management is striving to operate the equipment at its highest efficiency.
Real-time identification of production assets that are not performing to a standard is
critical to maintaining world-class efficiency. A thorough understanding of the details
behind production performance will allow you to identify sources of production
inefficiencies and to maximize asset utilization.
Historically, many custom solutions have been developed but have often failed to fulfill
expectations, essentially due to problems of long development times, high costs, and lack
of configurability.
The Discrete Machine Performance Solution (Discrete MPS) is a pre-developed system,
created to provide visualization and analysis of production asset performance based on
data acquired from a production control system. The Discrete MPS provides an industrial
computer with a standard operator interface application, and the ability to use a remote
web browser to access standard reports. The Discrete MPS is built using other successful
Rockwell Automation components, and is designed to be configured quickly to match the
production configuration or to be re-configured should the production configuration
change.
Features and benefits
Discrete MPS offers the following features and benefits:
Calculates the Overall Equipment Effectiveness (OEE) for a workcell to evaluate its
performance.
Process Event and Process Variable tracking.
Downtime duration and reason code tracking.
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DISCRETE MACHINE PERFORMANCE SOLUTION USER’SGUIDE
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• • • • •
The ability to track the performance and process data for up to five workcells.
Visibility and analysis tools for real-time and historical process information.
Pre-developed Operator Interface displays.
Pre-developed reports.
A configuration application used to configure the site-specific production details.
An entire solution based on a single industrial computer.
Intended audience
This User’s Guide is designed to help you understand how to access and use the Discrete
MPS product.
This document is intended for the following types of users:
System installer
This is an individual who installs the Discrete MPS computer and connects it to the plant
systems.
This individual should be familiar with:
Installation of industrial computers on the plant floor
Control systems
Ethernet networking
This user will be most interested in the following chapters of this document:
Discrete MPS Hardware Installation
Initial Operation and Setup
System configurator
This is an individual who configures the Discrete MPS so that it can capture performance
data from the control system and present the real time information to the line operator and
the historical reports to the Report User.
This individual should be familiar with:
Process information (machine, line, and plant)
Control systems
The OEE calculation
The Microsoft Windows operating system
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1 •WELCOME TO THE DISCRETE MACHINE PERFORMANCE SOLUTION
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1 • Welcome
This user will be most interested in the following chapters of this document:
Initial Operation and Setup
Collecting Performance Data
Discrete MPS Configurator Application
Line operator
This is the individual who uses the Discrete MPS Operator Interface on the shop floor.
He/she will make use of the Discrete MPS Operator Interface to enter any information that
is not automatically collected from the control system and, if required, he will select the
proper justification reason for a breakdown.
This individual should be familiar with:
Process information (machine, line)
Use of a plant floor HMI
Use of a touchscreen
This user will be most interested in the following chapters of this document:
Discrete MPS Operator Interface
Report user
This is the individual who makes use of the reports provided by the Discrete MPS.
This individual should be familiar with:
Process information (machine, line, and plant)
The Microsoft Internet Explorer Web browser
This user will be most interested in the following chapters of this document:
Discrete MPS Reporting
Where can I go for help?
Our commitment to your success starts with the suite of learning aids and assistance we
provide for the Discrete MPS. You have the following options for getting additional
information about this product:
Get Discrete MPS training
One of the best ways to increase your proficiency at using Rockwell Software products is
to attend Rockwell Software training programs. Our training programs can help you
master the basics and show you how to unleash the full potential of our software.
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DISCRETE MACHINE PERFORMANCE SOLUTION USER’SGUIDE
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We offer a wide range of training programs, from regularly scheduled classes conducted at
Rockwell Software facilities, to custom-tailored classes conducted at your enterprise. The
size of each class is kept small intentionally to maximize student engagement.
If you would like more information about our training programs, visit the Rockwell
Software site on the World Wide Web or contact the Rockwell Software Training
Coordinator. Our World Wide Web address and telephone numbers appear on the inside
front cover of this document.
Get phone support
Rockwell Software’s support team of outstanding professionals provides top-notch
technical support — monitoring and tracking your experience with our products to pave
the road to your success in understanding and improving your factory performance.
Questions concerning installation and the use of the software are handled by the Rockwell
Automation Customer Support Center, staffed Monday through Friday — except U.S.
holidays — from 8 AM to 5 PM Eastern time zone for calls originating within the U.S.
and Canada.
To reach the Customer Support Center, call 440-646-5800 and follow the prompts. For
calls originating outside the U.S./Canada, locate the number in your country by visiting
support.rockwellautomation.com and selecting the Phone Support link.
W HEN Y OU C ALL
When you call, you should be at your computer prepared to give the following
information:
your a support contract number
the type of control system hardware you are using
the exact wording of any errors or messages that appeared on your screen
a description of what happened and what you were doing when the problem occurred
a description of how you attempted to solve the problem
Get web support
In addition to phone support, the Rockwell Automation Customer Support Center offers
extensive online knowledgebases of tech notes and frequently asked questions for support
of non-urgent issues. These databases are updated daily by our support specialists.
To receive regular e-mail messages with links to the latest tech notes, software updates,
and firmware updates for the products that are of interest to you or to submit an online
support request, visit support.rockwellautomation.com/supportrequests.
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